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TECHNICAL FIELD
[0001] The present application relates generally to image capture devices and, more specifically for a mobile device capable of being operated by motion gestures detected by a camera.
BACKGROUND
[0002] Digital camera devices have become ubiquitous. In addition to dedicated digital cameras (e.g., a handheld photo camera, a video camera), many other types of devices now incorporate digital cameras, including computers and smartphones. Mobile phones with built-in, high quality, digital cameras are perhaps the most popular communication platform in existence. Consumers use mobile phones to take pictures of others as well as pictures of themselves (i.e., selfies) and then upload the pictures to various social media platforms.
[0003] Digital cameras are not without some user-unfriendly aspects, however. Taking a photo of oneself (and/or others) from a remote position with a digital camera, particularly a mobile phone camera, is not easy to do. If a smartphone user wants to take a selfie picture (including of a group that includes the user), the user may take a close-up shot by extending his or her arm outward or by using a selfie stick. Alternatively, the user may take a longer distance picture using some sort of timer or remote control function in the smartphone. But, in that situation, after propping the smartphone up in a position to take the picture, the user then must rush into position in the picture frame and then freeze in position until the timer goes off. A remote control device may allow the user and others to prepare for the picture. However, this requires a piece of equipment separate from the digital camera that may get lost or may break.
[0004] Therefore, there is a need in the art for improved methods and apparatuses for operating a digital camera system. In particular, there is a need for a digital camera system that can be remotely operated by a user without the need for a remote controller separate from the digital camera system.
SUMMARY
[0005] To address the above-discussed deficiencies of the prior art, it is a primary object to provide a mobile device comprising: i) transmit path circuitry and receive path circuitry configured to communicate with a wireless network; ii) a memory configured to store a plurality of application programs; iii) a digital camera configured to record an image and to generate a live video stream; and iv) processing circuitry configured to analyze the live video stream and to detect therein a gesture made by a person in the recorded image. In response to detection of the gesture, the processing circuitry performs an operation associated with the detected gesture.
[0006] In one embodiment, in response to detection of the gesture, the processing circuitry causes the digital camera to take a picture of the image.
[0007] In another embodiment, in response to detection of the gesture, the processing circuitry causes the digital camera to take a picture of the image after a predetermined delay.
[0008] In still another embodiment, a duration of the delay is determined by the detected gesture.
[0009] In yet another embodiment, in response to detection of the gesture, the processing circuitry launches one of the plurality of application programs stored in the memory.
[0010] In a further embodiment, in response to detection of the gesture, the processing circuitry launches a music player application program stored in the memory.
[0011] In a still further embodiment, the processing circuitry is further configured to detect in the live video stream a face of the person who made the gesture in the recorded image and to determine if the person who made the gesture in the recorded image is an authorized user of the mobile device.
[0012] In a yet further embodiment, the processing circuitry performs the operation associated with the detected gesture in response to a determination that the person who made the gesture in the recorded image is an authorized user of the mobile device.
[0013] Before undertaking the DETAILED DESCRIPTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, such a device may be implemented in hardware, firmware or software, or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
[0015] FIG. 1A illustrates an “OK” hand gesture for controlling an operation of a digital camera system according to one embodiment of the disclosure.
[0016] FIG. 1B illustrates “heart” hand gesture for controlling an operation of a digital camera system according to one embodiment of the disclosure.
[0017] FIG. 2 illustrates a digital camera system architecture according to one embodiment of the disclosure.
[0018] FIG. 3 illustrates a mobile phone incorporating a digital camera system according to one embodiment of the disclosure.
DETAILED DESCRIPTION
[0019] FIGS. 1 through 3 , discussed below, and the various embodiments used to describe the principles of the present disclosure herein are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged digital camera system.
[0020] FIG. 1A illustrates “OK” hand gesture 110 for controlling an operation of a digital camera system according to one embodiment of the disclosure. FIG. 1B illustrates “heart” hand gesture 120 for controlling an operation of a digital camera system according to one embodiment of the disclosure. According to the principles of the present disclosure, a pre-configured hand gesture or hand motion is detected by a smartphone or digital camera from a live video stream and an action or operation in the smartphone or digital camera is triggered or activated. By way of example, if a smartphone camera detects OK hand gesture 110 , the smartphone may take a picture. Alternatively, if the smartphone camera detects heart hand gesture 120 , the smartphone may play music.
[0021] The smartphone camera may take the picture immediately after detecting OK hand gesture 110 or may issue a beep or other sound notification and delay, for example, three seconds in order to allow the user to stop making OK hand gesture 110 and pose in a preferred position. In an advantageous embodiment, the user may make a hand gesture or motion that modifies a parameter of the smartphone camera. By way of example, the user may hold up three fingers to set up a three second timer delay before the smartphone camera takes a picture. Optionally, this may be combined with another hand gesture. For instance, the user may make OK hand gesture 110 to command the smartphone camera to take a picture. After receiving an acknowledgement beep from the smartphone, the user may hold up three fingers for a three second delay or four fingers for a four second delay.
[0022] In an exemplary embodiment, the smartphone or digital camera may be setup by the manufacturer with pre-configured hand gestures (e.g., heart hand gesture 120 , OK hand gesture 110 ) stored in memory that control the operation of the device. Advantageously, the smartphone or digital camera may include the capability of learning customized gestures selected by the user. By way of example, the user may launch a camera application on the smartphone and select a Learn mode. The user may then stand in the picture frame and make a customized gesture for several seconds (e.g., circling arms, two “thumbs up” hand gestures, two hand up, palms towards camera, and the like). The camera application records the customized gesture for several second and emits a beep when done. The camera application then processes and stores the customized gesture for subsequent pattern recognition.
[0023] Once the customized gesture is detected and stored, the user can then associate the customized gesture with a selected operation of the smartphone (e.g., Start Video Record, Stop Video Record, Start Audio Record, Initiate Phone Call, and the like). In an advantageous embodiment, the smartphone camera is configure to perform face recognition and is capable of identifying the face of the smartphone user. This enables the smartphone to associate a hand gesture or other body motion with the authenticated user of the smartphone. This prevents the smartphone application from being accidentally or deliberately controlled by a person or persons in the camera frame other than the user of the smartphone.
[0024] FIG. 2 illustrates digital camera system architecture 200 according to one embodiment of the disclosure. Digital camera system architecture 200 comprises camera 210 , live stream analyzer 220 , pattern matching engine 230 , face recognition engine 240 , motion/gesture configuration engine 250 , and memory 260 , which stores a plurality of multimedia application programs, including photo application 262 , video recorder application 264 , and music player application 266 . Camera 210 records the live images in front of camera 210 and outputs a live image video stream to live stream analyzer 220 . Live stream analyzer 220 captures frames from the live image stream and sends the frames to pattern matching engine 230 and face recognition engine 240 .
[0025] Pattern matching engine 230 is configured to detect and identify pre-configured gestures and/or customized gestures in a video frame and face recognition engine 240 is configured to detect and identify the face of the user of digital camera system architecture 200 . If the user's face is recognized and authenticated and a pre-configured gesture or customized gesture is detected, the detected gesture then invokes an associated application program in memory 260 . Motion/gesture configuration engine 250 learns customized gestures selected by the user and associates the customized gestures with particular operations, as described above.
[0026] FIG. 3 illustrates mobile phone 201 , which incorporates a digital camera system according to one embodiment of the disclosure. Mobile phone 201 is one particular embodiment of digital camera system architecture 200 in FIG. 2 . Mobile phone 201 includes a camera, a live stream analyzer, a pattern matching engine, a face recognition engine, a motion/gesture configuration engine, and a memory as described above in FIG. 2 .
[0027] Mobile phone 201 comprises core circuitry 300 , which includes read-only memory (ROM) 305 , random access memory (RAM) 310 , central processing unit (CPU) 315 , digital signal processor (DSP) 320 , digital-to-analog converter (DAC)/analog-to-digital converter (ADC) circuitry 325 , baseband (BB) circuitry block 330 , codec circuitry block 335 , radio frequency (RF) circuitry block 340 , transmit (TX)/receive (RX) switch 345 , and antenna 395 .
[0028] In one embodiment, ROM 305 may store a boot-routine and other static data and RAM 310 may store an operating system (not shown), applications 312 , and protocol stack 314 . In an advantageous embodiment, ROM 305 and RAM 310 may comprise a single electronically erasable memory, such as a Flash memory, that is used in conjunction with a conventional RAM memory that is used to store dynamic data. Applications in memory 312 may include a social presence application (i.e., RCS Presence), an IP multimedia subsystem (IMS) framework that delivers IP multimedia services, a Calendar application, and specific Social Network Site (SNS) applications (e.g., Facebook, Twitter), and the like. Mobile phone 201 further comprises SIM card interface 350 , USB interface 355 , GPS receiver 360 , Bluetooth (BT) transceiver 365 , WiFi (or WLAN) transceiver 370 , speaker and microphone circuitry block 375 , keyboard 380 , display 385 , and camera 390 . In some embodiment, keyboard 380 and display 385 may be implemented together as a touch screen display.
[0029] CPU 315 is responsible for the overall operation of mobile phone 201 . In an exemplary embodiment, CPU 315 executes applications 312 and protocol stack 314 . CPU 315 runs the application layer and a wide variety of applications may be run in a smart phone implementation. Applications 312 may include audio, video, and image/graphics applications. CPU 315 may run applications 312 that support various audio formats such as MP3, MP4, WAV, and rm. CPU 315 may run image applications 312 that support JPEG image formats and video applications 312 that support video formats (e.g., MPEG-1 to MPEG-5). CPU 315 may support various operating systems (not shown), such as Symbian, java, android, RT-Linux, Palm, and the like. For time critical applications, CPU 315 runs a real-time operating system (RTOS). In addition to the physical layer, there are other layers, including protocol stack 314 , that enable mobile phone 201 to work with a network base station. In an exemplary embodiment, protocol stack 314 is ported on CPU 315 .
[0030] DAC/ADC circuitry block 325 converts analog speech signals to digital signals, and vice versa, in mobile phone 201 . In the transmit path, the ADC-converted digital signal is sent to a speech coder. Various types of ADCs are available, including sigma delta type. Automatic gain control (AGC) and automatic frequency control (AFC) are used in the receive path to control gain and frequency. AGC helps maintain satisfactory DAC performance by keepings signals within the dynamic range of the DAC circuits. AFC keeps frequency error within limit to achieve better receiver performance.
[0031] Baseband (BB) circuitry block 330 may be implemented as part of DSP 320 , which executes many of the baseband processing functions (i.e., physical layer, Layer 1, or L1 functions). BB circuitry block 300 may be ported on DSP 320 to meet the latency and power requirements of mobile phone 201 . BB circuitry block 330 converts voice and data to be carried over the air interface to I/Q baseband signals.
[0032] BB circuitry block 330 may change from modem to modem for various air interface standards, such as GSM, CDMA, Wimax, LTE, HSPA, and others. BB circuitry block 330 is often referred to as the physical layer, or Layer 1, or L1. For mobile phones that work on GSM networks, the baseband part (Layer 1) running on DSP 320 and the protocol stack 314 running on CPU 315 are based on the GSM standard. For CDMA mobile phones, the Layer 1 and protocol stack 314 are based on the CDMA standard, and so on, for the LTE and HSPA standards-based mobile phones.
[0033] For speech or audio inputs, codec circuitry block 335 may compress and decompress the signal to match the data rate to the frame in which the data is sent. By way of example, codec circuitry block 335 may convert speech at an 8 KHz sampling rate to a 13 kbps rate for a full rate speech traffic channel. To do this, a residually excited linear predictive coder (RELP) speech coder may be which compresses 260 bits into a 20 millisecond duration to achieve a 13 kbps rate.
[0034] The baseband or physical layer adds redundant bits to enable error detection as well as error correction. Error detection may be obtained with CRC and error correction using forward error correction techniques, such as a convolutional encoder (used in transmitter path) and a Viterbi decoder (used in receive path). Interleaving may be done for the data, which helps in spreading the error over time, thereby helping the receiver de-interleave and decode the frame correctly.
[0035] RF circuitry block 340 includes an RF up-converter and an RF down-converter. For a GSM system, the RF up-converter converts modulated baseband signals (I and Q) either at zero intermediate frequency (IF) or some IF to RF frequency (890-915 MHz). The RF down-converter converts RF signals (935 to 960 MHz) to baseband signals (I and Q). For a GSM system, GMSK modulation is used.
[0036] Antenna 395 is a metallic object that converts and electro-magnetic signal to and electric signal and vice versa. Commonly used antennas may include a helix type, a planar inverted F-type, a whip, or a patch type. Microstrip patch type antennas are popular among mobile phones due to small size, easy integration on a printed circuit board and multi-frequency band of operation. In a preferred embodiment of mobile phone 201 , antenna 395 may support different wire-area standards, including GSM, CDMA, LTE, and WiMAX, as well as short-range standards, including WiFi (WLAN), Bluetooth, and so on.
[0037] If antenna 395 comprises only one antenna used for both transmit and receive operations at different times, the TX/RX switch 345 couples both the transmit (TX) path and the receive (RX) path to antenna 395 at different times. TX/RS switch 345 is controlled automatically by DSP 320 based on a GSM frame structure with respect to the physical slot allocated for that particular GSM mobile phone in both the downlink and the uplink. For frequency division duplexing (FDD) systems, TX/RX switch 345 may be implement as a diplexer that acts as filter to separate various frequency bands.
[0038] Mobile phone 201 provides connectivity with laptops or other devices using WiFi (or WLAN) transceiver 370 , BT transceiver 365 , and universal serial bus (USB) interface 355 . Mobile phone 201 also uses GPS receiver 360 in applications 312 that require position information. If mobile phone 201 is a conventional smart phone, applications 312 may include many popular applications, such as Facebook, Twitter, a browser, and numerous games that come pre-installed with mobile phone 201 .
[0039] Speaker and microphone circuitry block 375 comprises microphone circuitry (or mic) that converts acoustic energy (i.e., air pressure changes caused by speech or other sounds) to electrical signals for subsequent processing. Speaker and microphone 375 further comprise speaker circuitry that converts an electrical audio signal to an audible signal (pressure changes) for human hearing. The speaker circuitry may include an audio amplifier to get required amplification of the audio signal and may further include a volume control circuit to change (increase or decrease) the amplitude of the audio signal.
[0040] Mobile phone 201 preferably includes camera 390 . Presently, almost all mobile phones feature a camera module. Camera 390 may comprise a 12 megapixel, 14 megapixel, or a 41 megapixel camera.
[0041] Display 385 may comprise, by way of example, a liquid crystal display (LCD), a thin-film transistor (TFT) screen, and organic light emitting diode (OLED) display, a thin film diode (TFD) display, or a touch screen of capacitive and resistive type.
[0042] In a simple embodiment, keypad 380 may comprise a simple matrix type keypad that contains numeric digits (0 to 9), alphabetic characters (A to Z), special characters, and specific function keys. In a more advanced embodiment for a smart phone implementation, keypad 380 may be implemented in the mobile phone software, so that keyboard 380 appears on display 385 and is operated by the user using the touch of a finger tip.
[0043] Accordingly, in the exemplary embodiment in FIG. 3 , camera 390 captures a live video stream, similarly to camera 210 in FIG. 2 . Applications 312 in memory 310 include multimedia applications similar to photo application 262 , video recorder application 264 , and music player application 266 in memory 260 in FIG. 2 . Finally, CP 315 is configured to perform the same functions as live stream analyzer 220 , pattern matching engine 230 , face recognition engine 240 , and motion/gesture configuration engine 250 in FIG. 2 .
[0044] The systems and methods disclosed herein enable a user to dynamically associate any motion with a multimedia application (e.g., a finger gesture for various timer operation, taking a photo with okay sign, etc.). The association between a selected multimedia application and a random gesture/motion by a user is freely configurable. Thus, instead of being limited by a remote controller and predetermined actions, the present disclosure provides a mechanism to customize a wide range of operations for the any selected motion/gestures.
[0045] Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims. | A mobile device responsive to hand gestures or hand motions detected by a camera. The mobile device comprises: i) transmit path circuitry and receive path circuitry configured to communicate with a wireless network; ii) a memory configured to store a plurality of application programs; iii) a digital camera configured to record an image and to generate a live video stream; and iv) processing circuitry configured to analyze the live video stream and to detect therein a gesture made by a person in the recorded image. In response to detection of the gesture, the processing circuitry performs an operation associated with the detected gesture, such as taking a picture of the image or playing music. | 7 |
BACKGROUND OF INVENTION
[0001] Information about formation dip angles (“dip angles”) is a very important issue in oilfield exploration. In particular, dip angle information is used to determine the location of particular zones (e.g., shale zone, sand zone, etc.) within a formation. This information is subsequently used to determine whether a well is being drilled or can be drilled in an appropriate formation.
[0002] Dip angles are typically measured on a small scale (i.e., a few centimeters) or on a large scale (i.e., tens of meters). The measurement of dip angles on a small scale is typically conducted using well logging tools such as a Fullbore Formation MicroImager (FMI) tool, a Dipmeter tool, etc. The measurement of dip angles on a large scale is typically conducted using seismic equipment. Multiple well logs from one or multiple tools are typically required to determine the dip angles for a particular formation.
[0003] Dipmeters make high resolution micro-resistivity measurements around the borehole circumference, which are correlated to produce dip information. This is merged with tool orientation/navigation data to provide formation dips in the earth's frame of reference.
[0004] Dipmeters are commonly made in two sections. A lower caliper arm sub-section contains the mechanism for holding the dipmeter pads against the borehole wall, and the pads contain the micro-resistivity electrodes. An upper sub-section contains the magnetometers and level cells or accelerometers necessary to define the orientation of the tool in three dimensions. The two sections are joined in such a way as to prevent relative rotation.
[0005] A minimum of three circumferential measurements are needed to define a plane. Traditional slim dipmeters therefore have 3-arms 120° apart. Each caliper arm terminates in a pad from which a resistivity measurement is made. The pads themselves are made as short as possible to allow them to enter small cavities. Resistivities are measured with small laterolog-3 type arrays. The sense electrodes are typically located some distance above the caliper arms and sense the current returning to the body of the dipmeter. Pad traces are generally correlated automatically using an interval correlation technique. This can be augmented by machine-aided manual correlation.
[0006] A window of data on the reference pad (the “reference interval”) is correlated with corresponding intervals on the other pads, plus or minus an additional amount of data defined by a search angle. The reference interval is then moved by an amount known as a step.
[0007] The reference interval is typically determined by the information content of the data. For example, if the pad traces are poor as a result of intermittent contact in rugose conditions, the best results may come from a short interval rather than a long one. However, as a general rule, stratigraphic interpretations are more accurate using a short interval. The step and interval usually overlap by some fraction, commonly a half, e.g., for a 2 meter interval, use a 1 meter step. Some overlap is justified because correlatable features may fall at or near an interval boundary, and might not result in an identifiable peak on the correlogram if there is no overlap. Comparing plots obtained with and without overlap may be useful; however, there is little or no justification for more than two fold overlap.
[0008] The search angle is the angle above and below the interval on the reference pad which, when projected across the well, defines the trace lengths from the other pads which enter the correlation algorithm. Therefore, the search angle defines the maximum apparent dip that can be computed. Note that search angles are defined with respect to the borehole, so the borehole tilt is subtracted to find the maximum true dip angle that can be computed in a vertical well.
[0009] Once the dipmeter tool has traversed the depth of the well, or the area of interest within the well, a plurality of resistivity logs is produced. There is typically one dip angle calculated per step. By properly correlating the fluctuations of these resistivity logs, the positioning of a bedding plane relative to the tool position can be readily calculated. Then, by measuring the bearing of the tool relative to some azimuthal reference, such as magnetic north, and the inclination of the tool relative to the true vertical or gravitational axis, the position of a bedding plane relative to the north and true vertical axes can be determined. To obtain an accurate dip angle, performing accurate correlations of a number of signals is generally necessary.
[0010] In addition, some prior art modeling methods combine information from offset well logs, production data, geologic maps and cross-sections to generate an initial geometric framework. The geometric framework typically includes a basic model providing of the formation. The geometric framework is subsequently augmented with estimates obtained from seismic data, more detailed correlation studies, log plots from the pilot hole, etc. The additional data from the offset wells and the pilot holes provide information about the layer thickness and various layer properties. The layer boundaries are typically determined from the inflection points on the offset well logs and the average layer properties are extracted from the corresponding well log values. Further, the dip angles associated with the layer model are typically derived using a combination of geologic maps and a cross-section of the formation, oriented along the wellbore.
SUMMARY OF INVENTION
[0011] In general, in one aspect, the invention relates to a method for determining a formation dip angle comprising extracting features from an acquired well log to obtain a set of features, validating the set of features to obtain a subset of features, generating a layered model using the subset of features, and generating a synthetic log using the layered model and a forward model.
[0012] In general, in one aspect, the invention relates to a computer system determining a formation dip angle comprising, a processor, a memory, a storage device, a computer display, and software instructions stored in the memory for enabling the computer system under control of the processor, to perform extracting features from an acquired well log to obtain a set of features, validating the set of features to obtain a subset of features, generating a layered model using the subset of features, and generating a synthetic log using the layered model and a forward model.
[0013] In general, in one aspect, the invention relates to a system for determining a formation dip angle comprising a well log data acquisition system for acquiring a well log, and a well log data processing system, wherein the well log data processing system extracts features from the acquired well log to obtain a set of features, validates the set of features to obtain a subset of features, generates a layered model using the subset of features, and generates a synthetic log using the layered model and a forward model.
[0014] In general, in one aspect, the invention relates to an apparatus for determining a formation dip angle comprising means for extracting features from an acquired well log to obtain a set of features, means for validating the set of features to obtain a sub-set of features, means for generating a layered model using the subset of features, and means for generating a synthetic log using the layered model and a forward model.
[0015] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0016] [0016]FIG. 1 illustrates a typical computer system.
[0017] [0017]FIG. 2 illustrates a flow chart in accordance with one embodiment of the invention.
[0018] [0018]FIGS. 3 a - 3 i illustrate the application of the wavelet decomposition method to a well log in accordance with one embodiment of the invention.
[0019] [0019]FIG. 4 illustrates the results of feature extraction using the mirror image method after the well log has been filtered using the wavelet decomposition method.
[0020] [0020]FIG. 5 illustrates the application of a square log method to a well log prior to feature extraction in accordance with one embodiment of the invention.
[0021] [0021]FIG. 6 illustrates feature extraction using the multiple-log method in accordance with one embodiment of the invention.
[0022] [0022]FIG. 7 illustrates a layer model in accordance with one embodiment of the invention.
[0023] [0023]FIG. 8 illustrates a measured log and a synthetic log generated using the layer model shown in FIG. 7 and a forward model in accordance with one embodiment of the invention.
[0024] [0024]FIG. 9 illustrates an updated layer model using the synthetic log shown in FIG. 8.
[0025] [0025]FIG. 10 illustrates a measured log and a synthetic log generated using the updated layer model shown in FIG. 9 and a forward model in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
[0026] Exemplary embodiments of the invention will be described with reference to the accompanying drawings. Like items in the drawings are shown with the same reference numbers.
[0027] In the following detailed description of the invention, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid obscuring the invention.
[0028] The present invention relates to a method for determining regional dip angles. Further, the present invention relates to using only one well log to determine the regional dip angles. Further, the present invention relates to generating a synthetic log and verifying the synthetic log to determine consistency with an original well log.
[0029] The invention may be implemented on virtually any type computer regardless of the platform being used. For example, as shown in FIG. 1, a typical networked computer ( 70 ) includes a processor ( 72 ), memory ( 74 ), a storage device ( 76 ), and numerous other elements and functionalities typical of today's computers (not shown). The computer ( 70 ) may also include input means, such as a keyboard ( 78 ) and a mouse ( 80 ), and output means, such as a monitor ( 82 ). The networked computer system ( 70 ) is connected to a wide area network (“WAN”) ( 81 ) (e.g., the Internet) via network interface connection (not shown). Those skilled in the art will appreciate that these input and output means may take other forms.
[0030] [0030]FIG. 2 illustrates a flow chart in accordance with one embodiment of the invention. Initially, a well logging tool such as an Array Resistivity Compensated Tool (ARC5) (ARC5 is a mark of Schlumberger) is used to obtain well log data such as resistivity (Step 100 ). Feature extraction is subsequently performed on the well log data (Step 102 ). The purpose of the feature extraction is to initially identify all potential layer boundaries (“horizons”) within the formation being logged.
[0031] In one embodiment of the invention, feature extraction is performed using a mirror image extraction method that identifies the mirror image portions of the well log or regions that are nearly mirror images (i.e., similar images within an acceptable tolerance range) of the well log. One method for determining all the mirror images (or similar images) within a given well log is to define a well log as a function ƒ(x) and use a second function d(τ,x) where d(τ,x):=ƒ(x)−ƒ(τ−x). It follows that d(τ,x) is the difference between the original well log, defined by the function ƒ(x) and its reversed version (i.e., ƒ(−x)) shifted by τ. Thus, if there are regions in ƒ(x) that are mirror images, then for some set of τ, there are regions in d(τ,x) that will be zero (i.e., mirror images) or less than a certain pre-selected threshold (i.e., nearly mirror images). Accordingly, by varying τ, all possible mirror images or nearly mirror images within the well log may be identified.
[0032] In some cases, the identification of mirror images and/or nearly mirror images within a well log may be performed using a filtered log. In one embodiment of the invention, a wavelet decomposition method is used to obtain a filtered log prior to performing feature extraction as defined above. In the wavelet decomposition method, a continuous signal (i.e., the well log), ƒ(x), is first mapped into ƒ M εV M where V M represents a space spanned by {φ(2 M x−k):kεZ} and Z:{. . . ,−1,0,1, . . . }. The resolution, M, is determined by a sampling rate. The function φ is a scaling function and has low pass filter characteristics. ƒ M is passed through a series of low pass filters, φ, and high pass/wavelet filters, ψ, to produce the filtered log. The mapping step ƒ(x) α ƒ M is described in more detail below.
f α f M = ∑ k a k , M φ ( 2 M x - k ) ∈ V M
f M = f M - 1 + g M - 1 = f M - 2 + g M - 2 + g M - 1 = f M - N + g M - N + Λ + g M - 1
[0033] where, for j<M,
V j ∋ f j = ∑ k a k , j φ ( 2 j x - k ) W j ∋ g j = ∑ k w k , j ψ ( 2 j x - k ) ,
[0034] and W j represents a space spanned by {ψ(2 M x−k):kεZ}. Based on the above formulas, the signal is downsampled by a factor of 2 after each filtering iteration. The resulting low pass filtered signal (φ) is further divided into low pass and high pass filter components during the next iteration. Thus, if an original log has 2991 data points, after four iterations (i.e., four decompositions), the resulting filtered log only has 190 data points.
[0035] [0035]FIGS. 3 a - 3 j illustrate the application of the wavelet decomposition method to a well log in accordance with one embodiment of the invention. The initial well log, shown in FIG. 3 a , contains 2991 data points. During a first pass through the high pass filter and the low pass filter, in accordance with the wavelet decomposition method described above, the well log ƒ(x) (as shown in FIG. 3 a ) is down sampled by a factor of 2, via the low pass filter, to produce ƒ 1 (x) as shown in FIG. 3 b . The difference d 1 between ƒ(x) and ƒ 1 (x) is shown in FIG. 3 c.
[0036] The filtered well log shown in FIG. 3 b now contains only 1497 data samples. The filtered log shown in FIG. 3 b is then subject to a second pass of the low pass filter and the high pass filter to produce FIGS. 3 d and 3 e , respectively. Similar to FIGS. 3 b and 3 c , FIG. 3 d shows ƒ 1 (x) down sampled by a factor of 2 to produce ƒ 2 (x) and FIG. 3 e shows the difference (d 2 ) between ƒ 1 (x) and ƒ 2 (x). The process is repeated to subsequently produce ƒ 3 (x),d 3 , and ƒ 4 (x),d 4 (FIGS. 3 f - 3 i , respectively). While FIGS. 3 a - 3 i show the wavelet decomposition method being applied four times to the original well log (FIG. 3 a ), those skilled in the art will appreciate that the wavelet decomposition method may be applied any number of times.
[0037] [0037]FIG. 4 illustrates the results of feature extraction using the mirror image method after the well log has been filtered using the wavelength decomposition method. The filtered well log ( 400 ) contains five mirror images denoted as A-A, B-B, C-C, D-D, and E-E. The filtered well log is the result of applying the wavelet decomposition method to the well log shown in FIG. 3 a.
[0038] Another method that may be used for feature extraction is a squaring log method. Using this method, similar features are extracted by first squaring the log (i.e., representing the original log as a series of piecewise constant regions), and then using the regions with large amplitude variations as templates for cross correlating with the reversed square log representation of the original well log to identify similar features. Alternatively, the squared log is maintained and the template is reversed.
[0039] [0039]FIG. 5 illustrates the application of a square log method to a well log prior to feature extraction in accordance with one embodiment of the invention.
[0040] The well log ( 500 ) is approximated using a piecewise continuous approximation ( 502 ). The piecewise continuous approximation ( 502 ) is a series of segments (i.e., 504 , 506 ). The piecewise approximation ( 502 ) may be determined using a pre-determined number of segments or using an error tolerance between the well log ( 500 ) and the piecewise continuous approximation ( 502 ). In the latter case, the well log will be segmented until the error tolerance is met.
[0041] Another method that may be used for feature extraction is a multiple-log method. The multiple-log method overlays multiple logs, such as phase and attenuation resistivity logs, and extracts features by determining where the logs separate. In the particular case of phase and attenuation resistivity logs, the regions where the well log curves start separating indicate resistivity boundaries. These separations may be used to identify similar features, such as bed boundaries.
[0042] [0042]FIG. 6 illustrates feature extraction using a multiple-log method in accordance with one embodiment of the invention. The phase resistivity log ( 600 ) is overlaid on the attenuation resistivity log ( 602 ). Separations ( 604 , 606 , and 608 ) between the phase resistivity log ( 600 ) and the attenuation log ( 602 ) indicate that a horizon may be present.
[0043] Returning to FIG. 2, once the features have been extracted, three-dimensional (3D) validation is performed (Step 104 ). The purpose of the 3D validation process is to determine which of the potential horizons represents an actual layer boundary within the formation. During the 3D validation process, additional information is correlated with the extracted features. The additional information may include, but is not limited to, tool trajectory. Once the extracted features are correlated with the well log data, the results are validated using specific pre-defined criteria. The pre-defined criteria may include but is not limited to, magnitude of extracted feature, inconsistent inclination, whether particular extracted feature represents a layer that crosses another layer (i.e., the extracted feature represent nonphysical feature), etc.
[0044] Using the results of the 3D processing step, a layer model is generated (Step 106 ). The layer model is generated using the extracted features that are validated during the 3D validation process. Each layer is assigned specific properties based on the well log data. For example, if the ACR5 tool was used to generate the original well log, then the layered model would include a median resistivity for each layer.
[0045] Using the wavelet decomposition method and the mirror image method, five features were extracted from the well log (A-A, B-B, C-C, D-D, E-E) as shown in FIG. 5. Using the tool trajectory and the 3D validation method described above, the following layer model was generated as shown in FIG. 6 in accordance with one embodiment of the invention. Using the tool trajectory ( 600 ) and the 3D validation method described above, features A-A and C-C correspond to physical layers, while features B-B, D-D, and E-E provide inconsistent inclination or result in a crossing of a formation layer. Accordingly, features B-B, D-D, and E-E are deemed nonphysical. Using the trajectory ( 600 ) and features A-A and C-C, a layer model with four layers ( 602 , 604 , 606 , 608 ) having resistivities, 25 Ω-m, 15 Ω-m, 29 Ω-m, and 9 Ω-m, respectively, is generated. The resistivity values are determined, as mentioned before, from the median log data in each of the respective layers. Those skilled in the art will appreciate that any number of features may be extracted from the well log and used to generate a layer model with any number of layers.
[0046] Returning to FIG. 2, a synthetic log is subsequently generated using a forward model and the information from the layered model (Step 108 ). Any number of forward models may be used to generate the synthetic log. For example, one may use an electromagnetic forward model to generate the synthetic log. The synthetic log is then compared to the original log, or alternatively to the filtered log (Step 110 ).
[0047] [0047]FIG. 8 illustrates a synthetic log generated using the layer model shown in FIG. 7 and a forward model in accordance with one embodiment of the invention. The original well log ( 800 ) is overlaid with a synthetic log ( 802 ) generated using the layered model in FIG. 6 and a forward model.
[0048] Returning to FIG. 2, in one embodiment of the invention, the synthetic log should be within an acceptable threshold of the original log to be considered consistent. If the synthetic log is consistent with the original and/or filtered log, then the layered model is inferred to accurately reflect the formation surrounding the borehole. If the synthetic log is not consistent with the original log, then the parameters and assumptions used to generate the layered model are modified using the synthetic log as a starting point (Step 112 ) and an updated layer model is subsequently generated (Step 114 ). Once the layer model has been updated, a synthetic log is generated using the updated layer model (Step 108 ), and subsequently compared to determine whether the synthetic log is consistent with the original well log or filter log (Step 110 ). Steps 108 - 114 are repeated until the synthetic log is consistent with the original and/or filtered well log. The result of the process shown in FIG. 2 is a formation model.
[0049] [0049]FIG. 9 illustrates an updated layer model in using the synthetic log shown in FIG. 8. Using the trajectory ( 600 ) and features A-A and C-C, the layer model is updated to include four layers ( 902 - 908 ) having resistivities, 26.4 Ω-m, 16 Ω-m, 28 Ω-m, and 7 Ω-m, respectively. FIG. 10 illustrates a synthetic log generated using the layer model shown in FIG. 9 and a forward model according to one embodiment of the invention. The original well log ( 1000 ) is overlaid with a synthetic log ( 1002 ) generated using the layered model in FIG. 9 and a forward model.
[0050] Embodiments of the invention may have one or more of the following advantages. A series of methods to automatically extract features from a single well log are provided. Further, a method that uses a single log to estimate the subsurface regional dip in highly deviated wells that intersect specific horizons in at least two locations is provided. Moreover, more accurate formation information to allow for better tool positioning in geo-steering applications can be obtained. Further, a mechanism for real-time geo-steering is provided. In particular, in one aspect, once a layered model has been generated using the proposed method by processing log data up to certain measured depth, any new log data may be added to continuously monitor the model and correcting tool trajectory such that drilling may proceed in the desired layer. Additionally, a user is able to determine regional dip angles on an intermediate scale.
[0051] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A method for determining a formation dip angle including extracting features from an acquired well log to obtain a set of features, validating the set of features to obtain a subset of features, generating a layered model using the subset of features, and generating a synthetic log using the layered model and a forward model. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of photonics, and in particular to a method of making specular infrared mirrors for use in optical devices, such as multiplexers and demultiplexers for use in wavelength division multiplex communication systems.
[0003] 2. Description of Related Art
[0004] The manufacture of optical devices such as multiplexers and demultiplexers requires the fabrication of a highly reflective infrared mirror in the 1.55 μm and/or 1.30 μm optical bands. Such a highly reflective infrared mirror is typically required on the sidewall of deep vertical-etched optical components to reflect an infrared laser beam with maximum efficiency.
[0005] Typical fabrication techniques of infrared mirrors result in relatively poor surface quality, in lower reflectivity values at 1.55 μm wavelength and in significant optical losses from infrared light scattering from the surface defects.
[0006] Optical multiplexers and demultiplexers have been described in the scientific literature for at least 20 years. The following USA patents and published technical information will review the various manufacturing techniques used to produce the highly reflective infrared mirror of multiplexers, demultiplexers and other infrared optical devices:
[0007] U.S. Pat. No. 4,274,706, Hughes Aircraft Company
[0008] This patent describes the mirror of infrared multiplexers and demultiplexers shown in FIGS. 1 a and 1 b. The multiplexers and demultiplexers incorporating the mirror allowing the reflection of infrared light are manufactured using a sodium glass microscope slide substrate; a planar wave guide produced by increasing the refractive index of the surface of this substrate to a depth of about 100 μm using an ion exchange process replacing the sodium atoms of the substrate by lithium atoms from a LiSO 4 salt heated at about 580° C. in oxygen; a grind-and-polished cylindrical shaped surface transverse to the surface of the glass substrate as to achieve the curved wave guide of radius R of FIG. 1 a (This cylindrical transverse surface is used to focus the light emanating from the input plane (identified as 14 in FIG. 1 b ) back to the input plane and has a series of parallel grooves forming a series of pairs of facets of uniform spacing); a replica grating comprising a 0.005 inch thick acetate plastic film having 512 grooves/mm coated with an aluminum as to achieve high reflectivity; and an epoxy glue to bond this transversal cylindrical shaped surface to the replica grating.
[0009] This manufacturing technique involves the gluing of an aluminum coated thin flexible material such as an acetate plastic film onto a grind-and-polished sodium glass microscope slide. No further detail on the mirror characteristics and/or fabrication technique is given.
[0010] U.S. Pat. No. 4,786,133, Commissariat à l'énergie atomique
[0011] This U.S. patent describes the mirror of the infrared multiplexers and demultiplexers shown on FIGS. 2 a and 2 b . The multiplexers and demultiplexers incorporating the mirror allowing the reflection of infrared light is manufactured using a silicon substrate, identified as 20 in FIG. 2 b ; a stack of three transparent silica layers, identified as 22 , 24 and 26 in FIG. 2 b , with the intermediate 4 to 5 μm thick phosphorus-doped silica layer 24 having a 10-3 to 10-2 higher refraction index than the lower 6 to 8 μm thick undoped silica layer 22 and the upper 6 to 8 μm thick undoped silica layer 26 surrounding it; a plurality of optical microguides, identified as G 1 to G N in FIG. 2 a ; a concave and elliptic shaped reflective diffraction grating, identified as R in FIG. 2 a , constituted by etched facets etched in the stack of three layers; and an aluminum metal layer, identified as 28 in FIG. 2 b.
[0012] This manufacturing technique involves the vertical etching of facets through a three-layer optical waveguide followed by an aluminum coating. No detail is given on the aluminum coating fabrication technique.
[0013] U.S. Pat. Nos. 5,450,510, 5,608,826 and 5 , 793 , 912 , APA Optics, Inc.
[0014] These three USA patents describe the mirror of similar variations of the infrared wavelength division multiplexed optical modulator shown in FIGS. 3 a and 3 b . The infrared wavelength division multiplexed optical modulator incorporating the mirror allowing the reflection of infrared light is assembled using a wavelength dispersive multiplexer transmitter, identified as 21 in FIG. 3 a , and consisting of a laser power and laser temperature control circuitry, identified as 23 in FIG. 3 a , used to maintain the laser power and temperature at stable pre-set values; a directional coupler controller, identified as 24 in FIG. 3 a , used to control the integrated modulator; a semiconductor laser diode, identified as 26 in FIG. 3, maintained at constant temperature as to minimise wavelength variations of about 0.0005 μm/° C.; a first reflective holographic diffraction grating, identified as 27 in FIG. 3 a , used to demultiplex the various wavelengths from each other with a 0.0007 μm separation by using a series of 6190/cm parallel grooves replicated in its surface and overcoated with a reflecting material such as aluminum; a first collimating optics, identified as 28 in FIG. 3 a , used to collimate the output beam of the laser diode; a first focusing optics, identified as 29 in FIG. 3 a , used to inject the collimated output beam into the external integrated modulator; a mirror, identified as 30 in FIG. 3 a , used to reflect the laser diode beam toward the diffraction grating; an integrated modulator, identified as 31 in FIG. 3 b , used to attenuate the various wavelengths of the separated beam and used as a directional coupler of the separated beams into the optical fibre; an optical fibre, identified as 21 in FIG. 3 a , used to connect the wavelength dispersive multiplexer transmitter and the wavelength dispersive multiplexer receiver; a wavelength dispersive multiplexer receiver, identified as 22 in FIG. 3 a , and consisting of a detector array controller, identified as 25 in FIG. 3 a , used to control the detector array; a second reflective holographic diffraction grating, identified as 27 ′ in FIG. 3 a , used to multiplex the various wavelengths together and also consisting in a series of 6190/cm parallel grooves ruled or replicated in its surface and overcoated with a reflecting material such as aluminum; a second collimating optics, identified as 28 ′ in FIG. 3 a , used to focus the dispersed wavelengths onto the detector array; a second focusing optics, identified as 29 ′ in FIG. 3 a , used to collimate the multiple wavelength light coming out of the optical fibre with a minimum angular dispersion; a detector array, identified as 32 in FIG. 3 a , used to detect the dispersed longitudinal modes; and the two reflective holographic diffraction gratings of this infrared wavelength division multiplexed optical modulator involve an aluminum coating. No detail is given on the aluminum coating fabrication technique.
[0015] The highly reflective infrared mirror from Newport Corporation Newport Corporation, Irvine, Calif., is a worldwide manufacturer and distributor of precision components and systems used for development and application of laser and optical technologies in semiconductor manufacturing and testing, fiber optic communications and other commercial applications. The reflectivity spectra of the ER.1 enhanced aluminum coating near infrared mirror shown in FIG. 4 is a re-print of the information provided at two locations of their web site:
[0016] http://www.newport.com/file_store/PDFs/tempPDFs/Broadband_Metallic.pdf
[0017] http://www.newport.comstore/product.asp?lone=Optics&ltwo=Mirrors&lthree=B roadband+Metallic+Mirrors&lfour=&id=3522
[0018] These reflectivity spectra will be used as comparative reference the results for the present invention.
[0019] Marxer C. and Al, Vertical mirrors fabricated by deep reactive ion etching for fiber-optics switching applications. Journal of Microelectromechanical Systems, Vol 6 (3), pp. 277-285. September 1997
[0020] This paper describes the characteristics and performance of various metal-coated silicon mirrors to be used for electrostatic switches capable of switching 1.3 μm infrared light from optical fibres. The electrostatic switch is shown in FIG. 5 a . This paper also describes different metal coatings such as gold, aluminum, nickel and chromium and concludes that as shown in FIG. 5 b , the 1.3 μm reflectivity of aluminum-coated silicon increases with increasing aluminum thickness but saturates to the reflectivity of bulk aluminum when the thickness attains 40 nm; only 100 nm of aluminum is required as to prevent the transmission of less than 1 ppm (60 dB isolation) at 1.3 μm wavelength; the other two metals, nickel and chromium, exhibit inferior reflectivity values at 1.3 μm wavelength even for much thicker mirrors; higher reflectivity values are associated to thicker aluminum but the surface roughness associated with thicker aluminum induces a non-specular reflectivity and overall light loss due to diffused light scattering estimated by the following formula:
P scat =P tot {1 −exp[−( 4πσ cosθ 1 /λ) 2 ]}
[0021] where P scat is the flux of light scattered away from the specular direction, P tot is the total reflected flux, σ is the RMS surface roughness of the mirror, θ 1 is the incident angle and λ is the wavelength of light.
[0022] The surface roughness can be measured using an Atomic Force Microscope (AFM) profiling of the aluminum surface and the reduction of the surface roughness is key to achieve a highly reflective specular infrared mirror. An example of such AFM profiling is shown in FIG. 5 c.
[0023] An object of the present invention is to provide an improved fabrication process for a low surface roughness highly-reflective specular infrared mirror so as to allow the fabrication of optical devices such as multiplexers, demultiplexers and other optical devices operating in the 1.55 μm and/or 1.30 μm optical bands with minimum optical losses.
SUMMARY OF THE INVENTION
[0024] The present invention provides a novel approach for producing an atomic scale surface roughness aluminum mirror with high infrared specular reflectivity, for example, using a commercially available M2i cluster tool manufactured by Novellus Systems in California, USA. This highly reflective infrared mirror is to be coated onto the facets of a deep-etched grating such as the one shown in FIG. 6.
[0025] Accordingly the present invention provides a method of making highly reflective mirrors on a wafer in the manufacture of photonic devices, comprising the steps of preheating a wafer to remove adsorbed volatile contaminants at a temperature between about 300 and 600° C.; etching the wafer surface at a temperature between about 300 and 600° C. to remove absorbed and chemically absorbed contaminants in the presence of a glow-discharge to reduce poisoning; thoroughly cooling the wafer surface so as to as reduce the surface mobility of the impinging metal atoms during a subsequent metallic deposition; carrying out a deposition on the cooled wafer of a gettering layer for gettering at least one contaminant selected from the group consisting of hydrogen, oxygen and nitrogen; depositing a metallic reflective layer in a deposition chamber; and removing the wafer from the deposition chamber to prevent excessive bulk oxidation.
[0026] The invention is useful in the manufacture of echelle gratings in multplexers and demultplexers, especially in the infrared region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:
[0028] [0028]FIGS. 1 a and 1 b illustrate a prior art reflective diffraction grating disclosed in U.S. Pat. No. 4,274,706;
[0029] [0029]FIGS. 2 a and 2 b illustrate a prior art reflective diffraction grating disclosed in U.S. Pat. No. 4,786,133;
[0030] [0030]FIGS. 3 a and 3 b illustrate a prior art a multiplexer/demultiplexer disclosed in U.S. Pat. No. 5,450,510;
[0031] [0031]FIG. 4 illustrates the optical properties of the enhanced aluminum mirror ER.1-PF (Newport Corporation, Irvine, Calif.);
[0032] [0032]FIGS. 5 a - c illustrate the effect of surface roughness of the mirror on the performance of optical switches (From Marxer's paper);
[0033] [0033]FIG. 6 shows the deep-etched grating facets on which a highly reflective infrared mirror is to be coated;
[0034] [0034]FIG. 7 shows a Novellus M2i cluster tool;
[0035] [0035]FIG. 8 shows a first deposition sequence (Sequence 1 ) in a Novellus M2i cluster tool;
[0036] [0036]FIG. 9 shows a second deposition sequence (Sequence 2 ) in a Novellus M2i cluster tool;
[0037] [0037]FIG. 10 shows a third deposition sequence (Sequence 3 ) in a Novellus M2i cluster tool;
[0038] [0038]FIG. 11 shows the hydrogen and oxygen getter from an integrated titanium-based layer deposited under the aluminum layer;
[0039] [0039]FIG. 12 shows the effect of the deposition sequence on the surface roughness of a highly reflective infrared mirror;
[0040] [0040]FIG. 13 shows the effect of the deposition sequence on the RMS surface roughness of a highly reflective infrared mirror;
[0041] [0041]FIG. 14 shows the effect of the deposition sequence on the 440 nm ultra-violet reflectivity of a highly reflective infrared mirror;
[0042] [0042]FIG. 15 shows the FTIR calibration prior to measurement of a highly reflective infrared mirror;
[0043] [0043]FIG. 16 shows the FTIR measurement of a highly reflective infrared mirror;
[0044] [0044]FIG. 17 shows the effect of the deposition sequence on the FTIR spectra of a highly reflective infrared mirror;
[0045] [0045]FIG. 18 is a performance comparison of the 50 nm thick highly reflective infrared aluminum mirrors with Newport's ER1-PF enhanced aluminum mirror;
[0046] [0046]FIG. 19 is a performance comparison of the 100 nm thick highly-reflective infrared aluminum mirrors with Newport's ER.1-PF enhanced aluminum mirror; and
[0047] [0047]FIG. 20 is a performance comparison of the 150 nm thick highly reflective infrared aluminum mirrors with Newport's ER.1-PF enhanced aluminum mirror.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] An exemplary fabrication process for a low surface roughness highly reflective specular infrared mirror will now be described.
[0049] As shown in FIG. 7, an M2i cluster tool is equipped with a custom-made vacuum preheating station capable of heating the wafer under vacuum up to a maximum temperature of about 550° C. prior to its loading in a high-vacuum transfer module; a very-high-vacuum etch chamber capable of cooling the wafer after the completion of the etching; two custom-made very-high-vacuum collimated titanium and titanium nitride deposition chambers capable of depositing titanium and/or titanium nitride through a collimator; and two very-high-vacuum aluminum deposition chambers.
[0050] The description and performance of these two custom-made very-high-vacuum collimated titanium and titanium nitride deposition chambers are documented in the scientific literature by the inventors of the following publications, which are hereby incorporated herein by reference: Recent advances in metallization technologies for ULSI applications—Collimated Ti/TiN for 0.50 & 0.35 μm technologies, Semicon Korea, November 1992, Varian technical report No. 238; Adhesion and barrier layers for CVD tungsten and PVD aluminum filled contacts and vias of various aspect ratios, Semicon Korea, Seoul, Jan. 19, 1995; Elastic recoil detection using time-of-flight analysis of TiN/AlSiCu/TiN/Ti contact metallization structures, IBA-13, Thirteenth International Conference on Ion Beam Analysis, Sacavem, Portugal, Jul. 27 th 1997, E.N. 10, 2685; The determination of the phases formed in AlSiCu/TiN/Ti contact metallization structure on integrated circuits by X-ray diffraction, J. Appl. Phys., 83 (1), January 1998, p. 132-138;
[0051] Three deposition sequences for making highly reflective infrared mirrors will now be described:
[0052] [0052]FIG. 8 illustrates Sequence 1 :
[0053] i. 30 seconds pre-heating at 485° C. as to reduce the adsorbed volatile contaminants such as water vapour;
[0054] ii. No etch at 485° C;
[0055] iii. 80 sec cooling at 25° C. as to chill the surface of the wafer;
[0056] iv. 50 nm, 100 nm or 150 nm aluminum mirror deposition at 25° C. as to minimise grain growth;
[0057] v. Wafer out at 25° C. as to prevent excessive bulk oxidation.
[0058] [0058]FIG. 9 describes Sequence 2 :
[0059] i. 90 seconds pre-heating at 485° C. as to thoroughly eliminate the adsorbed volatile contaminants such as water vapour;
[0060] ii. 15 nm SiO 2 etch at 485° C. so as to thoroughly eliminate the absorbed and chemically absorbed contaminants such as water vapour absorbed as Si—OH and Si—H using an argon plasma and a high wafer temperature of 485° C. in conformance with our U.S. Pat. No. 5,447,613: Preventing of via poisoning by glow discharge induced desorption;
[0061] iii. 300 sec cooling at 25° C. as to as to thoroughly cool the surface of the wafer and reduce the surface mobility of the impinging aluminum atoms during the following aluminum deposition;
[0062] iv. 50 nm, 100 nm or 150 nm aluminum mirror deposition at 25° C. as to minimise surface diffusion and grain growth;
[0063] v. Wafer out at 25° C. as to prevent excessive bulk oxidation.
[0064] [0064]FIG. 10 describes Sequence 3 :
[0065] i. 90 seconds pre-heating at 485° C. as to eliminate the adsorbed volatile contaminants such as water vapour;
[0066] ii. 15 nm SiO 2 etch at 485° C. so as to thoroughly eliminate the absorbed and chemically absorbed contaminants such as water vapour absorbed as Si—OH and Si—H using an argon plasma and a high wafer temperature of 485° C. in conformance with our U.S. Pat. No. 5,447,613: Preventing of via poisoning by glow discharge induced desorption;
[0067] iii. 300 sec cooling at 25° C. as to as to thoroughly cool the surface of the wafer and reduce the surface mobility of the impinging aluminum atoms during the following aluminum deposition;
[0068] iv. 10 nm collimated titanium deposition at 25° C. so as to deposit a hydrogen, oxygen and nitrogen gettering layer under the following aluminum layer, as demonstrated by FIG. 11 taken from our publication: Elastic recoil detection using time-of-flight analysis of TiN/AlSiCu/TiN/Ti contact metallization structures, IBA-13, Thirteenth International Conference on Ion Beam Analysis, Sacavem, Portugal, July 27 th 1997, E.N. 10, 2685;
[0069] v. 50 nm or 100 nm or 150 nm aluminum mirror deposition at 25° C. as to minimise surface diffusion and grain growth;
[0070] vi. Wafer out at 25° C. as to prevent excessive bulk oxidation.
[0071] Atomic Force Miscroscopy (AFM) measurements of the surface roughness of the highly reflective infrared mirrors:
[0072] As discussed in Marxer's paper, an increasing thickness aluminum mirror allows a higher infrared reflectivity but the surface roughness associated with a thicker aluminum mirror induces a non-specular reflectivity and an overall light loss due to diffused light scattering from an increasing RMS surface roughness of the mirror. The RMS surface roughness of 50 nm, 100 nm and 150 nm thick highly-reflective infrared mirrors deposited by the three upper-mentioned deposition sequences was measured using a Digital Instrument Nanoscope Atomic Force Microscope (AFM) over a 3.0 μm by 3.0 μm area at a scan rate of 1.585 Hz and using a sample size of 256.
[0073] The obtained three-dimensional profiles using a 50 nm scale are shown in FIG. 12. It is clear from the AFM profiles of FIG. 12 that the deposition sequence used to deposit a given thickness aluminum mirror has a very important effect on its resulting RMS surface roughness.
[0074] [0074]FIG. 13 plots the resulting RMS surface roughness of 50 nm, 100 nm and 150 nm thick highly reflective infrared mirrors deposited using the three upper-described sequences. It is clear that Sequence 1 and Sequence 2 result in increased surface roughness as the thickness of the mirrors deposited by these two sequences is increased from 50 nm to 150 nm; and the surface roughness of the mirrors deposited with Sequence 3 is maintained constant to less than about 1.0 nm as their thickness is increased from 50 nm to 150 nm.
[0075] Knowing that the diameter of an aluminum atom is 0.364 nm, it is clear that Sequence 3 is capable of depositing up to 150 nm thick aluminum mirrors with a surface roughness of less than three atoms.
[0076] Ultra-violet reflectivity measurements of the highly reflective infrared mirrors:
[0077] The ultra-violet reflectivity of the 50 nm, 100 nm and 150 nm thick highly reflective infrared mirrors deposited by Sequence 1 , Sequence 2 and Sequence 3 was measured using a Prometrix FT-750 reflectometer operating at a 440 nm wavelength.
[0078] The measurements reported in FIG. 14 indicate that there are very little differences between the 440 nm ultra-violet reflectivity of the various mirrors deposited by Sequence 1 , Sequence 2 and Sequence 3 ; the 440 nm ultra-violet reflectivity of the various mirrors matches the reported value of the highly-reflective ER.1 enhanced aluminum coating near infrared mirror of Newport Corporation shown in FIG. 4.
[0079] Fourier Transformed Infrared Reflectivity (FTIR) measurements of the specular infrared reflectivity of the aluminum mirrors
[0080] The specular infrared reflectivity of the 50 nm, 100 nm and 150 nm thick highly reflective infrared mirrors deposited by Sequence 1 , Sequence 2 and Sequence 3 was measured by Fourier Transformed Infrared Reflectivity (FTIR).
[0081] [0081]FIG. 15 shows the FTIR set-up used for the calibration of the specular reflectivity measurements. This calibration set-up uses a source of infrared light; a properly aligned mirror-coated reflection prism ensuring the measurement of the specular reflectivity of a mirror sample via a double reflection at the surface of the prism; a calibration mirror with maximum reflectivity from 2.5 μm to 25 μm; a detector, capable of measuring the wavelength dependence of the reflectivity using the infrared light twice reflected by the mirror-coated prism and once reflected by the calibration mirror; a computer which memorizes the obtained calibration spectra used as reference to compare the specular infrared reflectivity of the 50 nm, 100 nm and 150 nm thick highly-reflective infrared mirrors deposited by Sequence 1 , Sequence 2 and Sequence 3 .
[0082] [0082]FIG. 16 shows the FTIR set-up used for the measurement of the specular reflectivity of the 50 nm, 100 nm and 150 nm thick highly reflective infrared mirrors by alternately replacing the calibration mirror by each one of the nine highly-reflective infrared mirrors.
[0083] [0083]FIG. 17 shows the results of the calibrated FTIR measurements of the specular reflectivity of the 50 nm, 100 nm and 150 nm thick highly reflective infrared mirrors from 2.5 μm to 25 μm.
[0084] [0084]FIG. 18 compares the various 50 nm thick highly reflective infrared mirrors of FIG. 17 with the highly reflective ER.1 enhanced aluminum coating near infrared mirror of Newport Corporation of FIG. 4.
[0085] [0085]FIG. 19 compares the various 100 nm thick highly reflective infrared mirrors of FIG. 17 with the highly reflective ER.1 enhanced aluminum coating near infrared mirror of Newport Corporation of FIG. 4.
[0086] [0086]FIG. 20 compares the various 150 nm thick highly reflective infrared mirrors of FIG. 17 with the highly reflective ER.1enhanced aluminum coating near infrared mirror of Newport Corporation of FIG. 4.
[0087] The analysis of FIG. 13, FIG. 18, FIG. 19 and FIG. 20 shows that independently of the thickness from 50 nm to 150 nm, Sequence 3 provides a lower surface roughness than Sequence 2 and Sequence 1 ; independently of the thickness from 50 nm to 150 nm, Sequence 3 provides a higher infrared specular reflectivity than Sequence 2 and Sequence 1 ; independently of the thickness from 50 nm to 150 nm, Sequence 3 provides mirrors with higher specular reflectivity at smaller infrared wavelengths approaching 1.55 μm than at higher infrared wavelengths. This contrasts with Newport's infrared mirror which shows a very important infrared reflectivity loss as the wavelength is reduced from 10 μm to 1.5 μm; since 50 nm aluminum mirrors are already opaque at 1.55 μm and since 100 nm aluminum mirrors have less than 1 ppm transmission, it is clear that Sequence 3 provides a technique capable of producing extremely high quality infrared mirrors with atomic scale surface roughness and excellent specular reflectivity at 1.55 μm which can be used to produce infrared multiplexers, demultiplexers and other infrared optical devices.
[0088] It is clear from the above discussion that sequence 3 is capable of producing a mirror that has atomic scale surface roughness and highly-reflective specular reflection properties so as to allow the fabrication of optical devices such as multiplexers, demultiplexers and other optical devices operating in the 1.55 Mm and/or 1.30 μm optical bands with minimum optical losses.
[0089] Many variations will be apparent to one skilled in the art. The following are some variations, but one skilled in the art will appreciate that other variations will be possible within the spirit of the invention and scope of the appended claims.
[0090] The 90 seconds pre-heating at 485° C. could be shortened down to 30 seconds if the preheating temperature is higher than 485° C. but yet less than 600° C.; increased up to 180 seconds if the pre-heating temperature is lower than 485° C. but yet higher than 300° C. The SiO 2 etch at 485° C. could be performed at a different temperature than 485° C. in the range between 300° C. and 600° C.; remove less than an equivalent of 15 nm of SiO 2 in the range between 5 nm and 50 nm; be performed in another inert gas than pure argon, including: neon, krypton and xenon; be performed in a non-inert gas, including: a fluorine based gas, a bromine based gas or a chlorine based gas.
[0091] The 300 sec cooling at 25° C. could be shortened down to 30 seconds if the cooling is performed using an cold electrostatic chuck or any other means of active cooling; shortened down to 30 seconds if the cooling is performed at a temperature lower than 25° C. using a cryogenic means.
[0092] The 10 nm collimated titanium deposition at 25° C. could use a different deposition technique such as standard physical vapor deposition (PVD), enhanced PVD with an inductively coupled plasma (ICP), enhanced PVD with any means of magnetic confinement, chemical vapor deposition (CVD), plasma enhanced chemical vapor deposition (PECVD) or metal organic chemical vapor deposition (MOCVD); use a different thickness in the range between 1 nm and 100 nm; use a different titanium-based material or combination of titanium-based materials such as: titanium (Ti), titanium nitride (TiN) or titanium-tungsten (TiW); use a different material known to getter hydrogen, oxygen or nitrogen; be performed at a temperature different than 25° C. in the range between −100° C. and 100° C.
[0093] The aluminum mirror deposition at 25° C. could be performed at a temperature different than 25° C. in the range between −100° C. and 100° C.; use a different thickness in the range between 40 nm and 800 nm; use an aluminum-based material such as: aluminum-silicon, aluminum-copper, aluminum-silicon-copper or any other commonly used aluminum interconnect compound; be replaced by gold, silver, nickel or chromium.
[0094] The wafer out at 25° C. could be performed at a temperature different than 25° C. in the range between −100° C. and 100° C.
[0095] The Novellus M2i cluster tool could use chambers positioned at different locations than the ones of FIG. 10; use a different combination of chambers than the one of FIG. 10; be replaced by another Novellus cluster tool, such as Innova; or be replaced by another cluster tool, such as Endura, Endura XP or similar cluster tool from Applied Materials.
[0096] The obtained RMS surface roughness could be different than about 1 nm in the range between 0.2 and 40 nm.
[0097] The obtained specular infrared reflectivity could be measured by another means than FTIR, such as using a dye laser, a laser diode or any other means to produce a near infrared light; different than the results of FIG. 18 since thickness dependent between 50 nm and 150 nm; show a lower specular reflectivity at smaller infrared wavelengths approaching 1.55 μm than at higher infrared wavelengths;
[0098] The invention can be applied in other optical devices such as Add-After-Drop Filters (AADF) devices; Arrayed Wave Guide (AWG) and Arrayed Wave Guide Grating (AWGG) devices; Athermal Arrayed Wave Guide (AAWGG) devices; Charged Coupled Devices (CCD) devices; Distributed Feedback Laser Diode (DFB-LD) devices; Erbium Doped Fiber Amplifier (EDFA) devices; Fiber-To-The-Home (FTTH) application devices; Four Wave Mixing (FWM) devices; Fresnel Mirror (FM) devices; Laser Diode (LD) devices; Light Emitting Diodes (LED) devices; Mach-Zenhder (MZ), MachZenhder Interferometer (MZI), Mach-Zenhder Interferometer Multiplexer (MZIM) devices; Micro-Opto-Electro-Mechanical Systems (MOEMS) devices; Monitor Photo Diode (MPD) devices; Multi-Wavelength Optical Sources (MWOS) devices; Optical Add/Drop Multiplexers (OADM) devices; Optical Amplifier (AF) devices; Optical Cross-Connect (OCC, OXC) devices; Optical Cross Point (OCP) devices; Optical Filter (OF) devices; Optical Interferometer (OI) devices; Optical Network Unit (ONU) devices; Optical Saw Wave (OSW) devices; Optical Splitter (OS) devices; Optical Switch (OSW) and Optical Switch Module (OSM) devices; Photonic ATM (PATM) switching devices; Planar Lightwave Circuits (PLC) devices; Positive Emitter Coupled Logic (PECL) devices; Quarter Wave (QW) devices; Receiver Photo Diode (RPD) devices; Semiconductor Optical Amplifier (SOA) devices; Spot-Size converter integrated Laser Diode (SS-LD) devices; Sub-Carrier Multiplexing Optical Network Unit (SCM-ONU) devices; Temperature Insensitive Arrayed Wave Guide (TI-AWG) devices; Thermo-Optic (TO) devices and Thermo-Optic Switch (TOS) devices; Time Compression Multiplexing —Time Division Multiple Access (TCM-TDMA) devices; Time Division Multiplexing (TDM) devices; Tunable Receiver (TR) devices; Uniform-Loss Cyclic-Frequency Arrayed Wave Guide (ULCF-AWG) devices; Vertical Cavity Surface Emitting Laser (VCSEL) devices; and Wavelength Dispersive Multiplexing (WDM), Wavelength Dispersive Multiplexing Transceivers (WDMT) devices; | A method of making highly reflective mirrors on a wafer in the manufacture of photonic devices involves preheating a wafer to remove adsorbed volatile contaminants at a temperature between about 300 and 600° C. The wafer surface is etched at a temperature between about 300 and 600° C. to remove absorbed and chemically absorbed contaminants in the presence of a plasma to prevent poisoning. The wafer surface is thoroughly cooled so as to as reduce the surface mobility of the impinging atoms during the subsequent metallic deposition. A deposition is then carried out on the cooled wafer of a gettering layer for gettering hydrogen, oxygen and nitrogen. A metallic reflective layer is then deposited in a deposition chamber, and finally the wafer is removed from the deposition chamber to prevent excessive bulk oxidation. | 6 |
FIELD OF THE INVENTION
The present invention relates to snubbers, and more particularly, to hydraulic snubbers.
BACKGROUND OF THE INVENTION
Airplanes rely on specialized doors for passenger boarding and deboarding, galley servicing, cargo loading, maintenance access, emergency egress, etc. Some airplane doors are hinged to the fuselage, others slide into a cavity in the wall of the fuselage, and still others translate by moving outward and then forward along the fuselage of the airplane. During door usage, the possibility exists for various applied forces (such as, effects of gravity, a pressure difference between the cabin and the outside air, or a high speed wind) to cause an airplane door to rapidly move open or shut. A rapidly moving door could be a serious hazard, capable of injuring people near the door. A rapidly moving airplane door can also cause yielding or failure of the airplane fuselage, door frame, hinge arm, or hinge linkages. In certain instances, a large force applied to a door can completely severe the door's connection to the airplane.
Snubbers are included in airplane door systems to control the rate of door opening and closing. Many types of doors require the use of snubbers, including translating doors, top hinged canopy doors, bottom hinged doors, upward opening plugged doors, overhead doors, etc. The primary purpose of a snubber is to enhance personnel safety and door integrity by limiting the peak forces applied to the door mechanisms. Snubbers are usually hydraulic devices that absorb energy-similar to shock absorbers. Various types of snubbers exist, including piston, rotary, gear, vane, blade, etc. The piston type comprises a housing in the form of a cylinder, a piston mounted in the cylinder, a rod attached to the piston, and hydraulic fluid. Hydraulic fluid flow between chambers located on either side of the piston controls the rate of movement of the piston, and, thus the rod. One commonly used hydraulic fluid flow passageway between the chambers is an orifice in the piston or housing. When a force is exerted upon the rod to urge it in a particular direction, hydraulic fluid flows from one side of the piston to the other side, through the orifice. If the hydraulic fluid flow passageway between the chambers is a simple fixed-size orifice, pressure of the fluid from one side of the piston to the other side will be directly proportional to the flow rate squared through the orifice. If the hydraulic fluid flow passageway is a flow regulation orifice, the passageway will be provided in a conduit connecting the chambers, and the orifice size will be variable. A typical flow regulator maintains a constant rate of fluid flowing through the orifice by adjusting the orifice size. The greater the force being applied to the rod, the smaller the orifice size.
Operationally, translating airplane doors are supported by a hinge arm rotatably connected at one end to a door frame and at the other end to the door. A roller chain is positioned about a first sprocket mounted on a hinge pin located at one end of the hinge arm and about a second sprocket mounted on a hinge pin located at the other end of the hinge arm. Under non-emergency situations, the door is opened or closed manually. When a manual force is applied to the door, it causes the roller chain to translate, effecting rotation of the door hinge arm and translation of the door between its open and closed positions. In emergency situations, an actuator is provided to power the door open. The actuator is located on one side of the hinge arm, in-line with the roller chain. The actuator includes a through-rod that replaces a portion of the chain. When the actuator is activated, it causes the actuator through-rod to translate. This action causes the roller chain to translate, again effecting rotation of the door hinge arm and translation of the door between its closed position to its opened position. As the door moves, the door is maintained at an attitude approximately parallel to the longitudinal centerline of the airplane. The maximum velocity of the door is controlled by a snubber installed between the door and the door frame.
Although snubbers are useful devices, current snubbers can have undesirable characteristics. A first such disadvantage (mainly applicable to some current linear-type snubbers) is a potential spiking load due to the snubber's location in the overall door system. When a snubber is located between two structural points (i.e., the door frame and the door, or the hinge arm and the door), the angle of the snubber relative to the door will change as the door opens or closes. Likewise, the available snubbing force will vary as the door angle varies. The resulting geometry can create sections of door travel in which the snubber is less effective. This occurs typically at mid-door rotation. While the start and end portions of the door travel path will receive snubbing force, the middle position will receive less snubbing force. This allows the door's velocity to increase during mid-door rotation, requiring a large, or "spike," snubbing force near the end of travel to reduce the door's velocity and prevent the door from slamming. Many current door snubbers are unable to deal effectively with the spike loads created by snubber-door geometry.
A second disadvantage of current snubbers (both linear and rotary types) regardless of their location in the overall door system, is that they are frequently unable to absorb large energies in a controlled manner. For example, when a large force is applied to a door while the door is being opened or closed, the door's velocity will increase. Snubbers respond to the door's increased velocity by hydraulically countering the force to prevent the door from moving too rapidly. While a fixed-size orifice snubber will damp the door's velocity, because the orifice remains a constant size, the door speed will still increase as the force applied to the door is increased. If the applied force is very large, the door's velocity increase will be relatively very large. As mentioned above, a rapidly moving door can be a hazard to personnel near the door. The rapidly moving door will end its movement by slamming to a stop, potentially causing damage to the airplane fuselage, as well as to the door. To prevent the door from moving rapidly, a snubber with a smaller orifice could be used. However, such a snubber would make the manual operation of the door more difficult and time consuming.
Flow regulator snubbers as formed in accordance with the present invention have a partially more desirable response than fixed orifice type snubbers in that they prohibit the door velocity from significantly increasing by providing increased resistance in the fluid flow resulting in increased snubbing force to counter increased door velocity.
Regardless of type, any snubber that is unable to absorb large energies and control velocities quickly enough, results in the application of forces to door components that may cause them to yield or fail. Ideally, the location and design of a snubber should be such that large forces are dissipated in a controlled manner, i.e., provide a balance between too much and too little snubbing. An ideal snubber should be located and designed such that large energies are absorbed fast enough to prevent door components from breaking, while still controlling the door's velocity in order to stop the door without slamming. The snubber location and design should allow a door to move fast enough to be comfortably moved manually, but slow enough not to injure anyone. Neither the location nor the design of present snubbers meet all of these ideal requirements. Thus, a need exists for a new and improved snubber for an airplane door system that is designed and located to provide snubbing force throughout the entire path traveled by the door as it moves between its opened and closed positions, while allowing the door to be easily opened when very little force is applied. The snubber design and location should allow the snubber to counteract large applied forces, in order to slow door movement and prevent possible injury to personnel. The snubber should be capable of quickly absorbing energies and controlling door velocities in order to protect the components of the door from yielding or failing during the door's travel, while preventing a buildup of velocity at the end of the door's travel. The present invention is directed to fulfilling this need.
SUMMARY OF THE INVENTION
In accordance with the present invention, a hydraulic snubber that is ideally suited for use on an airplane translating door hinge arm is provided. The door hinge arm is rotatably attached at one end to the door frame and at the other end to a door by hinge pins. Mounted on the hinge pins are first and second sprockets, one located at each end of the hinge arm. Two roller chains pieces are partially looped around the sprockets, one chain associated with each sprocket. A pneumatic actuator is provided, comprising a housing in the form of a cylinder, a piston mounted in the cylinder, and a through-rod passing through the cylinder and connected to the piston. The actuator through-rod connects one end of one of the roller chains to one end of the other roller chain. The snubber comprises a hydraulic device that joins the other ends of the chains. The hydraulic snubber is located generally parallel to the actuator. The hydraulic device includes a housing in the form of a cylinder, a piston mounted in the cylinder, and a through-rod passing through the cylinder and connected to the piston. The actuator and snubber housings are supported by a support member that is integral with the hinge arm.
During non-emergency situations, a manually applied force causes the roller chain to translate around the sprockets. This action causes the hinge arm to rotate relative to the door frame, and the door to rotate relative to the hinge arm. In emergency situations, pneumatic pressure is applied to one side of the actuator piston to cause the actuator through-rod to move, which forces the roller chain to translate and the door to open. As the door moves between its closed and opened positions, snubbing force is provided by the hydraulic device.
In accordance with further aspects of the present invention, the snubber also includes a fluid flow regulation system that controls the amount of snubbing force available, depending on the applied force to the door. The fluid flow regulation system comprises two flow regulators, one for each direction of door travel (i.e., door opening and door closing) during normal operating conditions.
In accordance with yet other aspects of this invention, the fluid flow regulation system also includes two high pressure relief valves for limiting large input forces to the snubber, one for each direction of snubber piston travel.
In accordance with still other aspects of this invention, low pressure check valves are provided throughout the snubber fluid flow regulation system to ensure that the fluid flows through the appropriate fluid path.
In accordance with still further aspects of this invention, a compensator is provided for hydraulically compensating the snubber for hydraulic leaks, thermal expansion, etc.
From the foregoing description, it will be appreciated that a new, and distinctly better, snubber whose position and design is ideally suited for use on an airplane translating door hinge arm is provided by the present invention. The location of the hydraulic device between the roller chain pieces allows the snubber to provide snubbing force throughout the entire path traveled by the door, thus controlling the angular velocity of the hinge arm for its total travel, thus reducing the application of spike loads to the snubber at the ends of the path of door travel. The flow regulators of the snubber's fluid flow regulation system allow the door to be easily moved during normal use by the application of minimal force. The flow regulators increase snubbing capability in response to larger applied forces in order to prevent the door from moving too quickly. The high pressure relief valves of the snubber's fluid flow regulation system limit very large applied loads quickly, thereby protecting the internal door mechanisms from yielding or failing. The combination of the flow regulators and the high pressure relief valves prevent a buildup of excessive velocity during the door's travel.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an pictorial view of the interior of selected components of an airplane translating passenger door showing the location of a door hinge arm relative to the door and in dashed lines, the location of the hinge arm components that control the movement of the door including a snubber formed in accordance with the present invention;
FIG. 2 is a plan view of the door hinge arm components that control the movement of the door including a snubber formed in accordance with the present invention shown in FIG. 1; and
FIG. 3 is a partially block and partially pictorial diagram of a hydraulic door snubber formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although, the present invention was developed for, and is described in connection with, an airplane translating passenger entry door, it is to be understood that the invention may also find use in other snubber applications, including other airplane snubber applications. Examples of such use are to control flutter on aircraft control surfaces and to absorb energy in landing gear systems.
The following paragraphs describe a snubber formed in accordance with the present invention and its preferred location in an airplane translating door system. The snubber is comprised of a hydraulic device 41 and a flow regulation system 40. The following description focuses first on the hydraulic device 41 in terms of its placement in the overall door system and the operation of the snubber therein. (Shown generally in FIGS. 1 and 2.) Next, a detailed description of the flow regulation system 40 is given in terms of its elements and the effect those elements have on the performance of the snubber. (Shown generally in FIG. 3.)
FIG. 1 is a pictorial view of selected components of an airplane translating passenger door 11. More specifically, FIG. 1 shows a door 11, a hinge arm 13, an operating handle 12, first and second hinge pins 15, 17, a door bracket 19, translation-producing hinge arm components 20, and the hydraulic device 41 of a snubber formed in accordance with the present invention. Both the operating handle 12 and the hinge arm 13 are located on the side of the door 11 internal to the airplane. The door hinge arm 13 has a dog-leg shape. Both the operating handle 12 and the door hinge arm 13 are of a type known in the art. The first hinge pin 15 rotatably connects one end of the hinge arm 13 to a door frame bracket (not shown). The second hinge pin 17 rotatably connects the other end of the hinge arm 13 to the door bracket 19. Shown in dashed lines in FIG 1 within the hinge arm 13 are the translation-producing hinge arm components 20 that control the movement of the door and the hydraulic device 41. These elements are better seen in FIG. 2 and are described next.
FIG. 2 is a plan view of the hinge arm components that control the movement of the door 11 and of the snubber hydraulic device 41. The hinge arm components include first and second sprockets 25, 27; first and second idler sprockets 29a and 29b; two pieces of roller chain 31a, 31b; and a linear pneumatic actuator 33. The first sprocket 25 is mounted on the first hinge pin 15, and the second sprocket 27 is mounted on the second hinge pin 17. The first idler sprocket 29a is located near the inside turn of the dog-leg shaped hinge arm 13, and the second idler sprocket 29b is located near the outside turn.
One of the roller chain pieces 31b is positioned about the first hinge pin sprocket 25 and about the first and second idler sprockets 29a and 29b, thus, encompassing the arm of the dog-leg shaped door hinge arm 13 that extends to the frame hinge bracket (not shown). The other piece of roller chain 31a extends around the sprocket 27 mounted on the pin 17 that passes through the door hinge bracket 19. The linear pneumatic actuator 33 joins the ends of the roller chain pieces 31a, 31b located on the side of the hinge arm 13 nearest the door 11. The snubber hydraulic device 41 of the present invention joins the ends of the roller chain pieces 31a, 31b located on the side of the hinge arm 13 furthest from the door 11. A portion of the hydraulic device is attached to the side of the hinge arm 13 furthest from door 11.
The linear pneumatic actuator 33 (shown in FIG. 2) is of a type currently known in the art of airplane door actuators. It generally includes a cylinder 35, a piston 39, and a through-rod 37. The through-rod 37 is partially affixed to the piston 39 and passes through the ends of the cylinder 35. The ends of the through-rod 37 are connected by suitable couplers 38a, 38b to the above described ends of each of the roller chain pieces 31a, 31b. Only a chamber in the cylinder on one side of the piston is connected to a source of pneumatic power. The other chamber is not so connected. Thus, the pneumatic actuator is a unidirectional actuator, the actuation direction being the door open direction. Since unidirectional pneumatic actuators 33 capable of opening an airplane door and not interfering with the closing of the door are known, no specific actuator designed to accomplish these functions is described here.
The hydraulic device 41 of the snubber includes a housing in the form of a cylinder 47, a piston 45 and a through-rod 43. The through-rod 43 is affixed to the piston 45 and passes through the ends of the cylinder 47. The ends of the through-rod 43 are connected by suitable couplers 44a, 44b to the above-described ends of each of the roller chain pieces 31a, 31b. The cylinder 47 and the piston 45 together define first and second hydraulic fluid compartments 49, 51, one located on either side of the piston 45.
In the preferred embodiment, during non-emergency operations, the door is opened by manually rotating the door handle 12 to unlock the door, and manually applying a force to move the door 11 open. In emergencies, the rotation of the door handle 12 causes the linear pneumatic actuator 33 to create the force that translates the door open. The linear pneumatic actuator 33 is activated by a door system that does not form part of the present invention and thus is not described here. As noted above, preferably the linear pneumatic actuator operates only to open the door during emergency conditions and does not interfere with the manual closing of the door.
In more detail, when a manual force is applied to open or close the door, the roller chain pieces 31a, 31b translate around the sprockets 25, 27, 29a, 29b. When the roller chain 31b moves in one direction or the other around the first sprocket 25, the hinge arm 13 is caused to rotate around the hinge connection at the door frame. At the same time, the roller chain piece 31a is also revolving around the second sprocket 27, causing it to pivot the door 11, via the door bracket 19. As the roller chain pieces 31a, 31b translate along the hinge arm 13, the hinge arm 13 maintains the door's attitude approximately parallel to the longitudinal centerline of the airplane. Therefore, as the manually applied force moves the door, but the translation of the roller chain pieces synchronizes the rotation of the hinge arm to the door with the rotation of the hinge arm to the door frame, which causes the door to move along a path that maintains the door parallel to the airplane fuselage. If the pneumatic actuator is used to open the door, the actuator through-rod 37 causes the roller chain pieces 31a and 31b to translate and indirectly open the door.
All forces applied to the roller chain pieces 31a, 31b (vis-a-vis the door 11 and/or the pneumatic actuator 33) are snubbed by the hydraulic device 41 under the control of, and according to, a flow regulation system 40. The flow regulation system 40 is shown in block form in FIG. 3, and is described below.
FIG. 3 is a partially block and partially pictorial diagram of a snubber formed in accordance with the present invention. The through-rod 43 in FIG. 3 is shown in mid-stroke, moving in the door opening direction shown by an arrow 53. The flow regulation system 40 comprises first and second conduits 57, 63; first and second flow regulators 59, 65; first and second high pressure relief valves 61, 67; four low pressure check valves 69a, 69b, 69c, 69d; and a spring loaded compensator 71. Overall, the flow regulation system 40 regulates the flow of hydraulic fluid between the compartments 49, 51 located on opposite sides of the piston 45. The flow regulation system 40 normally uses the flow regulators 59, 65 to control the rate of fluid transfer between the two compartments 49, 51, but during large applied force conditions, will use high pressure relief valves 61, 67 to quickly limit the applied force. The high pressure relief valves 61, 67 allow the door velocity to increase, thereby limiting the internal forces on the door components, potentially saving those components from yielding or failing.
Below is a description of the flow regulation system 40. First, a discussion of the components is presented. Next, the components are described in terms of their physical relation to one another. Lastly, a description of their operation is provided. A flow regulation system formed in accordance with the present invention is applicable to all types of snubbers (e.g., rotary, gear, vane, blade, etc.). It is to be understood that the discussion of a flow regulation system herein as applied to a piston type snubber is not meant to limit the present invention to piston type snubbers only. The discussion of a flow regulation system of the present invention as applied to a piston type snubber is exemplary.
With regard to the components of the flow regulation system 40, each is currently known in the art of snubbing. The novelty of the present invention does not reside in these components per se, but rather in the novel use of discrete high pressure relief in conjunction with flow regulation. Since current flow regulators, high pressure relief valves, low pressure check valves, and compensators are well known in the art, no detailed description of these components is provided.
The specific components selected for use in the present invention should be capable of performing as described herein. In particular, the flow regulator chosen should be capable of sensing the hydraulic fluid pressure difference between the faces of the snubber piston (or some related value, i.e., the velocity of the snubber through-rod or the applied force to the door) and responding to the sensed input by regulating the flow of hydraulic fluid between the compartments 49, 51. Preferably, the high pressure relief valves include a spring and ball valve that requires a certain threshold pressure in order to compress the spring and allow hydraulic fluid to pass.
The high pressure relief valve selected should be capable of quickly relieving high pressure hydraulic fluid by rapidly passing hydraulic fluid between the first and second compartments. (Obviously, if a pressure seal is used in the snubbing system it is capable of "blowing out" and thereby acting as a crude high pressure relief element, but that is not what is intended in the present invention. The present invention requires a discrete element acting for the purpose of high pressure relief.) The high pressure relief valves selected must also reseat, or close, when the high pressure is slightly reduced. Stated differently, the high pressure relief valve should close at roughly the same pressure that it opened, so that very little hysterisis between fluid pressure and through-rod velocity exists.
The compensator selected should be capable of adding or subtracting hydraulic fluid to or from the snubber to compensate for hydraulic volume changes (i.e., a slow leak, thermal changes, etc.) In the preferred embodiment, the compensator comprises a piston in a housing with hydraulic fluid on one side of the piston and a compression spring on the other side. The hydraulic fluid is in communication with a low pressure portion of the flow regulation system 40. The spring is in slight compression so that the compensator 71 keeps the hydraulic fluid under pressure at all times and continually attempts to add hydraulic fluid to the flow regulation system 40, but can just as easily accept additional hydraulic fluid from filling or thermal expansion.
With regard to the physical relation of the components, the first compartment 49 contains an outlet that is connected to the first conduit 57. The first conduit 57 is branched to reach the inputs of both the first flow regulator 59 and the first high pressure relief valve 61. FIG. 3 also shows that the third and fourth low pressure check valves 69c, 69d have their outputs connected to the first conduit 57. The output of the first flow regulator 59 is connected to the input of the first low pressure check valve 69a, which outputs to the second conduit 63. The output of the first high pressure relief valve 61 is connected to a shared passage 80 that connects to the input of the second low pressure check valve 69b. The second low pressure check valve 69b also outputs to the second conduit 63.
The above described connections are provided for use during door opening. For door closing, similar component connections are provided. Specifically, the second compartment 51 contains an outlet that is connected to the second conduit 63. The second conduit 63 is branched to reach the inputs of both the second flow regulator 65 and the second high pressure relief valve 67. The first and second low pressure check valves 69a, 69b have their outputs connected to the second conduit 63, as stated above. Downstream of the second flow regulator 65 is the third low pressure check valve 69c, which outputs to the first conduit 57. The output of the second high pressure relief valve 67 is connected to the shared passage 80, which connects to the input of the fourth low pressure check valve 69d. The fourth low pressure check valve 69d outputs to the first conduit 57. The hydraulic fluid port of the compensator 71 is also connected to the shared passage 80. Thus, the shared passage 80 therefore interconnects five items: the outputs of the first and second high pressure relief valves 61, 67; the inputs of both the second and fourth low pressure check valves 69b, 69d; and the hydraulic port of the compensator 71. The optimal position of the compensator 71 for the present invention is conventional and is shown herein to be between the inputs of the second and fourth low pressure check valves 69b, 69d. In this position, the compensator will see only low pressure. In this position, the compensator will not have to work as hard to add or subtract hydraulic fluid to or from the snubber as it would if it were located in other positions.
The operation of the flow regulation system 40 is discussed below in three sections: manual door opening operation, manual door closing operation, and actuator door opening operation. Within each section, the discussion includes the response of the system during low applied force conditions through high applied force conditions.
During door opening, the motion of the hinge arm also pushes the through-rod 43 and piston 45 of the snubber hydraulic device 47. The piston 45 forces hydraulic fluid from the first compartment 49 to flow into the first conduit 57. (For explanatory purposes, hydraulic fluid flow is defined as going from the first compartment 49 to the second compartment 51 during door opening. Likewise, during door closing, hydraulic fluid flow is defined as going from the second compartment 51 to the first compartment 49.)
When slow angular rotation of the hinge arm occurs during normal door opening, hydraulic fluid flows only from the first conduit 57, through an orifice (not shown) in the first flow regulator 59, through the first low pressure check valve 69a, through the second conduit 63 to the second chamber 51. The pressure in the first conduit 57 is insufficient to open the first high pressure relief valve 61. The third and fourth low pressure check valves 69c, 69d prevent hydraulic fluid from entering the outlet ends of either the second flow regulator 65 or the second high pressure relief valve 67. In this manner, hydraulic fluid is passed from the first compartment 49 into the second compartment 51 at a rate controlled by the first flow regulator 59 during slow angular rotation of the hinge arm.
The rate of hydraulic fluid flow through the first flow regulator 59 may be according to any schedule desired by a designer for a particular application. Preferably, the first flow regulator 59 has a spool valve (not shown) whose position depends on the difference in hydraulic pressure on opposite sides of the piston. The position of the spool valve determines the size of the orifice of the flow regulator. When the pressure difference is below a certain amount, the orifice is fully open. When the pressure increases above a certain valve, the orifice size begins to constrict to a size that keeps the rate of hydraulic fluid flow constant between the first and second compartments 49, 51. Controlling the rate of fluid flow controls the velocity of the piston 45, and the through-rod 43, and thus, the translation of the roller chain pieces 31a, 31b, and the movement of the door.
When a very large external dynamic force is applied to the door during opening or closing (such as caused by wind, pressure, airplane attitude, etc.), high angular rotation of the hinge arm occurs and a very large pressure difference exists across the flees of the piston 45. This cause the orifice of the first flow regulator 59 to constrict to a very small opening. At a certain pressure, the hydraulic fluid pressure in the first conduit 57 will be large enough to exceed the opening threshold of the first high pressure relief valve 61. When this threshold is reached, hydraulic fluid begins to pass through the first high pressure relief valve 61. Fluid passing through the first high pressure relief valve 61 enters the shared passage 80, passes through the second low pressure check valve 69b and the second conduit 63 into the second compartment 51. The first high pressure relief valve 61 adds an additional path through which hydraulic fluid quickly passes, dissipating excessive hydraulic fluid pressure by rapidly transferring fluid from the first compartment 49 to the second compartment 51.
As a side note, even though the shared passage 80 is connected to multiple components, the output of the first high pressure relief valve 61 only exits from the shared passage 80 through the second low pressure check valve 69b. This is because the output of the second high pressure relief valve 67 is connected to the shared passage 80. The hydraulic pressure in the shared passage 80 is greater than the hydraulic pressure in the second conduit 63, biasing the second high pressure relief valve closed. While the input of the fourth low pressure cheek valve 69d is connected to the shared passage 80, the high hydraulic fluid pressure on its output side is greater than that on its input side. Thus, the fourth low pressure check valve 69d is also biased closed. The compensator 71 is only open to the shared passage 80 and does not actually pass hydraulic fluid.
If the large applied force is reduced during door opening, hydraulic fluid pressure in the first compartment 49 decreases, causing the pressure in the first conduit 57 to decrease. If the hydraulic fluid pressure decreases sufficiently, the first high pressure relief valve 61 will revert back to its closed position. Thereafter, the first flow regulator 59 will operate alone, snubbing the applied force and keeping the hydraulic fluid flow rate, and hence, the door's velocity, at or below an acceptable value.
Identical regulation is provided for manual door closing. In this case, hydraulic fluid flows through the second conduit 63, through the second flow regulator 65, through the third low pressure check valve 69c, through the first conduit 57, and into the first compartment 49. The first and second low pressure check valves 69a, 69b are unaffected since they are oriented to allow hydraulic fluid to flow into, not out of, the second conduit 63. If the applied force exceeds a predetermined threshold, hydraulic fluid will also flow through the second high pressure relief valve 67, through the shared passage 80, through the fourth low pressure check valve 69d, through the first conduit 57, and into the first compartment 49. Again, even though the shared passage 80 is connected to multiple components, the output of the second high pressure relief valve 67 will flow only through the fourth low pressure check valve 69d. This is because the differential pressure across the first high pressure relief valve 61 and the second low pressure check valve 69b biases these vanes closed. The compensator 71 is only open to the shared passage 80 and does not actually pass hydraulic fluid.
Operation during emergency door opening is accomplished in a way similar to manual door opening. The significant difference being that instead of a manual force directly causing the movement of the door, the linear pneumatic actuator 33 moves the door 11 indirectly by forcing the roller chain pieces 31a, 31b to translate, which rotates the hinge arm connections to the door 11 and the door frame, urging the door to open. The snubbing device 41 and the flow regulation system 40 of the present invention snub the applied forces to the door during actuator 33 operation as during manual operation.
In summary, the first and second hydraulic fluid conduits 57, 63 each direct fluid to a flow regulator 59, 65 that operates to maintain the rate of hydraulic fluid flow between the first and second compartments 49, 51 regardless of the applied force. This allows the door to be opened and closed at an acceptable rate during normal operations with only low applied manual force. The first and second conduits 57, 63 also direct fluid to high pressure relief valves 61, 67 that rapidly dissipate excessive hydraulic fluid pressure when large applied forces are present. This prevents the door components from yielding or failing during all design operations.
While the presently preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. For example, as noted above, while the illustrated and described snubber has been described in an airplane door translating system, it is to be understood that the snubber may find use in other environments, including other airplane environments. Further, in some airplane and other door environments, an actuator, such as the pneumatic actuator, may be unnecessary, in which use the related ends of the chains would be connected together. Further, in some environments, the chain and sprockets could be replaced by belts and pulleys or four-bar linkages. Hence, it is to be understood that, within the scope of the appended claims, this invention can be practiced otherwise and in other airplane areas where energy needs to be absorbed to control dynamic forces than as specifically described herein. | A snubber is disclosed for use on an airplane translating door hinge arm (13) comprising a hydraulic device (41) and a flow regulation system (40). The hinge arm (13) includes sprockets (25, 27) placed at the ends (15, 17) of the hinge arm (13). Roller chain pieces (31) rotate partially about the sprockets (25, 27). A pneumatic actuator (33) having a through-rod (37) and housing (35) is located on one side of the hinge arm (13). The actuator housing (35) is supported by a support member (23) integral with the hinge arm (13). The ends of the actuator through-rod (43) are each coupled to first ends of each of the roller chain pieces (31). The hydraulic device (41) comprising a housing (47), a through-rod (43), a piston 45, a first compartment (49), a second compartment (51), and hydraulic fluid, is also supported by the support member (23). The ends of the hydraulic device through-rod (43) are each coupled to second ends of each of the roller chain pieces (31). The hydraulic device (41) is located on the side of the hinge arm (13) opposite the side having the actuator (33). Also provided is a snubber fluid flow regulation system (40) comprising first and second flow regulators (59, 65) and first and second high pressure relief valves (61, 67), one each for use during door opening and door closing. A compensator (71) is also provided in the fluid flow regulation system (40) to hydraulically compensate the snubber (41) during temperature changes and to supply make-up fluid in case there is external leakage. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/102,145 filed on Dec. 10, 2013, which is a divisional of U.S. patent application Ser. No. 13/658,523 filed on Oct. 23, 2012, issued as U.S. Pat. No. 8,658,803 B2 on Feb. 25, 2014, which claims the benefit of priority to U.S. Provisional Application Ser. No. 61/551,772 filed on Oct. 26, 2011, each of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to novel amide derivatives of N-urea substituted amino acids, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of the N-formyl peptide receptor like-1 (FPRL-1) receptor. The invention relates specifically to the use of these compounds and their pharmaceutical compositions to treat disorders associated with the N-formyl peptide receptor like-1 (FPRL-1) receptor modulation.
BACKGROUND OF THE INVENTION
The N-formyl peptide receptor like-1 (FPRL-1) receptor is a G protein-coupled receptor that is expressed on inflammatory cells such as monocytes and neutrophils, as well as T cells and has been shown to play a critical role in leukocyte trafficking during inflammation and human pathology. FPRL-1 is an exceptionally promiscuous receptor that responds to a large array of exogenous and endogenous ligands, including Serum amyloid A (SAA), chemokine variant sCKβ8-1, the neuroprotective peptide human, anti-inflammatory eicosanoid lipoxin A4 (LXA4) and glucocorticoid-modulated protein annexin A1. FPRL-1 transduces anti-inflammatory effects of LXA4 in many systems, but it also can mediate the pro-inflammatory signaling cascade of peptides such as SAA. The ability of the receptor to mediate two opposite effects is proposed to be a result of different receptor domains used by different agonists (Parmentier, Marc et al. Cytokine & Growth Factor Reviews 17 (2006) 501-519).
Activation of FPRL-1 by LXA4 or its analogs and by Annexin I protein has been shown to result in anti-inflammatory activity by promoting active resolution of inflammation which involves inhibition of polymorphonuclear neutrophil (PMN) and eosinophil migration and also stimulate monocyte migration enabling clearance of apoptotic cells from the site of inflammation in a nonphlogistic manner. In addition, FPRL-1 has been shown to inhibit natural killer (NK) cell cytotoxicity and promote activation of T cells which further contributes to down regulation of tissue damaging inflammatory signals. FPRL-1/LXA4 interaction has been shown to be beneficial in experimental models of ischemia reperfusion, angiogenesis, dermal inflammation, chemotherapy-induced alopecia, ocular inflammation such as endotoxin-induced uveitis, corneal wound healing, re-epithelialization etc. FPRL-1 thus represents an important novel pro-resolutionary molecular target for the development of new therapeutic agents in diseases with excessive inflammatory responses.
JP 06172288 discloses the preparation of phenylalanine derivatives of general formula:
as inhibitors of acyl-coenzyme A: cholesterol acyltransferase derivatives useful for the treatment of arteriosclerosis-related various diseases such as angina pectoris, cardiac infarction, temporary ischemic spasm, peripheral thrombosis or obstruction.
Journal of Combinatorial Chemistry (2007), 9(3), 370-385 teaches a thymidinyl dipeptide urea library with structural similarity to the nucleoside peptide class of antibiotics:
WO 9965932 discloses tetrapeptides or analogs or peptidomimetics that selectively bind mammalian opioid receptors:
Helvetica Chimica Acta (1998), 81(7), 1254-1263 teaches the synthesis and spectroscopic characterization of 4-chlorophenyl isocyanate (1-chloro-4-isocyanatobenzene) adducts with amino acids as potential dosimeters for the biomonitoring of isocyanate exposure:
EP 457195 discloses the preparation of peptides having endothelin antagonist activity and pharmaceutical compositions comprising them:
Yingyong Huaxue (1990), 7(1), 1-9 teaches the structure-activity relations of di- and tripeptide sweeteners and of L-phenyl alanine derivatives:
FR 2533210 discloses L-phenyl alanine derivatives as synthetic sweeteners:
WO2005047899 discloses compounds which selectively activate the FPRL-1 receptor represented by the following scaffolds:
SUMMARY OF THE INVENTION
A group of amide derivatives of N-urea substituted amino acids, which are potent and selective FPRL-1 modulators, has been discovered. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of FPRL-1 receptor. The term “modulator” as used herein, includes but is not limited to: receptor agonist, antagonist, inverse agonist, inverse antagonist, partial agonist, and partial antagonist.
This invention describes compounds of Formula I, which have FPRL-1 receptor biological activity. The compounds in accordance with the present invention are thus of use in medicine, for example in the treatment of humans with diseases and conditions that are alleviated by FPRL-1 modulation.
In one aspect, the invention provides a compound represented by Formula I or the individual geometrical isomers, individual enantiomers, individual diastereoisomers, individual tautomers, individual zwitterions or a pharmaceutically acceptable salt thereof:
wherein:
a is 0 or 1;
b is 0, 1, 2, 3 or 4;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NH 2 , —OH, —O(C 1-8 alkyl),
R 2 is optionally substituted C 1-8 alkyl, optionally substituted C 6-10 aryl,
R 3 is H, optionally substituted C 1-8 alkyl, halogen, —COOH, —OH, —NH 2 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl;
R 4 is H, optionally substituted C 1-8 alkyl, halogen, —COOH, —OH, —NH 2 , —NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl;
R 5 is optionally substituted C 1-8 alkyl, halogen, —COOH, —OH, —NH 2 , —NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl;
R 6 is H, optionally substituted C 1-8 alkyl, halogen, —COOH, —OH, —NH 2 , —NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl;
R 7 is H, optionally substituted C 1-8 alkyl, halogen, —COOH, —OH, —NH 2 , —NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl;
and compounds:
In another aspect, the invention provides a compound represented by Formula II or the geometrical isomers, enantiomers, diastereoisomers, tautomers, zwitterions, hydrates, crystal forms, solvates or a pharmaceutically acceptable salt thereof:
wherein:
a is 1 and b is 0;
a is 0 and b is 1;
a is 1 and b is 1;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen, CF 3 or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl;
with the provisos:
a). when a=1 and b=0 then:
R 9 is not optionally substituted benzyl; and
R 11 is not:
the compound of Formula II is not of structures:
and
b). when a=0 and b=1 then:
R 1 is OR 13 ; and
the compound of Formula II is not of structure:
and
c). when a=1 and b=1 then:
R 11 is not:
In another aspect, the invention provides a compound represented by Formula II,
wherein:
a is 1 and b is 0;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen, CF 3 or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl;
with the provisos:
R 9 is not optionally substituted benzyl; and
R 11 is not:
the compound of Formula II is not of structures:
In another aspect, the invention provides a compound represented by Formula II,
wherein:
a is 1 and b is 0;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen, CF 3 or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl;
with the provisos:
R 9 is not optionally substituted benzyl; and
R 11 is not:
the compound of Formula II is not of structures:
In another aspect, the invention provides a compound represented by Formula II,
wherein:
a is 1 and b is 0;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is —CF 3 ;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl;
with the provisos:
R 9 is not optionally substituted benzyl; and
R 11 is not:
the compound of Formula II is not of structures:
In another aspect, the invention provides a compound represented by Formula II, wherein:
a is 1 and b is 0;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is halogen;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl;
with the provisos:
R 9 is not optionally substituted benzyl;
and the compound of Formula II is not of structures:
and
R 11 is not:
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 1 and b is 0;
R 1 is optionally substituted C 1-8 alkyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 ;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 ;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 ;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 ;
R 8 is hydrogen or optionally substituted C 1-8 alkyl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen or optionally substituted C 1-8 ;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl;
with the provisos:
R 9 is not optionally substituted benzyl;
and the compound of Formula II is not of structures:
and
R 11 is not:
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 1 and b is 0;
R 1 is optionally substituted C 1-8 alkyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl;
R 3 is hydrogen or halogen;
R 4 is hydrogen;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen;
R 7 is hydrogen;
R 8 is hydrogen, optionally substituted C 1-8 alkyl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen or optionally substituted C 1-8 alkyl;
with the provisos:
R 9 is not optionally substituted benzyl;
and the compound of Formula II is not of structures:
and
R 11 is not:
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 0 and b is 1;
R 1 is —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen, CF 3 or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl; and
the compound of Formula II is not of structure:
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 0 and b is 1;
R 1 is —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is halogen;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl; and
the compound of Formula II is not of structure:
In another aspect, the invention provides a compound represented by Formula II,
wherein:
a is 0 and b is 1;
R 1 is —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 8 is hydrogen;
R 9 is hydrogen;
R 10 is hydrogen, optionally substituted C 1-8 alkyl;
R 9a is hydrogen, optionally substituted C 1-8 alkyl;
R 10a is hydrogen, optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl; and
R 14 is hydrogen, CF 3 or optionally substituted C 1-8 alkyl; and
the compound of Formula II is not of structure:
In another aspect, the invention provides a compound represented by Formula II,
wherein:
a is 0 and b is 1;
R 1 is —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl;
R 3 is hydrogen or halogen;
R 4 is hydrogen;
R 5 is halogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 8 is hydrogen;
R 9 is hydrogen;
R 10 is hydrogen or optionally substituted C 1-8 alkyl;
R 9a is hydrogen or optionally substituted C 1-8 alkyl;
R 10a is hydrogen or optionally substituted C 1-8 alkyl; and
R 13 is hydrogen; and
the compound of Formula II is not of structure:
In another aspect, the invention provides a compound represented by Formula II,
wherein:
a is 0 and b is 1;
R 1 is —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl;
R 3 is hydrogen or halogen;
R 4 is hydrogen;
R 5 is halogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 8 is hydrogen;
R 9 is hydrogen;
R 10 is hydrogen or optionally substituted C 1-8 alkyl;
R 9a is optionally substituted C 1-8 alkyl;
R 10a is optionally substituted C 1-8 alkyl; and
R 13 is hydrogen.
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 1 and b is 1;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen or optionally substituted C 1-8 alkyl; and
R 15 is hydrogen or optionally substituted C 1-8 alkyl; and
with the proviso:
that R 11 is not:
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 1 and b is 1;
R 1 is optionally substituted C 1-8 alkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted C 3-8 cycloalkenyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 5 is halogen;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen, —COOR 15 , —OR 13 , —NR 11 R 12 , NO 2 , optionally substituted heterocycle, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl or optionally substituted C 3-8 cycloalkenyl;
R 8 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 9a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 10a is hydrogen, optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 15 is hydrogen or optionally substituted C 1-8 alkyl; and
with the proviso:
that R 11 is not:
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 1 and b is 1;
R 1 is optionally substituted C 1-8 alkyl, —NR 11 R 12 or —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 4 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 5 is halogen, —CF 3 or —S(O) n R 14 ;
n is 0, 1 or 2;
R 6 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 7 is hydrogen, optionally substituted C 1-8 alkyl, halogen;
R 8 is hydrogen;
R 9 is hydrogen, optionally substituted C 1-8 alkyl;
R 10 is hydrogen, optionally substituted C 1-8 alkyl;
R 9a is hydrogen, optionally substituted C 1-8 alkyl;
R 10a is hydrogen, optionally substituted C 1-8 alkyl;
R 11 is hydrogen or optionally substituted C 1-8 alkyl;
R 12 is hydrogen or optionally substituted C 1-8 alkyl;
R 13 is hydrogen or optionally substituted C 1-8 alkyl;
R 14 is hydrogen or optionally substituted C 1-8 alkyl; and
R 15 is hydrogen or optionally substituted C 1-8 alkyl;
with the proviso:
that R 11 is not:
In another aspect, the invention provides a compound represented by Formula II,
wherein
a is 1 and b is 1;
R 1 is —OR 13 ;
R 2 is optionally substituted C 1-8 alkyl or optionally substituted C 6-10 aryl;
R 3 is hydrogen;
R 4 is hydrogen;
R 5 is halogen;
R 6 is hydrogen;
R 7 is hydrogen;
R 8 is hydrogen;
R 9 is hydrogen;
R 10 is hydrogen;
R 9a is hydrogen;
R 10a is hydrogen; and
R 13 is hydrogen or optionally substituted C 1-8 alkyl; and
with the proviso:
that R 11 is not:
The term “alkyl”, as used herein, refers to saturated, monovalent or divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 8 carbon atoms. One methylene (—CH 2 —) group, of the alkyl group can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. Alkyl groups can have one or more chiral centers. Alkyl groups can be independently substituted by halogen atoms, hydroxyl groups, cycloalkyl groups, amino groups, heterocyclic groups, aryl groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamide groups.
The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be independently substituted by halogen atoms, sulfonyl C 1-8 alkyl groups, sulfoxide C 1-8 alkyl groups, sulfonamide groups, nitro groups, cyano groups, —OC 1-8 alkyl groups, —SC 1-8 alkyl groups, —C 1-8 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cycloalkyl having at least one double bond. Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups can be independently substituted by halogen atoms, sulfonyl groups, sulfoxide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-6 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. One methylene (—CH 2 —) group, of the alkenyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. C 2-6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by alkyl groups, as defined above or by halogen atoms.
The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one triple bond. One methylene (—CH 2 —) group, of the alkynyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. Alkynyl groups can be substituted by alkyl groups, as defined above, or by halogen atoms.
The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which can be aromatic or non-aromatic, saturated or unsaturated, containing at least one heteroatom selected form oxygen, nitrogen, sulfur, or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be interrupted by a C═O; the S and N heteroatoms can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by halogen atoms, sulfonyl groups, sulfoxide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-8 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms, by removal of one hydrogen atom. Aryl can be substituted by halogen atoms, sulfonyl C 1-6 alkyl groups, sulfoxide C 1-6 alkyl groups, sulfonamide groups, carboxylic acid groups, C 1-6 alkyl carboxylates (ester) groups, amide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-6 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, aldehydes, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups. Aryls can be monocyclic or polycyclic.
The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The term “carbonyl” as used herein, represents a group of formula “—C(O)—”.
The term “ketone” as used herein, represents an organic compound having a carbonyl group linked to a carbon atom such as —(CO)R x wherein R x can be alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “amine” as used herein, represents a group of formula “—NR x R y ”, wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
The term “sulfonyl” as used herein, represents a group of formula “—SO 2 ”.
The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
The term “sulfonate” as used herein, represents a group of the formula “—S(O) 2 —O—”.
The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
The term “nitro” as used herein, represents a group of formula “—NO 2 ”.
The term “cyano” as used herein, represents a group of formula “—CN”.
The term “amide” as used herein, represents a group of formula “—C(O)NR x R y ” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “sulfonamide” as used herein, represents a group of formula “—S(O) 2 NR x R y ” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “sulfoxide” as used herein, represents a group of formula “—S(O)—”.
The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
The term “phosphoric acid” as used herein, represents a group of formula “—OP(O)(OH) 2 ”.
The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
The formula “H”, as used herein, represents a hydrogen atom.
The formula “O”, as used herein, represents an oxygen atom.
The formula “N”, as used herein, represents a nitrogen atom.
The formula “S”, as used herein, represents a sulfur atom.
The invention discloses compounds
{[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-indol-3-yl)propanoyl]amino}acetic acid; tert-butyl {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-indol-3-yl)propanoyl]amino}acetate; [(4-amino-2-{[(4-bromophenyl)carbamoyl]amino}-4-oxobutanoyl)amino]acetic acid; tert-butyl [(4-amino-2-{[(4-bromophenyl)carbamoyl]amino}-4-oxobutanoyl)amino]acetate; 2-{[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoic acid; tert-butyl 2-{[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoate; {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-imidazol-4-yl)propanoyl]amino}acetic acid; tert-butyl {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-imidazol-4-yl)propanoyl]amino}acetate; {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfonyl)butanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfonyl)butanoyl]amino}acetate; {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfanyl)butanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfanyl)butanoyl]amino}acetate; 2-methyl-2-{[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}propanoic acid; tert-butyl 2-methyl-2-{[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}propanoate; {[(2S)-4-methyl-2-({[4-(methylsulfonyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(methylsulfonyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; {[(2S)-4-methyl-2-({[4-(methylsulfinyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(methylsulfinyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; 2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoic acid; tert-butyl 2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoate; ({(2S)-4-methyl-2-[({4-[(trifluoromethyl)sulfanyl]phenyl}carbamoyl)amino]pentanoyl}amino)acetic acid; tert-butyl ({(2S)-4-methyl-2-[({4-[(trifluoromethyl)sulfanyl]phenyl}carbamoyl)amino]pentanoyl}amino)acetate; {[(2S)-4-methyl-2-({[4-(methylsulfanyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(methylsulfanyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; {[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetic acid; tert-butyl {[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetate; {[(2R,3R)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetic acid tert-butyl {[(2R,3R)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetate; {[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; {[(2R)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetic acid; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-[2-(dimethylamino)-2-oxoethyl]-4-methylpentanamide; [(2-{[(4-bromophenyl)carbamoyl]amino}-2-methylpropanoyl)amino]acetic acid; tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2-methylpropanoyl)amino]acetate; [(2-{[(4-bromophenyl)carbamoyl]amino}-2-ethylbutanoyl)amino]acetic acid; tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2-ethylbutanoyl)amino]acetate; [(2-{[(4-bromophenyl)carbamoyl]amino}-2,4-dimethylpentanoyl)amino]acetic acid; tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2,4-dimethylpentanoyl)amino]acetate; (2S)—N-[(1S)-2-amino-2-oxo-1-phenylethyl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}(phenyl)ethanoic acid; tert-butyl (2S)-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}(phenyl)ethanoate; (2S)—N-[(2S)-1-amino-1-oxopentan-2-yl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}pentanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}pentanoate; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-[(2R)-1-hydroxypropan-2-yl]-4-methylpentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2,3-dihydroxypropyl)-4-methylpentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(1,3-dihydroxypropan-2-yl)-4-methylpentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-hydroxy-2-methylpropyl)-4-methylpentanamide; (2S)—N-[(2S)-1-amino-3-methyl-1-oxobutan-2-yl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-3-methylbutanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-3-methylbutanoate; (2S)—N-[(2S)-1-amino-1-oxopropan-2-yl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino)}propanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}propanoate; (2S)—N-[(2S)-1-amino-1-oxopropan-2-yl]-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}propanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}propanoate; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)-4-methylpentanamide; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methyl-N-(2-oxopropyl)pentanamide; (2S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanamide; {[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetate; (2S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}pentanamide; (2S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromophenyl)carbamoyl]amino}pentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methyl-N-(2-oxopropyl)pentanamide; (2S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetic acid; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)-4-methylpentanamide; tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetate; {[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}pentanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}pentanoyl]amino}acetate; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-oxopropyl)pentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-oxopropyl)pentanamide; propan-2-yl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate; ethyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate; methyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)pentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)pentanamide; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)-3-phenylpropanamide; {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}pentanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-oxopropyl)-3-phenylpropanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-oxopropyl)-3-phenylpropanamide; (2S,3S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)-3-methylpentanamide; (2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)-3-methylpentanamide; (2S,3S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-3-methyl-N-(2-oxopropyl)pentanamide; (2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methyl-N-(2-oxopropyl)pentanamide; (2S,3S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-3-methylpentanamide; (2S,3S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanamide; {[(2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetic acid; tert-butyl {[(2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetate; {[(2S,3S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetic acid; tert-butyl {[(2S,3S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetate; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)-3-phenylpropanamide; 3-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-phenylpropanoyl]amino}propanoic acid; tert-butyl 3-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-phenylpropanoyl]amino}propanoate; {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-phenylpropanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-phenylpropanoyl]amino}acetate.
In another aspect the invention discloses compounds:
{[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-imidazol-4-yl)propanoyl]amino}acetic acid; tert-butyl {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-imidazol-4-yl)propanoyl]amino}acetate; {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfonyl)butanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfonyl)butanoyl]amino}acetate; {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfanyl)butanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-(methylsulfanyl)butanoyl]amino}acetate; 2-methyl-2-{[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}propanoic acid; tert-butyl 2-methyl-2-{[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}propanoate; {[(2S)-4-methyl-2-({[4-(methylsulfonyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(methylsulfonyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; {[(2S)-4-methyl-2-({[4-(methylsulfinyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(methylsulfinyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; 2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoic acid; tert-butyl 2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoate; ({(2S)-4-methyl-2-[({4-[(trifluoromethyl)sulfanyl]phenyl}carbamoyl)amino]pentanoyl}amino)acetic acid; tert-butyl ({(2S)-4-methyl-2-[({4-[(trifluoromethyl)sulfanyl]phenyl}carbamoyl)amino]pentanoyl}amino)acetate; {[(2S)-4-methyl-2-({[4-(methylsulfanyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(methylsulfanyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; {[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetic acid; tert-butyl {[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetate; {[(2R,3R)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetic acid; tert-butyl {[(2R,3R)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanoyl]amino}acetate; {[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetic acid; tert-butyl {[(2S)-4-methyl-2-({[4-(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}acetate; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-[2-(dimethylamino)-2-oxoethyl]-4-methylpentanamide; [(2-{[(4-bromophenyl)carbamoyl]amino}-2-methylpropanoyl)amino]acetic acid; tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2-methylpropanoyl)amino]acetate; [(2-{[(4-bromophenyl)carbamoyl]amino}-2-ethylbutanoyl)amino]acetic acid; tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2-ethylbutanoyl)amino]acetate; [(2-{[(4-bromophenyl)carbamoyl]amino}-2,4-dimethylpentanoyl)amino]acetic acid; tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2,4-dimethylpentanoyl)amino]acetate; (2S)—N-[(1S)-2-amino-2-oxo-1-phenylethyl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}(phenyl)ethanoic acid; tert-butyl (2S)-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}(phenyl)ethanoate; (2S)—N-[(2S)-1-amino-1-oxopentan-2-yl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}pentanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}pentanoate; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-[(2R)-1-hydroxypropan-2-yl]-4-methylpentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2,3-dihydroxypropyl)-4-methylpentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(1,3-dihydroxypropan-2-yl)-4-methylpentanamide; (2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-hydroxy-2-methylpropyl)-4-methylpentanamide; (2S)—N-[(2S)-1-amino-3-methyl-1-oxobutan-2-yl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-3-methylbutanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-3-methylbutanoate; (2S)—N-[(2S)-1-amino-1-oxopropan-2-yl]-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino)}propanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}propanoate; (2S)—N-[(2S)-1-amino-1-oxopropan-2-yl]-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanamide; (2S)-2-{[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}propanoic acid; tert-butyl (2S)-2-{[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}propanoate; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-hydroxyethyl)-4-methylpentanamide; (2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methyl-N-(2-oxopropyl)pentanamide; (2S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanamide; {[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetic acid; tert-butyl {[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}acetate; tert-butyl 2-{[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoate; 2-{[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-2-methylpropanoic acid; tert-butyl [(4-amino-2-{[(4-bromophenyl)carbamoyl]amino}-4-oxobutanoyl)amino]acetate; [(4-amino-2-{[(4-bromophenyl)carbamoyl]amino}-4-oxobutanoyl)amino]acetic acid; tert-butyl {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-indol-3-yl)propanoyl]amino}acetate; {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-indol-3-yl)propanoyl]amino}acetic acid.
Some compounds of Formula I and of Formula II and some of their intermediates have at least one asymmetric center in their structure. This asymmetric center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I and of Formula II are able to form.
The acid addition salt form of a compound of Formula I and of Formula II that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic acid, for example, hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic acid, hydroxyacetic acid, propanoic acid, lactic acid, pyruvic acid, malonic acid, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric acid, methylsulfonic acid, ethanesulfonic acid, benzenesulfonic acid, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta-Zürich, 2002, 329-345).
The base addition salt form of a compound of Formula I and of Formula II that occurs in its acid form can be obtained by treating the acid with an appropriate base such as an inorganic base, for example, sodium hydroxide, magnesium hydroxide, potassium hydroxide, calcium hydroxide, ammonia and the like; or an organic base such as for example, L-arginine, ethanolamine, betaine, benzathine, morpholine and the like. (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta-Zurich, 2002, 329-345).
Compounds of Formula I and of Formula II and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically.
Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
The compounds of the invention are indicated for use in treating or preventing conditions in which there is likely to be a component involving the N-formyl peptide receptor like-1 receptor.
In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
In a further embodiment of the invention, there are provided methods for treating disorders associated with modulation of the N-formyl peptide receptor like-1 receptor.
Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one compound of the invention.
Therapeutic utilities of the N-formyl peptide receptor like-1 receptor modulators are ocular inflammatory diseases including, but not limited to, wet and dry age-related macular degeneration (ARMD), uveitis, dry eye, Keratitis, allergic eye disease and conditions affecting the posterior part of the eye, such as maculopathies and retinal degeneration including non-exudative age related macular degeneration, exudative age related macular degeneration, choroidal neovascularization, diabetic retinopathy (proliferative), retinopathy of prematurity (ROP), acute macular neuroretinopathy, central serous chorioretinopathy; cystoid macular edema, and diabetic macular edema; infectious keratitis, uveitis, herpetic keratitis, corneal angiogenesis, lymphangiogenesis, uveitis, retinitis, and choroiditis such as acute multifocal placoid pigment epitheliopathy, Behcet's disease, birdshot retinochoroidopathy, infectious (syphilis, lyre, tuberculosis, toxoplasmosis), intermediate uveitis (pars planitis), multifocal choroiditis, multiple evanescent white dot syndrome (mewds), ocular sarcoidosis, posterior scleritis, serpiginous choroiditis, subretinal fibrosis and uveitis syndrome, Vogt-Koyanagi- and Harada syndrome; vascular diseases/exudative diseases such as retinal arterial occlusive disease, central retinal vein occlusion, cystoids macular edema, disseminated intravascular coagulopathy, branch retinal vein occlusion, hypertensive fundus changes, ocular ischemic syndrome, retinal arterial microaneurysms, Coat's disease, parafoveal telangiectasis, hemi-retinal vein occlusion, papillophlebitis, central retinal artery occlusion, branch retinal artery occlusion, carotid artery disease (CAD), frosted branch angiitis, sickle cell retinopathy and other hemoglobinopathies, angioid streaks, familial exudative vitreoretinopathy, and Eales disease; traumatic/surgical conditions such as sympathetic ophthalmia, uveitic retinal disease, retinal detachment, trauma, post surgical corneal wound healing, conditions caused by laser, conditions caused by photodynamic therapy, photocoagulation, hypoperfusion during surgery, radiation retinopathy, and bone marrow transplant retinopathy; proliferative disorders such as proliferative vitreal retinopathy and epiretinal membranes, and proliferative diabetic retinopathy; infectious disorders such as ocular histoplasmosis, ocular toxocariasis, presumed ocular histoplasmosis syndrome (POHS), endophthalmitis, toxoplasmosis, retinal diseases associated with HIV infection, choroidal disease associate with HIV infection, uveitic disease associate with HIV infection, viral retinitis, acute retinal necrosis, progressive outer retinal necrosis, fungal retinal diseases, ocular syphilis, ocular tuberculosis, diffuse unilateral subacute neuroretinitis, and myiasis; genetic disorders such as retinitis pigmentosa, systemic disorders with associated retinal dystrophies, congenital stationary night blindness, cone dystrophies, Stargardt's disease and fundus flavimaculatus, Best's disease, pattern dystrophy of the retinal pigmented epithelium, X-linked retinoschisis, Sorsby's fundus dystrophy, benign concentric maculopathy, Bietti's crystalline dystrophy, and pseudoxanthoma elasticum; retinal tears/holes such as retinal detachment, macular hole, and giant retinal tear; tumors such as retinal disease associated with tumors, congenital hypertrophy of the retinal pigmented epithelium, posterior uveal melanoma, choroidal hemangioma, choroidal osteoma, choroidal metastasis, combined hamartoma of the retina and retinal pigmented epithelium, retinoblastoma, vasoproliferative tumors of the ocular fundus, retinal astrocytoma, and intraocular lymphoid tumors; and miscellaneous other diseases affecting the posterior part of the eye such as punctate inner choroidopathy, acute posterior multifocal placoid pigment epitheliopathy, myopic retinal degeneration, and acute retinal epitheliitis, systemic inflammatory diseases such as stroke, coronary artery disease, obstructive airway diseases, HIV-mediated retroviral infections, cardiovascular disorders including coronary artery disease, neuroinflammation, neurological disorders, pain and immunological disorders, asthma, allergic disorders, inflammation, systemic lupus erythematosus, psoriasis, CNS disorders such as Alzheimer's disease, arthritis, sepsis, inflammatory bowel disease, cachexia, angina pectoris, post-surgical corneal inflammation, blepharitis, MGD, dermal wound healing, burns, rosacea, atopic dermatitis, acne, psoriasis, seborrheic dermatitis, actinic keratoses, viral warts, photoaging rheumatoid arthritis and related inflammatory disorders, alopecia, glaucoma, branch vein occlusion, Best's vitelliform macular degeneration, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the RPE (Perretti, Mauro et al. Pharmacology & Therapeutics 127 (2010) 175-188.) These compounds are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by the N-formyl peptide receptor like-1 receptor modulation: including, but not limited to the treatment of wet and dry age-related macular degeneration (ARMD), diabetic retinopathy (proliferative), retinopathy of prematurity (ROP), diabetic macular edema, uveitis, retinal vein occlusion, cystoids macular edema, glaucoma, branch vein occlusion, Best's vitelliform macular degeneration, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the RPE.
In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of the FPRL-1 receptor. Such methods can be performed, for example, by administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention, or any combination thereof, or pharmaceutically acceptable salts, hydrates, solvates, crystal forms and individual isomers, enantiomers, and diastereomers thereof.
The present invention concerns the use of a compound of Formula I and of Formula II or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament for the treatment of ocular inflammatory diseases including, but not limited to, wet and dry age-related macular degeneration (ARMD), uveitis, dry eye, Keratitis, allergic eye disease and conditions affecting the posterior part of the eye, such as maculopathies and retinal degeneration including non-exudative age related macular degeneration, exudative age related macular degeneration, choroidal neovascularization, diabetic retinopathy (proliferative), retinopathy of prematurity (ROP), acute macular neuroretinopathy, central serous chorioretinopathy, cystoid macular edema, and diabetic macular edema; infectious keratitis, uveitis, herpetic keratitis, corneal angiogenesis, lymphangiogenesis, uveitis, retinitis, and choroiditis such as acute multifocal placoid pigment epitheliopathy, Behcet's disease, birdshot retinochoroidopathy, infectious (syphilis, lyme, tuberculosis, toxoplasmosis), intermediate uveitis (pars planitis), multifocal choroiditis, multiple evanescent white dot syndrome (mewds), ocular sarcoidosis, posterior scleritis, serpiginous choroiditis, subretinal fibrosis and uveitis syndrome, Vogt-Koyanagi- and Harada syndrome; vascular diseases/exudative diseases such as retinal arterial occlusive disease, central retinal vein occlusion, cystoids macular edema, disseminated intravascular coagulopathy, branch retinal vein occlusion, hypertensive fundus changes, ocular ischemic syndrome, retinal arterial microaneurysms, Coat's disease, parafoveal telangiectasis, hemi-retinal vein occlusion, papillophlebitis, central retinal artery occlusion, branch retinal artery occlusion, carotid artery disease (CAD), frosted branch angiitis, sickle cell retinopathy and other hemoglobinopathies, angioid streaks, familial exudative vitreoretinopathy, and Eales disease; traumatic/surgical conditions such as sympathetic ophthalmia, uveitic retinal disease, retinal detachment, trauma, post surgical corneal wound healing, conditions caused by laser, conditions caused by photodynamic therapy, photocoagulation, hypoperfusion during surgery, radiation retinopathy, and bone marrow transplant retinopathy; proliferative disorders such as proliferative vitreal retinopathy and epiretinal membranes, and proliferative diabetic retinopathy; infectious disorders such as ocular histoplasmosis, ocular toxocariasis, presumed ocular histoplasmosis syndrome (POHS), endophthalmitis, toxoplasmosis, retinal diseases associated with HIV infection, choroidal disease associate with HIV infection, uveitic disease associate with HIV infection, viral retinitis, acute retinal necrosis, progressive outer retinal necrosis, fungal retinal diseases, ocular syphilis, ocular tuberculosis, diffuse unilateral subacute neuroretinitis, and myiasis; genetic disorders such as retinitis pigmentosa, systemic disorders with associated retinal dystrophies, congenital stationary night blindness, cone dystrophies, Stargardt's disease and fundus flavimaculatus, Best's disease, pattern dystrophy of the retinal pigmented epithelium, X-linked retinoschisis, Sorsby's fundus dystrophy, benign concentric maculopathy, Bietti's crystalline dystrophy, and pseudoxanthoma elasticum; retinal tears/holes such as retinal detachment, macular hole, and giant retinal tear; tumors such as retinal disease associated with tumors, congenital hypertrophy of the retinal pigmented epithelium, posterior uveal melanoma, choroidal hemangioma, choroidal osteoma, choroidal metastasis, combined hamartoma of the retina and retinal pigmented epithelium, retinoblastoma, vasoproliferative tumors of the ocular fundus, retinal astrocytoma, and intraocular lymphoid tumors; and miscellaneous other diseases affecting the posterior part of the eye such as punctate inner choroidopathy, acute posterior multifocal placoid pigment epitheliopathy, myopic retinal degeneration, and acute retinal pigement epitheliitis, systemic inflammatory diseases such as stroke, coronary artery disease, obstructive airway diseases, HIV-mediated retroviral infections, cardiovascular disorders including coronary artery disease, neuroinflammation, neurological disorders, pain and immunological disorders, asthma, allergic disorders, inflammation, systemic lupus erythematosus, psoriasis, CNS disorders such as Alzheimer's disease, arthritis, sepsis, inflammatory bowel disease, cachexia, angina pectoris, post-surgical corneal inflammation, blepharitis, MGD, dermal wound healing, burns, rosacea, atopic dermatitis, acne, psoriasis, seborrheic dermatitis, actinic keratoses, viral warts, photoaging rheumatoid arthritis and related inflammatory disorders, alopecia, glaucoma, branch vein occlusion, Best's vitelliform macular degeneration, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the RPE.
The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier thereof. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a patch, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known in the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as 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 monostearate or glyceryl distearate may be employed.
In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin or olive oil.
The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
The compounds of the invention may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
The compounds and pharmaceutical compositions described herein are useful as medicaments in mammals, including humans, for treatment of diseases and/or alleviations of conditions which are responsive to treatment by agonists or functional antagonists of the N-formyl peptide receptor like-1 (FPRL-1) receptor. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of the N-formyl peptide receptor like-1 (FPRL-1) receptor. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one invention compound. As used herein, the term “therapeutically effective amount” means the amount of the pharmaceutical composition that will elicit the biological or medical response of a subject in need thereof that is being sought by the researcher, veterinarian, medical doctor or other clinician. In some embodiments, the subject in need thereof is a mammal. In some embodiments, the mammal is human.
The present invention concerns also processes for preparing the compounds of Formula I. The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. Synthetic Scheme 1 set forth below, illustrates how the compounds according to the invention can be made.
Compounds of Formula I were prepared as depicted in Scheme 1. Compounds of Formula II were prepared as depicted in Scheme 2. In general, a t-butyl ester derivative of an amino acid is reacted with a substituted phenylisocyanate to produce a phenylurea derivative. The t-butyl ester protecting group is then removed under acidic conditions to give the amino acid urea. The carboxylic acid group is then converted to an amide by treating the compound with activating reagents, such as 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide (EDCI) and Hydroxybenzotriazole (HOBt) in the presence of an amine, or by other methods known to those skilled in the art. At this stage, those skilled in the art will appreciate that many additional compounds that fall under the scope of the invention may be prepared by performing various common chemical reactions. Details of certain specific chemical transformations are provided in the examples.
Those skilled in the art will be able to routinely modify and/or adapt the following scheme to synthesize any compounds of the invention covered by Formula I or Formula II.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of hydrogen 1H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diastereoisomeric isomers, chromatographic separation may be employed. Compound names were generated with ACD version 12.5. In general, characterization of the compounds is performed according to the following methods, NMR spectra are recorded on 300 or 600 MHz Varian and acquired at room temperature. Chemical shifts are given in ppm referenced either to internal TMS or to the solvent signal.
All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Combi-blocks, TCI, VWR, Lancaster, Oakwood, Trans World Chemical, Alfa, Fisher, Maybridge, Frontier, Matrix, Ukrorgsynth, Toronto, Ryan Scientific, SiliCycle, Anaspec, Syn Chem, Chem-Impex, MIC-scientific, Ltd; however some known intermediates, were prepared according to published procedures.
Usually the compounds of the invention were purified by medium pressure liquid chromatography, unless noted otherwise.
The following abbreviations are used in the examples:
Et 3 N triethylamine
CH 2 Cl 2 dichloromethane
CDCl 3 deuterated chloroform
MeOH methanol
CD 3 OD deuterated methanol
Na 2 SO 4 sodium sulfate
DMF N,N dimethylformamide
EDCI 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide
HOBt Hydroxybenzotriazole
THF tetrahydrofuran
ClCO 2 Et ethylchloroformate
NH 3 ammonia
The following synthetic schemes illustrate how compounds according to the invention can be made. Those skilled in the art will be routinely able to modify and/or adapt the following schemes to synthesize any compound of the invention covered by Formula II.
Example 1
Intermediate 1
tert-Butyl (2S)-2-{[(4-Bromophenyl)carbamoyl]amino}-3-phenylpropanoate
To a solution of L-phenyl-alanine tert-butyl ester hydrochloride (100 mg, 0.41 mmol) and 6 mL of methylene chloride at 25° C. was added 4-bromo-phenyl isocyanate (81 mg, 0.41 mmol) and triethylamine (62 mg, 0.62 mmol). The resulting mixture was stirred at 25° C. for 30 minutes. The mixture was concentrated and the residue was purified by medium pressure liquid chromatography on silica gel using ethyl acetate:hexane (20:80) to yield Intermediate 1, as a white solid.
1 H NMR (CDCl 3 , 300 MHz) δ: 7.20-7.35 (m, 5H), 7.13-7.20 (m, 2H), 7.01-7.10 (m, 2H), 6.79 (br. s., NH), 5.52 (br. s., NH), 4.70 (t, J=6.2 Hz, 1H), 2.91 (ddd, J=19.0 Hz, J=6.0 Hz, 2H), 1.47 (m, 9H).
Intermediates 2, 3 and 4 were prepared from the corresponding amino acid in a similar manner to the procedure described in Example 1 for Intermediate 1, starting with the appropriate amino acid. The results are described below in Table 1.
TABLE 1
Interm.
IUPAC name
No.
Structure
1 H NMR δ (ppm)
2
tert-Butyl (2S,3S)-2-{[(4-bromo phenyl)carbamoyl]amino{-3- methylpentanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.29- 7.39 (m, 2H), 7.10-7.22 (m, 2H), 6.83 (br. s., 1H), 4.44 (d, J = 4.4 Hz, 1H), 1.81-1.99 (m, 1H), 1.36-1.46 (m, 1H), 1.08-1.31 (m, 1H), 0.86- 1.02 (m, 6H).
3
tert-Butyl (2S)-2-{[(4-bromophenyl) carbamoyl]amino}-pentanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.26- 7.36 (m, 2H), 7.09-7.18 (m, 2H), 6.95 (br. s., NH), 4.40-4.50 (m, 1H), 1.73-1.89 (m, 1H), 1.52-1.72 (m, 1H), 1.25-1.46 (m, 2H), 0.95 (t, 2H).
4
tert-butyl (2S)-2-{[(4-bromo phenyl) carbamoyl]amino}-4- methylpentanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.20- 7.33 (m, 2H), 7.04-7.15 (m, 2H), 4.44 (dd, J = 9.1, 5.3 Hz, 1H), 1.74 (dd, J = 12.9, 6.4 Hz, 1H), 1.54-1.68 (m, 1H), 1.50 (s, 9H), 1.40-1.47 (m, 1H), 0.97 (d, J = 3.5 Hz, 3H), 0.95 (d, 3H).
Example 2
Intermediate 5
(2S)-2-{[(4-Bromophenyl)carbamoyl]amino}-3-phenylpropanoic Acid
A solution of Intermediate 1 (60 mg, 0.15 mmol) and 0.5 mL of formic acid was stirred at 25° C. for 3 hours. The resulting mixture was quenched with water (imp then extracted with ethyl acetate. The organic layer was washed with water, brine, dried over Na 2 SO 4 , filtered, and the filtrate was concentrated under reduced pressure. The residue was rinsed 4 times with methylene chloride:hexane (1:1) to yield Intermediate 5 as a white solid.
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.29 (s, NH), 7.40-7.50 (m, 2H), 7.32-7.40 (m, 2H), 7.18-7.31 (m, 5H), 5.98 (d, J=7.9 Hz, NH), 4.67 (m, 1H), 3.02 (ddd, J=19.0 Hz, J=6.0 Hz, 2H).
Intermediates 6, 7 and 8 and Compounds 1 through 6 were prepared from the corresponding urea derivative in a similar manner to the procedure described in Example 2 for Intermediate 5. The results are described below in Table 2.
TABLE 2
Interm.
IUPAC name
No.
Structure
1 H NMR δ (ppm)
6
(2S,3S)-2-{[(4-bromophenyl) carbamoyl]amino}-3- methylpentanoic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.24 (br. s., 1H), 7.44-7.53 (m, 2H), 7.32- 7.42 (m, 2H), 6.08 (d, J = 8.8 Hz, 1H), 4.44 (dd, J = 8.6, 4.8 Hz, 1H), 1.86-2.00 (m, J = 9.1, 6.9, 4.6, 4.6 Hz, 1H), 1.43- 1.61 (m, 1H), 1.15-1.33 (m, 1H), 0.88- 1.04 (m, 6H).
7
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-pentanoic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.20 (s, NH), 7.43-7.52 (m, 2H), 7.33-7.41 (m, 2H), 6.08 (d, J = 9.1 Hz, NH), 4.38- 4.50 (m, 1H), 1.77-1.92 (m, 1H), 1.61- 1.76 (m, 1H), 1.36-1.53 (m, 2H), 0.89- 1.00 (m, 3H).
8
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-4- methylpentanoic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.17 (s, NH), 7.43-7.51 (m, 2H), 7.35-7.41 (m, 2H), 6.04 (d, J = 9.1 Hz, NH), 4.42-4.53 (m, 1H), 1.73-1.88 (m, 1H), 1.53-1.73 (m, 2H), 0.97 (d, J = 2.1 Hz, 3H), 0.95 (d, 3H).
Comp.
IUPAC name
No.
Structure
1 H NMR δ (ppm)
1
{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-3- phenylpropanoyl]amino}acetic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.26 (s, NH), 7.71 (br. s., NH), 7.32-7.46 (m, 4H), 7.13-7.31 (m, 5H), 6.03 (d, J = 8.5 Hz, NH), 4.71 (td, J = 7.7, 5.4 Hz, 1H), 3.98 (d, J = 5.9 Hz, 2H), 3.14-3.26 (m, 1H), 3.01 (dd, 1H).
2
3-{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-3- phenylpropanoyl]amino}propanoic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.27 (s, NH), 7.44 (s, NH), 7.33-7.43 (m, 4H), 7.15-7.30 (m, 5H), 6.03 (d, J = 7.9 Hz, NH), 4.53-4.65 (m, 1H), 3.34-3.51 (m, 2H), 2.93-3.15 (m, 2H), 2.47 (td, 2H).
3
{[(2S,3S)-2-{[(4-bromo-2- fluorophenyl)carbamoyl]amino}-3- methylpentanoyl]amino}acetic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.28 (t, J = 8.9 Hz, 1H), 8.16 (br. s., NH), 7.67 (br. s., NH), 7.34 (dd, J = 11.0, 2.2 Hz, 1H), 7.23-7.30 (m, 1H), 6.57 (d, J = 9.4 Hz, NH), 4.37 (dd, J = 8.6, 5.7 Hz, 1H), 3.89- 4.08 (m, 2H), 1.86-1.98 (m, 1H), 1.53- 1.67 (m, 1H), 1.10-1.27 (m, 1H), 0.98 (d, J = 6.7 Hz, 3H), 0.85-0.94 (m, 3H).
4
{[(2S,3S)-2-{[(4- bromophenyl)carbamoyl]amino}-3- methylpentanoyl]amino}acetic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.27 (s, NH), 7.66 (br. s., NH), 7.42-7.51 (m, 2H), 7.32-7.41 (m, 2H), 6.08 (d, J = 8.2 Hz, NH), 4.34 (dd, J = 8.6, 5.7 Hz, 1H), 3.88-4.09 (m, 2H), 1.81-1.96 (m, 1H), 1.49-1.67 (m, 1H), 1.06-1.27 (m, 1H), 0.97 (d, J = 6.7 Hz, 3H), 0.86-0.93 (m, 3H).
5
{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino} pentanoyl]amino}acetic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.25 (s, NH), 7.67 (br. s., NH), 7.41-7.51 (m, 2H), 7.34-7.41 (m, 2H), 6.13 (d, J = 7.9 Hz, NH), 4.42 (td, J = 7.7, 5.4 Hz, 1H), 3.89-4.08 (m, 2H), 1.73-1.89 (m, 1H), 1.54-1.69 (m, 1H), 1.34-1.51 (m, 2H), 0.91 (t, J = 7.3 Hz, 3H).
6
{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}acetic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.19 (s, NH), 7.70 (br. s., NH), 7.42-7.51 (m, 2H), 7.33-7.41 (m, 2H), 6.07 (d, J = 7.6 Hz, NH), 4.46 (ddd, J = 9.6, 8.3, 5.0 Hz, 1H), 3.87-4.07 (m, 2H), 1.72-1.86 (m, 1H), 1.61-1.72 (m, 1H), 1.46-1.59 (m, 1H), 0.95 (s, 3H), 0.93 (s, 3H).
Example 3
Compound 7
tert-Butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-phenylpropanoyl]amino}acetate
To a solution of Intermediate 5 (80 mg, 0.22 mmol) and 2 mL of anhydrous DMF at 25° C. was added EDCI (64 mg, 0.33 mmol), HOBt (45 mg, 0.33 mmol), glycine tert-butyl ester (44 mg, 0.33 mmol) and N-methylmorpholine (44 mg, 0.44 mmol). The resulting mixture was stirred at 25° C. for 12 hours. The mixture was quenched with water (1 mL), and the product was extracted with ethyl acetate (20 mL). The layers were separated, and the organic layer was washed with water, brine, dried over Na 2 SO 4 , filtered, and the filtrate was concentrated under reduced pressure. The resulting product was purified by medium pressure liquid chromatography on silica gel using ethyl acetate:hexane (40:60) to yield Compound 7 as a white solid.
1 H NMR (CDCl 3 , 300 MHz) δ: 7.18-7.35 (m, 7H), 7.03 (d, J=8.5 Hz, 2H), 6.85 (br. s., 1H), 4.69 (t, J=7.5 Hz, 1H), 3.74-3.96 (m, 2H), 2.98-3.19 (m, 2H), 1.42 (s, 9H).
Compounds 8 through 27 and Intermediate 9 were prepared from the corresponding urea derivative in a similar manner to the procedure described in Example 3 for Compound 7. The results are described below in Table 3.
TABLE 3
Comp.
IUPAC name
No.
Structure
1 H NMR δ (ppm)
8
tert-butyl 3-{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}- 3-phenylpropanoyl] amino}propanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.18- 7.35 (m, 7H), 7.08-7.17 (m, 2H), 4.54-4.64 (m, 1H), 3.28-3.52 (m, 2H), 2.94-3.17 (m, 2H), 2.18-2.40 (m, 2H), 1.41 (s, 9H).
9
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)-3-phenylpropanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.30- 7.37 (m, 2H), 7.17-7.30 (m, 7H), 4.50 (dd, J = 7.8, 6.3 Hz, 1H), 3.44- 3.59 (m, 2H), 3.23-3.30 (m, 2H), 3.05-3.15 (m, 1H), 2.90-3.01 (m, 1H).
10
tert-butyl {[(2S,3S)-2-{[(4-bromo-2- fluorophenyl) carbamoyl]amino}-3- methylpentanoyl]amino}acetate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.92- 7.99 (t, J = 8.9 Hz, 1H), 7.40 (br. s., NH), 7.07-7.16 (m, 2H), 6.67 (s, NH), 6.54 (br. s., NH), 4.21-4.27 (m, 1H), 4.05-4.15 (m, 1H), 3.83- 3.92 (m, 1H), 1.79-1.88 (m, 1H), 1.57-1.64 (m, 1H), 1.47 (s, 9H), 1.19-1.24 (m, 1H), 1.00 (d, J = 6.7 Hz, 3H), 0.92 (t, 3H).
11
tert-butyl {[(2S,3S)-2-{[(4- bromophenyl) carbamoyl]amino}-3- methylpentanoyl]amino}acetate
1H NMR (CD 3 OD, 300 MHz) δ: 8.55 (s, NH), 8.36 (br. s., NH), 7.33-7.40 (m, 2H), 7.26-7.33 (m, 2H), 6.28 (d, J = 8.5 Hz, NH), 4.20 (dd, J = 8.6, 6.3 Hz, 1H), 3.72-3.97 (m, 2H), 1.80-1.94 (m, 1H), 1.56-1.70 (m, 1H), 1.45 (s, 9H), 1.13-1.31 (m, 1H), 1.01 (d, J = 6.7 Hz, 3H), 0.92- 0.98 (m, 3H).
12
(2S,3S)-2-{[(4-bromophenyl) carbamoyl]amino}-3-methyl-N-(2- oxopropyl)pentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.34- 7.41 (m, 2H), 7.26-7.34 (m, 2H), 4.22 (d, J = 6.2 Hz, 1H), 4.05 (d, J = 8.2 Hz, 2H), 2.14 (s, 3H), 1.80-1.94 (m, 1H), 1.53-1.68 (m, 1H), 1.14- 1.26 (m, 1H), 0.81-1.07 (m, 6H).
13
(2S,3S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-3-methyl-N-(2- oxopropyl)pentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.99 (t, J = 8.8 Hz, 1H), 7.31 (dd, J = 10.7, 2.2 Hz, 1H), 7.16-7.27 (m, 1H), 4.22 (d, J = 5.9 Hz, 1H), 3.94- 4.14 (m, 2H), 2.14 (s, 3H), 1.84- 1.96 (m, 1H), 1.52-1.67 (m, 1H), 1.14-1.32 (m, 1H), 1.01 (d, J = 7.0 Hz, 3H), 0.92-0.98 (m, 3H).
14
(2S,3S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)-3-methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33-7.42 (m, 2H), 7.26-7.33 (m, 2H), 4.12 (d, J = 6.4 Hz, 1H), 3.55- 3.65 (m, 2H), 3.32-3.37 (m, 1H), 1.76-1.91 (m, 1H), 1.48-1.63 (m, 1H), 1.09-1.31 (m, 2H), 0.90-0.99 (m, 6H).
15
(2S,3S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)-3-methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.99 (t, J = 8.6 Hz, 1H), 7.31 (dd, J = 10.8, 2.3 Hz, 1H), 7.18-7.27 (m, 1H), 4.13 (d, J = 6.4 Hz, 1H), 3.56- 3.65 (m, 2H), 3.31-3.37 (m, 1H), 1.77-1.89 (m, 1H), 1.50-1.61 (m, 1H), 1.10-1.26 (m, 1H), 0.88-1.01 (m, 6H).
16
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-(2-oxopropyl)-3- phenylpropanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.23 (s, NH), 7.59 (br. s., NH), 7.32- 7.47 (m, 4H), 7.15-7.29 (m, 5H), 6.01 (d, J = 8.2 Hz, NH), 4.70 (td, J = 7.7, 5.7 Hz, 1H), 4.05 (d, J = 5.3 Hz, 2H), 3.12-3.24 (m, 1H), 2.95- 3.06 (m, 1H), 2.10 (s, 3H).
17
(2S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-N-(2-oxopropyl)-3- phenylpropanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.22 (t, J = 8.9 Hz, 1H), 8.12 (br. s., NH), 7.61 (br. s., NH), 7.32 (dd, J = 11.0, 2.2 Hz, 1H), 7.15-7.29 (m, 6H), 6.51 (d, J = 7.3 Hz, NH), 4.72 (td, J = 7.9, 5.6 Hz, 1H), 4.05 (dd, J = 5.6, 1.2 Hz, 2H), 3.14-3.24 (m, 1H), 2.95-3.05 (m, 1H), 2.10 (s, 3H).
18
tert-butyl {[(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-pentanoyl]amino} acetate
1H NMR (acetone-d 6 , 300 MHz) δ: 8.20 (s, NH), 7.60 (br. s., NH), 7.42- 7.51 (m, 2H), 7.32-7.41 (m, 2H), 6.07 (d, J = 7.6 Hz, NH), 4.41 (td, J = 7.9, 5.3 Hz, 1H), 3.75-3.99 (m, 2H), 1.73-1.89 (m, 1H), 1.53-1.70 (m, 1H), 1.43 (s, 9H), 1.37-1.48 (m, 2H), 0.92 (t, J = 7.3 Hz, 3H).
19
(2S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)-3-phenylpropanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.91 (t, J = 8.6 Hz, 1H), 7.17-7.34 (m, 7H), 4.50 (dd, J = 8.2, 6.2 Hz, 1H), 3.44-3.59 (m, 2H), 3.23-3.27 (m, 2H), 3.05-3.17 (m, 1H), 2.87- 2.99 (m, 1H).
20
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)pentanamid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.41 (m, 2H), 7.25-7.33 (m, 2H), 4.23 (dd, J = 8.2, 5.6 Hz, 1H), 3.56- 3.63 (m, 2H), 1.69-1.84 (m, 1H), 1.54-1.68 (m, 1H), 1.29-1.51 (m, 2H), 0.91-1.02 (m, 3H).
21
(2S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)pentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.97 (t, J = 8.6 Hz, 1H), 7.31 (dd, J = 10.7, 2.2 Hz, 1H), 7.19-7.27 (m, 1H), 4.23 (dd, J = 8.1, 5.4 Hz, 1H), 3.56-3.66 (m, 2H), 1.68-1.83 (m, 1H), 1.54-1.68 (m, 1H), 1.34-1.51 (m, 2H), 0.91-1.03 (m, 3H).
22
methyl {[(2S)-2-{[(4-bromophenyl) carbamoyl]amino}- pentanoyl]amino}acetate
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.19 (s, NH), 7.71 (br. s., NH), 7.42- 7.52 (m, 2H), 7.31-7.42 (m, 2H), 6.07 (d, J = 8.2 Hz, NH), 4.34-4.47 (m, 1H), 3.86-4.10 (m, 2H), 3.66 (s, 3H), 1.73-1.87 (m, 1H), 1.55-1.71 (m, 1H), 1.35-1.51 (m, 2H), 0.92 (t, 3H).
23
ethyl {[(2S)-2-{[(4-bromophenyl) carbamoyl]amino}- pentanoyl]amino}acetate
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.19 (s, NH), 7.69 (br. s., NH), 7.42- 7.50 (m, 2H), 7.32-7.40 (m, 2H), 6.07 (d, J = 8.2 Hz, NH), 4.42 (td, J = 7.9, 5.6 Hz, 1H), 4.13 (q, J = 7.2 Hz, 2H), 3.85-4.06 (m, 2H), 1.73- 1.88 (m, 1H), 1.55-1.69 (m, 1H), 1.34-1.51 (m, 2H), 1.20 (t, J = 7.3, 3H), 0.92 (t, J = 7.3, 3H).
24
isopropyl {[(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-pentanoyl]amino} acetate
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.20 (s, NH), 7.67 (br. s., NH), 7.43- 7.51 (m, 2H), 7.33-7.42 (m, 2H), 6.07 (d, J = 9.7 Hz, NH), 4.97 (dt, J = 12.5, 6.2 Hz, 1H), 4.41 (td, J = 7.8, 5.4 Hz, 1H), 3.82-4.04 (m, 2H), 1.73-1.89 (m, 1H), 1.55-1.70 (m, 1H), 1.34-1.50 (m, 2H), 1.22 (s, 3H), 1.20 (s, 3H), 0.92 (t, J = 7.3, 3H).
25
tert-butyl {[(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-4- methylpentanoyl]amino}acetate
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.16 (s, NH), 7.62 (br. s., NH), 7.42- 7.49 (m, 2H), 7.33-7.40 (m, 2H), 6.03 (d, J = 8.8 Hz, NH), 4.40-4.51 (m, 1H), 3.76-3.95 (m, 2H), 1.72- 1.84 (m, 1H), 1.60-1.73 (m, 1H), 1.45-1.58 (m, 1H), 0.95 (s, 3H), 0.93 (s, 3H).
26
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)-4-methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.34-7.41 (m, 2H), 7.26-7.33 (m, 2H), 4.24-4.33 (m, 1H), 3.55-3.64 (m, 2H), 3.32-3.35 (m, 2H), 1.64- 1.79 (m, 1H), 1.48-1.62 (m, 2H), 0.98 (d, J = 4.1 Hz, 3H), 0.96 (d, J = 3.8 Hz, 3H).
27
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-4-methyl-N-(2- oxopropyl)pentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.17 (s, NH), 7.61 (br. s., NH), 7.42- 7.50 (m, 2H), 7.32-7.42 (m, 2H), 6.06 (d, J = 8.5 Hz, NH), 4.45 (ddd, J = 9.7, 8.1, 5.0 Hz, 1H), 4.04 (d, J = 5.6 Hz, 2H), 2.12 (s, 3H), 1.72-1.84 (m, 1H), 1.60-1.72 (m, 1H), 1.45- 1.58 (m, 1H), 0.95 (s, 3H), 0.93 (s, 3H).
Interm.
IUPAC name
No.
Structure
1 H NMR δ (ppm)
9
(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N- hydroxypentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 10.27 (br. s., OH), 8.18 (br. s., NH), 8.03 (s, NH), 7.42-7.50 (m, 2H), 7.32-7.41 (m, 2H), 6.11 (d, J = 9.1 Hz, NH), 4.23-4.34 (m, 1H), 1.52- 1.80 (m, 2H), 1.27-1.49 (m, 2H), 0.87-0.95 (t, J = 7.3 Hz, 3H).
Example 4
Compound 28
(2S,3S)—N-(2-amino-2-oxoethyl)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methylpentanamide
To a solution of Compound 11 (50 mg, 0.13 mmol) and 5 mL of anhydrous tetrahydrofuran under argon at −78° C. was added triethylamine (24 mg, 0.17 mmol) and ethyl chloroformate (17 mg, 0.16 mmol). The mixture was stirred at −78° C. for 30 minutes, and then ammonia gas was bubbled into reaction flask for 1 minute. The resulting mixture was stirred at 25° C. for 2 hours. The reaction was quenched with water (1 mL), and the residue was extracted with ethyl acetate (20 mL). The layers were separated, and the organic layer was washed with water, brine, dried over Na 2 SO 4 , filtered, and the filtrate was concentrated under reduced pressure. The resulting product was purified by medium pressure chromatography on silica gel using an eluent of methanol:dichloromethane (10:90) to yield to yield Compound 28 as a white solid.
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33-7.40 (m, 2H), 7.26-7.33 (m, 2H), 4.05 (d, J=6.7 Hz, 1H), 3.85 (q, J=17.0 Hz, 2H), 1.78-1.91 (m, 1H), 1.54-1.69 (m, 1H), 1.16-1.33 (m, 1H), 0.99 (d, J=6.7 Hz, 3H), 0.92-0.98 (m, 3H).
Compounds 29 through 85 as well as Intermediates 10 through 35 were prepared from the corresponding acid derivative in a similar manner to the procedure described in Example 4 for Compound 28.
TABLE 4 Comp. IUPAC name No. Structure 1 H NMR δ (ppm) 29 (2S,3S)-N-(2-amino-2-oxoethyl)-2- {[(4-bromo-2-fluorophenyl) carbamoyl]amino}-3- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 8.00 (t, J = 8.6 Hz, 1H), 7.32 (dd, J = 10.7, 2.2 Hz, 1H), 7.18-7.26 (m, 1H), 4.05 (d, J = 6.4 Hz, 1H), 3.74-3.95 (m, 2H), 1.80-1.91 (m, 1H), 1.51-1.69 (m, 1H), 1.18-1.32 (m, 1H), 1.00 (d, J = 7.0 Hz, 3H), 0.92-0.98 (m, 3H). 30 (2S)-N-(2-amino-2-oxoethyl)-2- {[(4-bromophenyl) carbamoyl]amino}-pentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.27 (s, NH), 7.70 (br. s., NH), 7.41-7.48 (m, 2H), 7.33-7.41 (m, 2H), 7.02 (s, NH), 6.30 (s, NH), 6.22 (d, J = 5.3 Hz, NH), 4.22-4.32 (m, 1H), 3.72-3.91 (m, 2H), 1.73-1.88 (m, 1H), 1.56- 1.71 (m, 1H), 1.37-1.53 (m, 2H), 0.88- 0.97 (m, 3H). 31 (2S)-N-(2-amino-2-oxoethyl)-2- {[(4-bromo-2-fluorophenyl] carbamoyl}amino)pentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.23 (t, J = 8.8 Hz, 1H), 8.13 (br. s., NH), 7.72 (s, NH), 7.35 (dd, J = 10.8, 2.3 Hz, 1H), 7.26 (dt, J = 8.9, 1.9 Hz, 1H), 7.00 (s, NH), 6.66 (d, J = 6.7 Hz, NH), 6.34 (s, NH), 4.29 (dd, J = 12.2, 8.1 Hz, 1H), 3.82 (dd, J = 5.9, 1.8 Hz, 2H), 1.75- 1.90 (m, 1H), 1.58-1.73 (m, 1H), 1.37- 1.53 (m, 2H), 0.89-0.98 (m, 3H). 32 (2S)-N-(2-amino-2-oxoethyl)-2- {[(4-bromophenyl) carbamoyl]amino}-4- methylpentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.20 (s, NH), 7.77 (br. s., NH), 7.40-7.47 (m, 2H), 7.32-7.39 (m, 2H), 7.04 (br. s., NH), 6.38 (br. s., NH), 6.18 (d, J = 7.3 Hz, NH), 4.31 (ddd, J = 9.4, 7.0, 5.3 Hz, 1H), 3.71-3.93 (m, 2H), 1.69- 1.85 (m, 1H), 1.49-1.69 (m, 2H), 0.96 (d, J = 3.2 Hz, 3H), 0.93 (d, J = 3.2 Hz, 3H). 33 tert-butyl {[(2S)-2-{[(4-bromo-2- fluorophenyl) carbamoyl] amino}- 4-methylpentanoyl] amino}acetate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.89 (t, J = 8.8 Hz, 1H), 7.55 (br. s., NH), 7.07 (dd, J = 10.7, 2.2 Hz, 1H), 6.95-7.04 (m, 1H), 6.84 (br. s., NH), 4.43 (br. s., NH), 4.00-4.16 (m, 1H), 3.81-3.92 (m, 1H), 1.69-1.88 (m, 1H), 1.56- 1.70 (m, 2H), 1.47 (s, 9H), 0.97 (d, J = 4.7 Hz, 3H), 0.95 (d, 3H). 34 {[(2S)-2-{[(4-bromo-2- fluorophenyl) carbamoyl]amino}-4- methylpentanoyl]amino}acetic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.27 (t, J = 8.8 Hz, 1H), 8.07 (br. s., NH), 7.71 (br. s., NH), 7.34 (dd, J = 10.8, 2.1 Hz, 1H), 7.27 (dt, J = 8.8, 1.8 Hz, 1H), 6.54 (d, J = 8.8 Hz, NH), 4.42-4.53 (m, 1H), 3.93-4.01 (m, 2H), 1.72- 1.86 (m, 1H), 1.63-1.74 (m, 1H), 1.46- 1.60 (m, 1H), 0.96 (s, 3H), 0.93 (s, 3H). 35 (2S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-4-methyl-N-(2- oxopropyl)pentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.30 (t, J = 8.8 Hz, 1H), 8.06 (br. s., NH), 7.62 (br. s., NH), 7.31-7.38 (m, 2H), 7.24-7.30 (m, 2H), 6.52 (d, J = 8.2 Hz, NH), 4.39-4.53 (m, 1H), 4.04 (d, J = 5.6 Hz, 2H), 2.10-2.15 (m, 3H), 1.70- 1.86 (m, 1H), 1.61-1.71 (m, 1H), 1.47- 1.62 (m, 1H), 0.96 (s, 3H), 0.93 (s, 3H). 36 (2S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-N-(2- hydroxyethyl)-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.97 (t, J = 8.8 Hz, 1H), 7.31 (dd, J = 10.8, 2.3 Hz, 1H), 7.18-7.27 (m, 1H), 4.28 (dd, J = 9.2, 5.4 Hz, 1H), 3.56-3.64 (m, 2H), 3.32-3.37 (m, 2H), 1.64-1.80 (m, 1H), 1.50-1.62 (m, 2H), 0.98 (d, J = 4.4 Hz, 3H), 0.96 (d, 3H). 37 (2S)-N-(2-amino-2-oxoethyl)-2-{[(4- bromo-2-fluorophenyl) carbamoyl]amino}-4- methylpentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.22 (t, J = 8.8 Hz, 1H), 8.09 (br. s., NH), 7.77 (br. s., NH), 7.34 (dd, J = 11.0, 2.2 Hz, 1H), 7.25 (dt, J = 8.9, 1.7 Hz, 1H), 6.99 (br. s., NH), 6.62 (d, J = 7.0 Hz, NH), 6.37 (br. s., NH), 4.33 (ddd, J = 9.6, 7.0, 5.1 Hz, 1H), 3.72-3.92 (m, 2H), 1.68-1.86 (m, 1H), 1.49-1.70 (m, 2H), 0.96 (d, J = 3.5 Hz, 3H), 0.94 (d, 3H). 38 tert-butyl (2S)-2-{[(2S)-2-{[(4- bromo-2-fluorophenyl) carbamoyl]amino}-4- methylpentanoyl]amino}propanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.90 (t, J = 8.8 Hz, 1H), 7.45 (br. s., NH), 7.02- 7.15 (m, 2H), 6.92 (s, NH), 6.61 (br. s., NH), 4.37-4.54 (m, 2H), 1.79 (dt, J = 13.2, 6.9 Hz, 1H), 1.56-1.69 (m, 2H), 1.46 (s, 9H), 1.40 (d, J = 7.3 Hz, 3H), 0.97 (s, 3H), 0.95 (s, 3H). 39 (2S)-2-{[(2S)-2-{[(4-bromo-2- fluorophenyl) carbamoyl]amino}-4- methylpentanoyl]amino}propanoic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.26 (t, J = 8.9 Hz, 1H), 8.08 (br. s., NH), 7.67 (d, J = 7.0 Hz, NH), 7.33 (dd, J = 10.8, 2.3 Hz, 1H), 7.27 (dt, J = 8.8, 1.8 Hz, 1H), 6.52 (d, J = 9.1 Hz, NH), 4.40- 4.54 (m, 2H), 1.72-1.87 (m, 1H), 1.59-1.72 (m, 1H), 1.45-1.57 (m, 1H), 1.39 (d, J = 7.3 Hz, 3H), 0.95 (s, 3H), 0.93 (s, 3H). 40 (2S)-N-[(1S)-2-amino-1-methyl-2- oxoethyl]-2-{[(4-bromo-2- fluorophenyl) carbamoyl]amino}-4- methylpentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.25 (t, J = 8.8 Hz, 1H), 8.09 (br. s., NH), 7.57 (d, J = 5.6 Hz, NH), 7.35 (dd, J = 11.0, 2.2 Hz, 1H), 7.22-7.31 (m, 1H), 6.92 (br. s., NH), 6.54 (d, J = 7.3 Hz, NH), 6.29 (br. s., NH), 4.30-4.44 (m, 2H), 1.73-1.90 (m, 1H), 1.47-1.72 (m, 2H), 1.30 (d, J = 7.0 Hz, 3H), 0.95 (d, J =1.5 Hz, 3H), 0.93 (d, 3H). 41 tert-butyl (2S)-2-{[(2S)-2-({[(4- bromophenyl) carbamoyl}amino)-4- methylpentanoyl]amino}propanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.62 (br. s., NH), 7.21-7.29 (m, 2H), 7.08-7.16 (m, 2H), 6.90 (br. s., NH), 4.39-4.50 (m, 1H), 4.35 (t, J = 7.0 Hz, 1H), 1.73- 1.86 (m, 1H), 1.54-1.67 (m, 2H), 1.45 (s, 9H), 1.38 (d, 3H), 0.97 (d, J = 2.9 Hz, 3H), 0.95 (d, J = 2.9 Hz, 3H). 42 tert-butyl (2S)-2-{[(2S)-2-{[(4- bromophenyl) carbamoyl]amino}- 4-methylpentanoyl]amino}-3- methylbutanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.45 (br. s., NH), 7.21-7.30 (m, 2H), 7.10-7.18 (m, 2H), 4.45 (t, J = 7.2 Hz, 1H), 4.32 (dd, J = 8.5, 5.0 Hz, 1H), 2.07-2.20 (m, 1H), 1.77 (dt, J = 13.3, 6.8 Hz, 1H), 1.56-1.67 (m, 2H), 1.47 (s, 9H), 0.98 (d, J = 2.3 Hz, 3H), 0.96 (d, 3H), 0.93 (s, 3H), 0.91 (s, 3H). 43 (2S)-2-{[(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-4- methylpentanoyl]amino}propanoic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.22 (s, NH), 7.66 (d, J = 6.4 Hz, NH), 7.43- 7.50 (m, 2H), 7.34-7.41 (m, 2H), 6.05 (d, J = 7.9 Hz, NH), 4.39-4.52 (m, 2H), 2.81 (br. s., 4H), 1.71-1.86 (m, 1H), 1.57-1.71 (m, 1H), 1.43-1.57 (m, 1H), 1.39 (d, J = 7.3 Hz, 3H), 0.94 (s, 3H), 0.92 (s, 3H). 44 (2S)-2-{[(2S)-2-{[(4-bromophenyl) carbamoyl]amino}-4- methylpentanoyl]amino}-3- methylbutanoic acid
1 H NMR (acetone-d 6 , 300 MHz) δ: 7.45 (br. s., NH), 7.21-7.30 (m, 2H), 7.10- 7.18 (m, 2H), 4.45 (t, J = 7.2 Hz, 1H), 4.32 (dd, J = 8.5, 5.0 Hz, 1H), 2.07- 2.20 (m, 1H), 1.77 (dt, J = 13.3, 6.8 Hz, 1H), 1.56-1.67 (m, 2H), 1.47 (s, 9H), 0.98 (d, J = 2.3 Hz, 3H), 0.96 (d, 3H), 0.93 (s, 3H), 0.91 (s, 3H). 45 (2S)-N-[(1S)-2-amino-1-methyl-2- oxoethyl]-2-{[(4-bromophenyl) carbamoyl]amino}-4- methylpentanamide
1 H NMR (acetone-d 6 , 300 MHz) δ: 8.21 (s, NH), 7.56 (s, NH), 7.42-7.49 (m, 2H), 7.33-7.40 (m, 2H), 6.06-6.12 (s, NH), 4.28-4.44 (m, 2H), 1.70-1.89 (m, 1H), 1.59-1.70 (m, 1H), 1.47- 1.59 (m, 1H), 1.30 (d, J = 7.3 Hz, 3H), 0.95 (s, 3H), 0.92 (s, 3H). 46 (2S)-N-[(1S)-1-(amino-3methyl-1- oxobutan-2-yl]-2-{[(4- bromophenyl) carbamoyl]amino}- 4-methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.34- 7.40 (m, 2H), 7.26-7.33 (m, 2H), 4.34 (dd, J = 9.5, 5.4 Hz, 1H), 4.21 (d, J = 7.0 Hz, 1H), 2.02-2.16 (m, 1H), 1.67- 1.79 (m, 1H), 1.51-1.65 (m, 1H), 0.94- 1.00 (m, 9H). 47 (2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-(2-hydroxy- 2-methylpropyl)-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.93 (s, NH), 7.33-7.40 (m, 2H), 7.26- 7.33 (m, 2H), 6.28 (br. s., NH), 4.25- 4.36 (m, 1H), 3.15-3.27 (m, 2H), 1.67- 1.81 (m, 1H), 1.50-1.67 (m, 2H), 1.17 (s, 6H), 0.99 (d, J = 4.7 Hz, 3H), 0.97 (d, 3H). 48 (2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-[2-hydroxy- 1-(hydroxymethyl)ethyI]-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.41 (m, 2H), 7.26-7.33 (m, 2H), 4.30 (dd, J = 9.4, 5.6 Hz, 1H), 3.86-3.96 (m, 1H), 3.62 (t, J = 5.6 Hz, 4H), 1.67- 1.81 (m, 1H), 1.52-1.67 (m, 2H), 0.98 (d, J = 3.8 Hz, 3H), 0.96 (d, 3H). 47 (2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-(2,3- dihydroxypropyl)-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.41 (m, 2H), 7.27-7.34 (m, 2H), 4.28 (dd, J = 8.9, 5.1 Hz, 1H), 3.64-3.76 (m, 1H), 3.46-3.52 (m, 2H), 3.33- 3.42 (m, 1H), 3.15-3.27 (m, 1H), 1.67- 1.80 (m, 1H), 1.48-1.67 (m, 2H), 0.98 (d, J = 4.7 Hz, 3H), 0.96 (d, 3H). 48 (2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-[(1R)-2- hydroxy-1-methylethyl]-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.40 (m, 2H), 7.26-7.32 (m, 2H), 4.26 (dd, J = 8.2, 6.7 Hz, 1H), 3.88-3.99 (m, 1H), 3.49 (dd, J = 5.4, 1.3 Hz, 2H), 1.72 (dt, J = 13.3, 6.8 Hz, 1H), 1.50- 1.60 (m, 2H), 1.14 (d, J = 6.7 Hz, 3H), 0.98 (d, J = 3.8 Hz, 3H), 0.96 (d, 3H). 49 tert-butyl (2S)-2-{[(2S)-2-{[4- bromophenyl)carbamoyl]amino}-4- methyl pentanoyl]amino}propanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.39 (m, 2H), 7.27-7.32 (m, 2H), 4.36 (dd, J = 9.5, 5.4 Hz, 1H), 4.26 (dd, J = 8.6, 5.4 Hz, 1H), 1.49-1.84 (m, 6H), 1.45 (s, 9H), 1.36-1.43 (m, 1H), 0.99 (d, J = 4.4 Hz, 3H), 0.97 (d, J = 4.1 Hz, 3H), 0.90-0.96 (m, 3H). 50 tert-butyl (2S)-{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}(phenyl)ethanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.32- 7.43 (m, 6H), 7.25-7.31 (m, 2H), 4.41 (dd, J = 9.4, 5.3 Hz, 1H), 1.72-1.81 (m, 1H), 1.49-1.70 (m, 2H), 1.40 (s, 9H), 1.17-1.19 (m, 0H), 0.99 (t, J = 6.7 Hz, 6H). 51 (2S)-2-{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}pentanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.40 (m, 2H), 7.25-7.33 (m, 2H), 4.32- 4.44 (m, 2H), 1.35-1.90 (m, 7H), 0.99 (d, J = 3.8 Hz, 3H), 0.97 (d, J = 3.8 Hz, 3H), 0.91-0.96 (m, 3H). 52 (2S)-{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}(phenyl)ethanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.40- 7.47 (m, 2H), 7.23-7.39 (m, 7H), 4.41 (dd, J = 9.4, 5.3 Hz, 1H), 1.70-1.84 (m, 1H), 1.48-1.69 (m, 2H), 0.98 (t, 6H). 53 (2S)-N-[(2S)-1-amino-1-oxopentan- 2-yl]-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.41 (m, 2H), 7.26-7.33 (m, 2H), 4.30 (ddd, J = 16.0, 9.4, 5.1 Hz, 1H), 1.50- 1.86 (m, 5H), 1.33-1.48 (m, 2H), 0.95- 1.01 (m, 6H), 0.89-0.96 (m, 3H). 54 (2S)-N-[(1S)-2-amino-2-oxo-1- phenylethyl]-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.41- 7.48 (m, 2H), 7.24-7.42 (m, 7H), 4.36 (dd, J = 9.7, 5.0 Hz, 1H), 1.52-1.82 (m, 3H), 0.92-1.02 (m, 6H). 55 tert-butyl{[2-{[(4-bromophenyl) carbamoyl]amino}-2,4- dimethylpentanoyl]amino}acetate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.30- 7.39 (m, 2H), 7.15-7.23 (m, 2H), 6.82 (br. s., 1H), 2.15-2.32 (m, 1H), 1.68- 1.79 (m, 2H), 1.63 (s, 3H), 1.48 (s, 9H), 0.93 (d, J = 6.4 Hz, 3H), 0.89 (d, J = 6.2 Hz, 3H). 56 {[2-{[(4-bromophenyl) carbamoyl]amino}-2,4- dimethylpentanoyl] amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.31 (d, J = 14.4 Hz, 2H), 3.92 (d, J = 1.2 Hz, 2H), 2.03-2.15 (m, 1H), 1.70- 1.86 (m, 2H), 1.58 (s, 3H), 0.95 (d, J = 6.4 Hz, 3H), 0.91 (d, J = 6.4 Hz, 3H). 57 tert-butyl {[2-{[(4-bromophenyl) carbamoyl]amino}-2- ethylbutanoyl] amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.247.39 (m, 2H), 7.24 (m, 2H), 6.50 (s, NH), 3.85 (s, 2H), 2.21-2.40 (m, 2H), 1.82 (dq, J = 14.2, 7.3 Hz, 2H), 1.45 (s, 9H), 0.85 (t, J = 7.3 Hz, 6H). 58 {[2-{[(4-bromophenyl) carbamoyl]amino}-2- ethylbutanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 600 MHz) δ: 7.35 (d, J = 8.8 Hz, 2H), 7.26-7.30 (m, 2H), 3.92 (s, 2H), 2.23-2.34 (m, 2H), 1.78- 1.89 (m, 2H), 0.85 (t, J = 7.5 Hz, 6H). 59 tert-butyl {[2-{[(4-bromophenyl) carbamoyl]amino}-2- methylpropanoyl]amino}acetate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.23 (m, 2H), 7.39 (m, 2H), 3.81 (s, 2H), 1.52 (s, 6H), 1.45 (s, 9H). 60 {[2-{[(4-bromophenyl) carbamoyl]amino}-2- methylpropanoyl] amino}acetate acid
1 H NMR (CDCl 3 , 300 MHz) δ: 7.23- 7.40 (m, 4H), 3.81 (s, 2H), 1.51 (s, 6H). 61 (2S)-2-{[(4-bromophenyl) carbamoyl]amino}-N-[2- (dimethylamino)-2-oxoethyl]-4- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.34- 7.39 (m, 2H), 7.28-7.33 (m, 2H), 4.36 (dd, J = 10.0, 4.7 Hz, 1H), 3.97-4.13 (m, 2H), 3.03 (s, 3H), 2.94 (s, 3H), 1.51- 1.83 (m, 3H), 0.94-1.03 (m, 6H). 62 tert-butyl {[(2S)-4-methyl-2-({[4- (trifluoromethyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.49- 7.56 (m, 4H), 4.36 (dd, J = 9.7, 5.3 Hz, 1H), 3.70-3.95 (m, 2H), 1.69-1.86 (m, 1H), 1.51-1.68 (m, 2H), 1.43- 1.46 (m, 9H), 0.99 (dd, J = 6.4, 4.1 Hz, 6H). 63 {[(2S)-4-methyl-2-({[4- (trifluoromethyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.50- 7.56 (m, 4H), 6.37 (d, J = 7.6 Hz, NH), 4.38 (dd, J = 9.7, 5.0 Hz, 1H), 3.79- 4.04 (m, 2H), 1.69-1.87 (m, 1H), 1.50- 1.70 (m, 2H), 0.99 (dd, J = 6.4, 3.8 Hz, 6H). 64 tert-butyl {[(2R,3R)-2-{[(4- bromophenyl)carbamoyl]amino}-3- methylpentanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.39 (m, 2H), 7.26-7.32 (m, 2H), 6.29 (s, NH), 4.17-4.24 (m, 0H), 3.73- 3.95 (m, 2H), 1.87 (dtd, J = 9.8, 6.5, 3.2 Hz, 0H), 1.61 (ddt, J = 17.0, 7.4, 3.6 Hz, 0H), 1.43-1.47 (m, 9H), 1.11- 1.27 (m, 0H), 0.90-1.03 (m, 6H). 65 {[(2R,3R)-2-{[(4- bromophenyl)carbamoyl]amino}-3- methylpentanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.39 (m, 2H), 7.27-7.32 (m, 2H), 6.29 (s, NH), 4.19-4.26 (m, 1H), 3.81- 4.00 (m, 2H), 1.84-1.94 (m, 1H), 1.60 (ddd, J = 13.2, 7.6, 3.5 Hz, 1H), 1.13- 1.30 (m, 2H), 1.13-1.30 (m, 2H), 0.96 (d, J = 17.6 Hz, 3H). 66 tert-butyl {[(2R)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}acetate
1 H NMR (CD 3 OD, 600 MHz) δ: 7.35- 7.38 (m, 2H), 7.28-7.31 (m, 2H), 4.34 (dd, J = 10.0, 5.0 Hz, 1H), 3.75-3.91 (m, 2H), 1.73-1.80 (m, 1H), 1.63- 1.68 (m, 1H), 1.53-1.59 (m, 1H), 1.44- 1.47 (m, 9H), 0.99 (d, J = 6.7 Hz, 3H), 0.97 (d, J = 6.7 Hz, 3H). 67 {[(2R)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 600 MHz) δ: 7.34- 7.39 (m, 2H), 7.26-7.32 (m, 2H), 4.32- 4.38 (m, 1H), 3.84-4.00 (m, 2H), 1.72-1.81 (m, 1H), 1.63-1.70 (m, 1H), 1.52-1.60 (m, 1H), 0.99 (d, J = 6.7 Hz, 3H), 0.97 (d, J = 6.7 Hz, 3H). 68 tert-butyl {[(2S)-4-methyl-2-({[4- (methylsulfanyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.27- 7.34 (m, 2H), 7.17-7.24 (m, 2H), 6.24 (d, J = 7.9 Hz, NH), 4.30-4.40 (m, 1H), 3.72-3.95 (m, 2H), 2.40-2.43 (m, 3H), 1.69-1.84 (m, 1H), 1.50- 1.68 (m, 2H), 1.44-1.47 (m, 9H), 0.99 (dd, J = 6.4, 4.7 Hz, 6H). 69 2-methyl-2-{[(2S)-4-methyl-2-({[4- (trifluoromethyl)phenyl]carbamoyl} amino)pentanoyl]amino}propanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 8.27 (s, NH), 7.52 (d, J = 19.9 Hz, 4H), 6.29 (d, J = 8.5 Hz, NH), 4.27-4.43 (m, 1H), 1.70-1.85 (m, 1H), 1.45-1.67 (m, 8H), 0.98 (dd, J = 6.4, 2.9 Hz, 6H). 70 {[(2S)-4-methyl-2-({[4- (methylsulfanyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.26- 7.34 (m, 2H), 7.17-7.24 (m, 2H), 4.30- 4.41 (m, 1H), 3.80-4.03 (m, 2H), 2.39-2.43 (m, 3H), 1.49-1.84 (m, 3H), 0.98 (dd, J = 6.4, 4.1 Hz, 6H). 71 tert-butyl ({(2S)-4-methyl-2-[({4- [(trifluoromethyl)sulfanyl]phenyl} carbamoyl)amino]pentanoyl}amino) acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.52- 7.57 (m, 2H), 7.47-7.52 (m, 2H), 4.32- 4.40 (m, 1H), 3.72-3.95 (m, 2H), 1.69-1.84 (m, 1H), 1.50-1.68 (m, 2H), 1.42-1.47 (m, 9H), 0.99 (dd, J = 6.3, 4.2 Hz, 6H). 72 ({(2S)-4-methyl-2-[({4- [(trifluoromethyl)sulfanyl]phenyl} carbamoyl)amino]pentanoyl}amino) acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.47- 7.57 (m, 4H), 4.37 (dd, J = 9.5, 5.1 Hz, 1H), 3.83-4.02 (m, 2H), 1.70-1.83 (m, 1H), 1.51-1.68 (m, 2H), 0.99 (d, J = 3.8 Hz, 3H), 0.97 (d, J = 3.8 Hz, 3H). 73 tert-buty l2-{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}-2- methylpropanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.38 (m, 2H), 7.26-7.32 (m, 2H), 4.31 (dd, J = 9.1, 5.6 Hz, 1H), 1.67-1.80 (m, 1H), 1.45-1.63 (m, 2H), 1.39- 1.44 (m, 15H), 0.97 (dd, J = 6.6, 3.1 Hz, 6H). 74 2-{[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}-2- methylpropanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 8.46 (s, NH), 8.26 (s, NH), 7.33-7.38 (m, 2H), 7.25-7.31 (m, 2H), 4.32 (dd, J = 9.2, 5.4 Hz, 1H), 1.68-1.80 (m, 1H), 1.51-1.65 (m, 2H), 1.49 (s, 3H), 1.48 (s, 3H), 0.98 (d, J = 3.5 Hz, 3H), 0.96 (d, J = 3.5 Hz, 3H). 75 tert-butyl {[(2S)-4-methyl-2-({[4- (methylsulfinyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.61 (s, 4H), 4.37 (dd, J = 9.8, 5.1 Hz, 1H), 3.72-3.96 (m, 2H), 2.77 (s, 3H), 1.69- 1.85 (m, 1H), 1.51-1.69 (m, 2H), 1.45 (s, 9H), 0.94-1.05 (m, 6H). 76 tert-butyl {[(2S)-4-methyl-2-({[4- (methylsulfonyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.77- 7.86 (m, 2H), 7.57-7.67 (m, 2H), 4.37 (dd, J = 9.7, 5.0 Hz, 1H), 3.71-3.96 (m, 2H), 3.07 (s, 3H), 1.69-1.83 (m, 1H), 1.51-1.70 (m, 2H), 1.40-1.49 (m, 9H), 0.94-1.03 (m, 6H). 77 {[(2S)-4-methyl-2-({[4- (methylsulfinyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.57- 7.66 (m, 4H), 4.38 (dd, J = 9.7, 5.0 Hz, 1H), 3.81-4.03 (m, 2H), 2.77 (s, 3H), 1.69-1.85 (m, 1H), 1.48-1.68 (m, 2H), 0.92-1.03 (m, 6H). 78 {[(2S)-4-methyl-2-({[4- (methylsulfonyl)phenyl]carbamoyl} amino)pentanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.76- 7.87 (m, 2H), 7.57-7.68 (m, 2H), 6.43 (d, J = 8.5 Hz, NH), 4.32-4.45 (m, 1H), 3.81-4.04 (m, 2H), 3.07 (s, 3H), 1.71-1.83 (m, 1H), 1.49-1.70 (m, 2H), 0.98 (dd, J = 6.4, 3.5 Hz, 6H). 79 tert-butyl 2-methyl-2-{[(2S)-4- methyl-2-({[4- (trifluoromethyl)phenyl]carbamoyl} amino)pentanoyl]amino}propanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.46- 7.58 (m, 2H), 4.33 (dd, J = 9.2, 5.7 Hz, 1H), 1.69-1.86 (m, 1H), 1.46-1.66 (m, 2H), 1.36-1.46 (m, 15H), 0.94- 1.04 (m, 6H). 80 tert-butyl {[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- (methylsulfanyl)butanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.24- 7.41 (m, 4H), 4.44 (dd, J = 7.8, 5.4 Hz, 1H), 3.70-3.99 (m, 2H), 2.54-2.68 (m, 2H), 2.12-2.18 (m, 1H), 2.11 (s, 3H), 1.85-2.02 (m, 1H), 1.41-1.50 (m, 9H). [α]D = −21.8 (c = 1.00, MeOH) 81 tert-butyl {[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- (methylsulfonyl)butanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.26- 7.43 (m, 4H), 4.43-4.57 (m, 1H), 3.70- 4.03 (m, 2H), 3.24 (s, 2H), 2.99 (s, 4H), 2.28-2.42 (m, 1H), 2.11-2.26 (m, 1H), 1.47 (s, 9H). 82 {[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- (methylsulfanyl)butanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.25- 7.44 (m, 4H), 6.55 (d, J = 7.3 Hz, NH), 4.53 (m, 1H), 3.79-4.10 (m, 2H), 3.26 (m., 2H), 2.98 (s, 3H), 2.26-2.42 (m, 1H), 2.20 (m, 1H). 83 {[(2S)-2-{[(4- bromophenyl)carbamoyl]amino}-4- (methylsulfonyl)butanoyl]amino}acetic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.26- 7.42 (m, 4H), 6.55 (d, J = 7.3 Hz, NH), 4.47-4.58 (m, 1H), 3.80-4.11 (m, 2H), 3.25 (m, 2H), 2.98 (s, 3H), 2.28- 2.43 (m, 1H), 2.11-2.27 (m, 1H). 84 tert-butyl {[2-{[(4- bromophenyl)carbamoyl]amino}-3- (1H-imidazol-4- yl)propanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.61 (s, 1H), 7.21-7.41 (m, 4H), 6.94 (s, 1H), 4.51-4.64 (m, 1H), 3.75-3.96 (m, 2H), 3.07-3.22 (m, 1H), 2.93- 3.06 (m, 1H), 1.49 (s, 9H). 85 {[2-{[(4- bromophenyl)carbamoyl]amino}-3- (1H-imidazol-4- yl)propanoyl]amino}acetic acid
1 H NMR (DMSO-D 6 , 300 MHz) δ: 8.93 (NH, 1H), 8.42 (br. s., NH), 7.67 (s, 1H), 7.34 (d, J = 4.1 Hz, 4H), 6.88 (s, 1H), 6.28 (d, J = 7.3 Hz, NH), 4.44 (m., 1H), 3.55-3.90 (m, 2H), 2.93 (m., 2H). 86 tert-butyl 2-{[(2R)-2-{[(4- bromophenyl)carbamoyl]amino}-4- methylpentanoyl]amino}-2- methylpropanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.38 (m, 2H), 7.26-7.32 (m, 2H), 4.31 (dd, J = 9.1, 5.6 Hz, 1H), 1.67-1.80 (m, 1H), 1.45-1.63 (m, 2H), 1.39- 1.44 (m, 15H), 0.97 (dd, J = 6.6, 3.1 Hz, 6H). 87 2-{[(2R)-2-{[(4-bromophenyl) carbamoyl]amino}-4- methylpentanoyl] amino}-2- methylpropanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 8.46 (s, NH), 8.23 (s, 2NH), 7.33-7.39 (m, 2H), 7.26-7.31 (m, 2H), 6.19 (d, J = 8.2 Hz, NH), 4.31 (m 1H), 1.73 (m, 1H), 1.51-1.65 (m, 2H), 1.49 (s, 3H), 1.48 (s, 3H), 0.98 (d, J = 3.8 Hz, 6H), 0.96 (d, J = 3.5 Hz, 6H). 88 tert-butyl {[4-amino-2-{[(4- bromophenyl) carbamoyl]amino}- 4-oxobutanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.27- 7.42 (m, 4H), 4.69 (t, J = 6.0 Hz, 1H), 3.75-3.94 (m, 2H), 2.70-2.78 (m, 2H), 1.45 (s, 9H). 89 4-amino-2-{[(4-bromophenyl) carbamoyl]amino}-4-oxobutanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.26- 7.44 (m, 4H), 4.62 (t, J = 5.3 Hz, 1H), 2.70-2.94 (m, 2H). 90 tert-butyl {[2-{[(4-bromophenyl) carbamoyl]amino}-3-(1H-indol-3- yl) propanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.56- 7.61 (m, 1H), 7.30-7.36 (m, 3H), 7.23- 7.26 (m, 2H), 7.16 (s, NH), 7.08 (td, J = 7.6, 1.2 Hz, 1H), 6.95-7.02 (m, 1H), 6.13 (d, J = 7.3 Hz, NH), 4.60-4.68 (m, 1H), 3.80 (s, 2H), 3.32-3.38 (m, 1H), 3.11-3.23 (m, 1H), 1.43-1.47 (m, 9H). 91 tert-butyl {[4-amino-2-{[(4- bromophenyl) carbamoyl]amino}- 4-oxobutanoyl]amino}acetate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.27- 7.42 (m, 4H), 4.69 (t, J = 6.0 Hz, 1H), 3.75-3.94 (m, 2H), 2.70-2.78 (m, 2H), 1.45 (s, 9H). Interm. IUPAC name No. Structure 1 H NMR δ (ppm) 10 (2S,3S)-2-{[(4-bromophenyl) carbamoyl]amino}-3- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.33- 7.41 (m, 2H), 7.26-7.33 (m, 2H), 4.18 (d, J = 6.2 Hz, 1H), 1.74-1.91 (m, 1H), 1.50-1.66 (m, 1H), 1.11-1.33 (m, 1H), 0.99 (d, J = 7.0 Hz, 3H), 0.91- 0.97 (m, 3H). 11 (2S,3S)-2-{[(4-bromo-2- fluorophenyl) carbamoyl]amino}-3- methylpentanamide
1 H NMR (CD 3 OD, 300 MHz) δ: 7.99 (t, J = 8.8 Hz, 1H), 7.31 (dd, J = 10.7, 2.2 Hz, 1H), 7.19-7.27 (m, 1H), 4.18 (d, J = 6.2 Hz, 1H), 1.78-1.95 (m, 1H), 1.49-1.65 (m, 1H), 1.10-1.27 (m, 1H), 1.00 (d, J = 6.7 Hz, 3H), 0.91- 0.98 (m, 3H). 12 (2S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-pentanamide
1 H NMR (acetone-d6, 300 MHz) δ: 8.28 (t, J = 8.8 Hz, 1H), 8.12 (br. s., NH), 7.33 (dd, J = 11.0, 2.2 Hz, 1H), 7.26 (dt, J = 8.9, 1.9 Hz, 1H), 7.07 (br. s., NH), 6.55 (d, J = 7.0 Hz, NH), 6.40 (br. s., NH), 4.38 (td, J = 7.8, 5.3 Hz, 1H), 1.73-1.89 (m, 1H), 1.54-1.70 (m, 1H), 1.24-1.49 (m, 2H), 0.92 (t, J = 7.3 Hz, 3H). 13 (2S)-2-{[(4-bromophenyl) carbamoyl]amino}-4- methylpentanamide
1 H NMR (acetone-d6, 300 MHz) δ: 8.17 (s, NH), 7.41-7.50 (m, 2H), 7.33- 7.40 (m, 2H), 6.03 (d, J = 8.2 Hz, NH), 4.39 (ddd, J = 9.4, 8.2, 5.0 Hz, 1H), 3.58 (q, J = 5.6 Hz, 2H), 3.26- 3.37 (m, 2H), 1.66-1.81 (m, 1H), 1.44- 1.67 (m, 2H), 0.94 (d, J = 1.5 Hz, 3H), 0.92 (d, J = 1.4 Hz, 3H). 14 (2S)-2({[(4-bromo-2-fluorophenyl) carbamoyl]amino}-4- methylpentanoate
1 H NMR (acetone-d6, 300 MHz) δ: 8.27 (t, J = 8.9 Hz, 1H), 8.06 (br. s., NH), 7.34 (dd, J = 10.8, 2.3 Hz, 1H), 7.25- 7.31 (m, 1H), 6.53 (d, J = 7.0 Hz, NH), 4.43-4.55 (m, 1H), 1.73-1.87 (m, 1H), 1.53-1.71 (m, 2H), 0.98 (d, J = 1.5 Hz, 3H), 0.96 (d, J = 1.5 Hz, 3H). 15 (2S)-2-{[(4-bromo-2-fluorophenyl) carbamoyl]amino}-4- methylpentanamide
1 H NMR (acetone-d6, 300 MHz) δ: 8.28 (t, J = 8.9 Hz, 1H), 8.07 (br. s., NH), 7.33 (dd, J = 10.8, 2.3 Hz, 1H), 7.23- 7.30 (m, 1H), 7.10 (br. s., NH), 6.50 (d, J = 8.2 Hz, NH), 6.38 (br. s., NH), 4.42 (ddd, J = 9.6, 8.3, 5.0 Hz, 1H), 1.70- 1.87 (m, 1H), 1.59-1.70 (m, 1H), 1.44- 1.59 (m, 1H), 0.95 (d, J = 1.5 Hz, 3H), 0.93 (d, 3H). 16 tert-butyl (2S)-2-{[(4-bromo-2- fluorophenyl) carbamoyl]amino}-4- methylpentanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.89 (t, J = 8.8 Hz, 1H), 7.14 (dd, J = 10.4, 2.2 Hz, 1H), 7.06 (d, J = 9.1 Hz, 1H), 6.80 (d, J = 2.6 Hz, NH), 5.79 (br. s., NH), 4.45 (dd, J = 8.8, 5.0 Hz, 1H), 1.69- 1.85 (m, 1H), 1.57-1.69 (m, 1H), 1.52 (s, 9H), 1.41-1.48 (m, 1H), 0.97 (d, J = 3.5 Hz, 3H), 0.95 (d, 3H). 17 2-{[(4-bromophenyl) carbamoyl]amino}-2,4- dimethylpentanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.31- 7.39 (m, 2H), 7.22-7.30 (m, 2H), 1.80- 1.92 (m, 2H), 1.71-1.82 (m, 1H), 1.56-1.67 (m, 2H), 1.44 (s, 3H), 0.98 (d, J = 1.2 Hz, 3H), 0.95 (d, J = 1.2 Hz, 3H). 18 tert-butyl {[2-{[(4-bromophenyl) carbamoyl]amino}-2- methylpropanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 9.29 (br. s., NH), 8.58-8.75 (m, 4H), 7.33 (br. s., NH), 2.65-2.75 (m, 9H). 19 2-{[(4-bromophenyl) carbamoyl]amino}-2- methylpropanoic acid
1H NMR (CD3OD, 300 MHz) δ: 7.32- 7.37 (m, 2H), 7.24-7.29 (m, 2H), 1.52 (s, 6H). 20 2-{[(4-bromophenyl) carbamoyl]amino}-2-ethylbutanoic acid
1 H NMR (acetone-d6, 300 MHz) δ: 8.76 (br. s., 1H), 7.44-7.52 (m, 2H), 7.31-7.40 (m, 2H), 6.30 (br. s., 1H), 2.29-2.48 (m, 2H), 1.75-1.92 (m, 2H), 0.76-0.86 (m, 6H). 21 tert-butyl (2S)-4-methyl-2-({[4- (trifluoromethyl)phenyl]carbamoyl} amino)pentanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.50 (s, 4H), 4.27 (dd, J = 9.1, 5.6 Hz, 1H), 1.68-1.86 (m, 1H), 1.52-1.66 (m, 2H), 1.45-1.50 (s, 9H), 0.95 (t, J = 6.9 Hz, 6H). 22 (2S)-4-methyl-2-({[4- (trifluoromethyl)phenyl]carbamoyl} amino)pentanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.49- 7.57 (m, 4H), 4.38 (dd, J = 9.4, 5.0 Hz, 1H), 1.69-1.87 (m, 1H), 1.51-1.69 (m, 2H), 0.92-1.01 (m, 6H). 23 tert-butyl (2S)-2-({(4-chlorophenyl) carbamoyl}amino)4- methylpentanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.30- 7.39 (m, 2H), 7.17-7.28 (m, 1H), 4.25 (dd, J = 8.9, 5.7 Hz, 1H), 1.74 (dd, J = 13.6, 7.5 Hz, 1H), 1.51-1.67 (m, 2H), 1.47 (s, 9H), 0.97 (t, J = 6.9 Hz, 6H). 24 (2S)-2-({(4-chlorophenyl) carbamoyl}amino)4- methylpentanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.29- 7.38 (m, 2H), 7.17-7.27 (m, 2H), 4.36 (dd, J = 9.4, 5.0 Hz, 1H), 1.73 (dd, J = 18.3, 5.7 Hz, 1H), 1.51-1.68 (m, 2H), 0.98 (dd, J = 6.4, 3.5 Hz, 6H). 25 tert-butyl (2S)-2-({(4-iodophenyl) carbamoyl}amino)4- methylpentanoate
1 H NMR (CD 3 OD, 300 MHz) δ: 7.50- 7.59 (m, 2H), 7.12-7.23 (m, 2H), 4.25 (m, 1H), 1.73 (m, 1H), 1.49-1.63 (m, 2H), 1.47 (s, 9H), 0.91-1.03 (m, 6H). 26 (2S)-2-({(4-iodophenyl) carbamoyl}amino)4- methylpentanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.50- 7.58 (m, 2H), 7.13-7.21 (m, 2H), 4.35 (dd, J = 9.4, 5.0 Hz, 1H), 1.50-1.86 (m, 2H), 1.01 (m, 6H). 27 (2R,3R)-2-({(4-bromophenyl) carbamoyl}amino)3- methylpentanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.35- 7.39 (m, 2H), 7.28-7.32 (m, 2H), 4.32 (d, J = 4.7 Hz, 1H), 1.92 (dq, J = 6.8, 4.6 Hz, 1H), 1.46-1.60 (m, 1H), 1.16- 1.33 (m, 1H), 0.93-1.02 (m, 6H). 28 tert-butyl (2R)-2-({(4- bromophenyl) carbamoyl}amino)4- methylpentanoate
1 H NMR (CDCl 3 , 300 MHz) δ: 7.33 (d, J = 8.5 Hz, 2H), 7.17 (s, 2H), 4.43 (dd, J = 9.1, 5.3 Hz, 1H), 1.68-1.79 (m, 1H), 1.56-1.67 (m, 1H), 1.48 (s, 9H), 1.44 (s, 1H), 0.97 (d, J = 4.1 Hz, 3H), 0.95 (d, J = 4.4 Hz, 3H). 29 (2R)-2-({(4-bromophenyl) carbamoyl}amino)4- methylpentanoic acid
1 H NMR (acetone-D6, 300 MHz) δ: 8.17 (s, NH), 7.43-7.50 (m, 2H), 7.33- 7.41 (m, 2H), 6.04 (d, J = 7.9 Hz, NH), 4.42-4.52 (m, 1H), 1.71-1.87 (m, 1H), 1.52-1.69 (m, 2H), 0.97 (d, J = 2.1 Hz, 3H), 0.95 (d, J = 2.3 Hz, 3H). 30 tert-butyl (2S)-4-methyl-2-({[4- (methylthio)phenyl] carbamoyl}amino)pentanoate
1 H NMR (CD3OD, 300 MHz) δ: 7.27- 7.32 (m, 2H), 7.18-7.23 (m, 2H), 4.22- 4.29 (m, 1H), 2.42 (s, 3H), 1.70-1.79 (m, 1H), 1.51-1.61 (m, 2H), 1.47 (s, 9H), 0.97 (t, J = 6.7 Hz, 6H). 31 (2S)-4-methyl-2-({[4- (methylthio)phenyl] carbamoyl}amino)pentanoic acid
1 H NMR (CD3OD, 300 MHz) δ: 7.25- 7.31 (m, 2H), 7.14-7.20 (m, 2H), 4.37 (dd, J = 9.2, 5.1 Hz, 1H), 2.39 (s, 3H), 1.68-1.83 (m, 1H), 1.51-1.67 (m, 2H), 0.96 (dd, J = 6.2, 2.3 Hz, 6H). 32 (2S)-4-methyl-2-{({4- [(trifluoromethyl)thio]phenyl} carbamoyl}amino)pentanoic acid
1 H NMR (CD3OD, 300 MHz) δ: 7.52- 7.58 (m, 2H), 7.47-7.52 (m, 2H), 4.37 (dd, J = 9.4, 5.0 Hz, 1H), 1.70-1.82 (m, 1H), 1.53-1.69 (m, 2H), 0.99 (d, J = 3.2 Hz, 3H), 0.97 (d, J = 3.2 Hz, 3H). 33 tert-butyl (2S)-4-methyl-2-{({4- [(trifluoromethyl)thio]phenyl} carbamoyl}amino)pentanoate
1 H NMR (CD3OD, 300 MHz) δ: 7.53- 7.57 (m, 2H), 7.47-7.51 (m, 2H), 4.26 (dd, J = 8.9, 5.7 Hz, 1H), 1.74 (td, J = 13.6, 6.7 Hz, 1H), 1.51-1.65 (m, 2H), 1.47 (s, 9H), 0.97 (t, J = 6.7 Hz, 6H). 34 (2S)-2-({(4-bromophenyl) carbamoyl}amino)4- (methylthio)butanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 7.23- 7.41 (m, 4H), 4.31-4.42 (m, 1H), 2.56 (d, J = 15.5 Hz, 2H), 2.12-2.23 (m, 1H), 2.08 (s, 3H), 1.98 (dt, J = 14.0, 7.2 Hz, 1H). 35 2-({(4-bromophenyl) carbamoyl}amino)3-(1H-imidazol- 4-yl)propanoic acid
1 H NMR (CD 3 OD, 300 MHz) δ: 8.76 (s, 1H), 7.23-7.40 (m, 6H), 4.65 (m, 1H), 3.03-3.27 (m, 2H).
Biological Data
Biological activity of compounds according to Formula II is set forth in Table 5 below. CHO-Gα16 cells stably expressing FPRL1 were cultured in (F12, 10% FBS, 1% PSA, 400 μg/ml geneticin and 50 μg/ml hygromycin) and HEK-Gqi5 cells stable expressing FPR1 were cultured in (DMEM high glucose, 10% FBS, 1% PSA, 400 μg/ml geneticin and 50 μg/ml hygromycin). In general, the day before the experiment, 18,000 cells/well were plated in a 384-well clear bottom poly-d-lysine coated plate. The following day the screening compound-induced calcium activity was assayed on the FLIPR Tetra . The drug plates were prepared in 384-well microplates using the EP3 and the MultiPROBE robotic liquid handling systems. Compounds were tested at concentrations ranging from 0.61 to 10,000 nM. Results are expressed as EC 50 (nM) and efficacy values.
TABLE 5
FPRL-1
Ga16-CHO
IUPAC Name
EC 50 (nM)
Compound
(Rel. eff.)
{[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-imidazol-4-
10.0
yl)propanoyl]amino}acetic acid
(0.95)
tert-butyl {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-
263
imidazol-4-yl)propanoyl]amino}acetate
(0.95)
{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
247
(methylsulfonyl)butanoyl]amino}acetic acid
(1.01)
tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
1238
(methylsulfonyl)butanoyl]amino}acetate
(0.97)
{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
7
(methylsulfanyl)butanoyl]amino}acetic acid
(1.03)
tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
127
(methylsulfanyl)butanoyl]amino}acetate
(0.98)
2-methyl-2-{[(2S)-4-methyl-2-({[4-
2.3
(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(0.92)
propanoic acid
tert-butyl 2-methyl-2-{[(2S)-4-methyl-2-({[4-
1016
(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(1.07)
propanoate
{[(2S)-4-methyl-2-({[4-
459
(methylsulfonyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(1.12)
acetic acid
tert-butyl {[(2S)-4-methyl-2-({[4-
1083
(methylsulfonyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(0.90)
acetate
{[(2S)-4-methyl-2-({[4-
358
(methylsulfinyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(1.21)
acetic acid
tert-butyl {[(2S)-4-methyl-2-({[4-
668
(methylsulfinyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(0.97)
acetate
2-{[(2S)-2-({[(4-bromophenyl)amino]carbamoyl}amino)-4-
1
methylpentanoyl] amino}-2-methylpropanoic acid
(0.96)
tert-butyl 2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-
133
4-methylpentanoyl]amino}-2-methylpropanoate
(1.16)
({(2S)-4-methyl-2-[({4-
560
[(trifluoromethyl)sulfanyl]phenyl}carbamoyl)amino]pentanoyl}
(1.07)
amino)acetic acid
tert-butyl ({(2S)-4-methyl-2-[({4-
3103
[(trifluoromethyl)sulfanyl]phenyl}carbamoyl)amino]pentanoyl}
(0.78)
amino)acetate
{[(2S)-4-methyl-2-({[4-
2.95
(methylsulfanyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(1.05)
acetic acid
tert-butyl {[(2S)-4-methyl-2-({[4-
116
(methylsulfanyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(0.98)
acetate
{[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
1229
methylpentanoyl]amino} acetic acid
(0.97)
tert-butyl {[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
3657
methylpentanoyl]amino}acetate
(0.92)
{[(2R,3R)-2-{[(4-bromophenyl)carbamoyl]amino}-3-
19315
methylpentanoyl]amino}acetic acid
(0.45)
tert-butyl {[(2R,3R)-2-{[(4-bromophenyl)carbamoyl]amino}-
3974
3-methylpentanoyl]amino}acetate
(0.44)
{[(2S)-4-methyl-2-({[4-
1.8
(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(0.99)
acetic acid
tert-butyl {[(2S)-4-methyl-2-({[4-
309
(trifluoromethyl)phenyl]carbamoyl}amino)pentanoyl]amino}
(0.81)
acetate
{[(2R)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-
1489
methylpentanoyl]amino}acetic acid
(0.87)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-[2-
1.4
(dimethylamino)-2-oxoethyl]-4-methylpentanamide
(0.90)
[(2-{[(4-bromophenyl)carbamoyl]amino}-2-
480
methylpropanoyl)amino]acetic acid
(0.99)
tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2-
114
methylpropanoyl)amino]acetate
(1.02)
[(2-{[(4-bromophenyl)carbamoyl]amino}-2-
19
ethylbutanoyl)amino]acetic acid
(1.04)
tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2-
31
ethylbutanoyl)amino]acetate
(1.03)
[(2-{[(4-bromophenyl)carbamoyl]amino}-2,4-
22
dimethylpentanoyl)amino]acetic acid
(0.98)
tert-butyl [(2-{[(4-bromophenyl)carbamoyl]amino}-2,4-
58
dimethylpentanoyl)amino]acetate
(0.98)
(2S)-N-[(1S)-2-amino-2-oxo-1-phenylethyl]-2-{[(4-
84
bromophenyl)carbamoyl]amino}-4-methylpentanamide
(0.99)
(2S)-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
9.1
methylpentanoyl]amino}(phenyl)ethanoic acid
(1.08)
tert-butyl (2S)-{[(2S)-2-{[(4-
122
bromophenyl)carbamoyl]amino}-4-
(1.02)
methylpentanoyl]amino}(phenyl)ethanoate
(2S)-N-[(2S)-1-amino-1-oxopentan-2-yl]-2-{[(4-
6.4
bromophenyl)carbamoyl]amino}-4-methylpentanamide
(1.03)
(2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
1.0
methylpentanoyl]amino}pentanoic acid
(0.89)
tert-butyl (2S)-2-{[(2S)-2-{[(4-
13
bromophenyl)carbamoyl]amino}-4-
(1.06)
methylpentanoyl]amino}pentanoate
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-[(2R)-1-
3.0
hydroxypropan-2-yl]-4-methylpentanamide
(1.00)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2,3-
5.1
dihydroxypropyl)-4-methylpentanamide
(0.98)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(1,3-
7.4
dihydroxypropan-2-yl)-4-methylpentanamide
(0.96)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-hydroxy-
2.1
2-methylpropyl)-4-methylpentanamide
(1.01)
(2S)-N-[(2S)-1-amino-3-methyl-1-oxobutan-2-yl]-2-{[(4-
1.3
bromophenyl)carbamoyl]amino}-4-methylpentanamide
(1.03)
(2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
1.83
methylpentanoyl]amino}-3-methylbutanoic acid
(1.13)
tert-butyl (2S)-2-{[(2S)-2-{[(4-
68
bromophenyl)carbamoyl]amino}-4-methylpentanoyl]amino}-
(0.98)
3-methylbutanoate
(2S)-N-[(2S)-1-amino-1-oxopropan-2-yl]-2-{[(4-
24
bromophenyl)carbamoyl]amino}-4-methylpentanamide
(0.96)
(2S)-2-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
11
methylpentanoyl]amino}propanoic acid
(1.05)
tert-butyl (2S)-2-{[(2S)-2-{[(4-
147
bromophenyl)carbamoyl]amino}-4-
(0.96)
methylpentanoyl]amino}propanoate
(2S)-N-[(2S)-1-amino-1-oxopropan-2-yl]-2-{[(4-bromo-2-
31
fluorophenyl)carbamoyl]amino}-4-methylpentanamide
(1.05)
(2S)-2-{[(2S)-2-{[(4-bromo-2-
12
fluorophenyl)carbamoyl]amino}-4-
(0.95)
methylpentanoyl]amino}propanoic acid
tert-butyl (2S)-2-{[(2S)-2-{[(4-bromo-2-
174
fluorophenyl)carbamoyl]amino}-4-
(1.00)
methylpentanoyl]amino}propanoate
(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-
77
hydroxyethyl)-4-methylpentanamide
(1.05)
(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-
20
methyl-N-(2-oxopropyl)pentanamide
(0.99)
(2S)-N-(2-amino-2-oxoethyl)-2-{[(4-bromo-2-
4.5
fluorophenyl)carbamoyl]amino}-4-methylpentanamide
(0.95)
{[(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-4-
3.6
methylpentanoyl]amino}acetic acid
(1.10)
tert-butyl {[(2S)-2- {[(4-bromo-2-
134
fluorophenyl)carbamoyl]amino}-4-
(1.19)
methylpentanoyl]amino}acetate
(2S)-N-(2-amino-2-oxoethyl)-2-{[(4-bromo-2-
5.2
fluorophenyl)carbamoyl]amino}pentanamide
(0.98)
(2S)-N-(2-amino-2-oxoethyl)-2-{[(4-
2.5
bromophenyl)carbamoyl]amino}pentanamide
(0.97)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-methyl-N-(2-
4.7
oxopropyl)pentanamide
(0.82)
(2S)-N-(2-amino-2-oxoethyl)-2-{[(4-
1.05
bromophenyl)carbamoyl]amino}-4-methylpentanamide
(1.08)
{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
0.88
methylpentanoyl]amino}acetic acid
(0.91)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-
11
hydroxyethyl)-4-methylpentanamide
(0.92)
tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
140
methylpentanoyl]amino}acetate
(0.85)
{[(2S)-2-{[(4-bromo-2-
4.8
fluorophenyl)carbamoyl]amino}pentanoyl]amino}acetic acid
(0.92)
tert-butyl {[(2S)-2-{[(4-bromo-2-
83
fluorophenyl)carbamoyl]amino}pentanoyl]amino}acetate
(0.95)
(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-
92
oxopropyl)pentanamide
(0.92)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-
35
oxopropyl)pentanamide
(1.05)
propan-2-yl {[(2S)-2-{[(4-
14
bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate
(1.04)
ethyl {[(2S)-2-{[(4-
57
bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate
(1.18)
methyl {[(2S)-2-{[(4-
17
bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate
(0.88)
(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-
105
hydroxyethyl)pentanamide
(0.87)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-
38
hydroxyethyl)pentanamide
(0.92)
(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-
16
hydroxyethyl)-3-phenylpropanamide
(0.98)
{[(2S)-2-{[(4-
3.2
bromophenyl)carbamoyl]amino}pentanoyl]amino}acetic acid
(0.91)
tert-butyl {[(2S)-2-{[(4-
31
bromophenyl)carbamoyl]amino}pentanoyl]amino}acetate
(0.95)
(2S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-(2-
12
oxopropyl)-3-phenylpropanamide
(0.94)
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-
29
oxopropyl)-3-phenylpropanamide
(0.96)
(2S,3S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-N-
62
(2-hydroxyethyl)-3-methylpentanamide
(1.00)
(2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-
24
hydroxyethyl)-3-methylpentanamide
(1.00)
(2S,3S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-3-
36
methyl-N-(2-oxopropyl)pentanamide
(1.01)
(2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-methyl-N-
10
(2-oxopropyl)pentanamide
(0.97)
(2S,3S)-N-(2-amino-2-oxoethyl)-2-{[(4-bromo-2-
10
fluorophenyl)carbamoyl]amino}-3-methylpentanamide
(1.00)
(2S,3S)-N-(2-amino-2-oxoethyl)-2-{[(4-
4.6
bromophenyl)carbamoyl]amino}-3-methylpentanamide
(0.81)
{[(2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-
2.7
methylpentanoyl]amino}acetic acid
(1.00)
tert-butyl {[(2S,3S)-2-{[(4-bromophenyl)carbamoyl]amino}-
280
3-methylpentanoyl]amino}acetate
(0.85)
{[(2S,3S)-2-{[(4-bromo-2-fluorophenyl)carbamoyl]amino}-
5.5
3-methylpentanoyl]amino}acetic acid
(0.95)
tert-butyl {[(2S,3S)-2-{[(4-bromo-2-
757
fluorophenyl)carbamoyl]amino}-3-
(0.86)
methylpentanoyl]amino}acetate
(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-N-(2-
6
hydroxyethyl)-3-phenylpropanamide
(0.92)
3-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-
18
phenylpropanoyl]amino}propanoic acid
(0.98)
tert-butyl 3-{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-
255
3-phenylpropanoyl]amino}propanoate
(1.00)
{[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-
7.7
phenylpropanoyl]amino}acetic acid
(0.99)
tert-butyl {[(2S)-2-{[(4-bromophenyl)carbamoyl]amino}-3-
118
phenylpropanoyl]amino}acetate
(0.91)
tert-butyl 2-{[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-
2725
4-methylpentanoyl]amino}-2-methylpropanoate
(0.74)
2-{[(2R)-2-{[(4-bromophenyl)carbamoyl]amino}-4-
490
methylpentanoyl]amino}-2-methylpropanoic acid
(0.74)
{[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-indol-3-
0.73
yl)propanoyl]amino}acetic acid
(0.97)
tert-butyl {[2-{[(4-bromophenyl)carbamoyl]amino}-3-(1H-
305
indol-3-yl)propanoyl]amino}acetate
(1.03)
[(4-amino-2-{[(4-bromophenyl)carbamoyl]amino}-4-
2938
oxobutanoyl)amino]acetic acid
(0.81)
tert-butyl [(4-amino-2-{[(4-bromophenyl)carbamoyl]amino}-
2306
4-oxobutanoyl)amino]acetate
(0.90) | The present invention relates to novel amide derivatives of N-urea substituted amino acids, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of the N-formyl peptide receptor like-1 (FPRL-1) receptor. | 0 |
FIELD OF THE INVENTION
[0001] There is a wide tradition in the field of applied economics in relation with diminishing the risk on your entrepreneurial activity. For the present case, the invention targets the farm economic activity. This invention consists on a computerized work, which is manifested in appearance in a system and method for compute synthetic data. It uses sophisticate econometric techniques and models, besides the intrinsic statistic information conveyed on the variables in a research study.
BACKGROUND
[0002] There is a considerable literature delving into risk and uncertainty, which are present in farm economic activity including an analysis for diminishing cost and losses and increasing profits, by using similar econometric techniques as this invention does. However, those techniques do not achieve the same precision grade and statistic significance as this invention does, while they neither use effectively simulation scenarios. This invention is not only important to assess the current situation for the farmer entrepreneur, but also provides tools in decision-making in the food-crop production, with a low cost. For example, food sovereignty is important since it is a milestone for supporting the economic growth of a nation. If there is no food sovereignty, the country might end not relying on its own decisions with respect to food production. As a result, a chain of undesirable economic consequences might follow.
[0003] Unique features of the invention: The author have knowledge of codes and/or system and methods that try to solve the same sample problem input that this invention uses. However, none of them are successful in solving the problem that this invention does.
[0004] List of competing inventors or labs or works that keeps a resemblance with the present invention: Compass Lexecon. Atanu Saha, Ph.D. Executive Vice President and Head of New York Office, 156 West 56 th Street, 19 th Floor, New York, N.Y. 10019. Regarding Saha similar work: Scripps Nob Hill versus Presley Companies, expert analysis regarding the timing and incidence of product failure; expert analysis on behalf of investment banks and financial institutions in several mutual fund ‘market timing’ and ‘A versus B’ shares matters. The analyses involved quantification of damages, if any, suffered by investors, using sophisticated econometric models and statistical tools; Sanchez versus Certified Grocers et al., expert analysis for defendant Certified Grocers regarding lost wages, lost future earnings and other economic damages.
[0005] List all of the features that distinguish the invention over the related technologies: It is well known that the use of farm data is very expensive, since there is a need to design and pay for the experiment, the survey, the data collection, etcetera. Also it is expensive, because it takes a long time for obtaining the crop production information i.e., some crops have one or two cycles per year; another crops, per example coffee, even can take three-to-four years to produce the seed. Thus, this invention is relevant because it makes possible to perform crop risk analysis and input-output prices studies from a computer desk. This invention provides a system and method that allows an analysis based on simulations. Thus, it allows testing for different uncertainty conditions or risk scenarios, providing information and criteria to determine the best decisions under these conditions. Very little data input is necessary. As a result, the experiment costs drops dramatically. This invention allows replicating the natural phenomena through a series of cycles or simulations based on the statistic information which has the intrinsic probabilistic distribution properties of the variables. In addition, this system and method is abled to replicate related published results. In this way this invention allows calibration and at the same time a high grade of precision based on its results as well as a 99% of statistic significance.
[0006] Best mode of making the invention: The best mode is using Matlab language. However, the implementation in other languages can be done using equivalent instructions in chosen programing languages i.e., Fortram, C, R, etcetera.
[0007] Possible alternative versions of the invention: Possible alternatives involve the use of this system and method to different crops. In part references it is mentioned the use of similar systems for raspberry. In fact, the author believes, any crop could be subjected to this type of analysis. In the sample problem input a sample of 60; 45 and 15 farms were used. The factor among them is a multiple of 15. An alternative version could involve using a different factor for a simulation in order to represent states or even a country i.e., 1,000; 1,000; 1,000,000; etcetera. Other option is using real data with this invention, in order to obtain results without involving random numbers. This could bring peace of mind for those parties that are interested in this analysis but do not fully understand the possibilities of synthetic data. One advantage of having this invention is that its user can calibrate it with those econometric models which use real data or vice versa, whatever it works better for the user. Finally, other type of alternative version is to modify this invention slightly such as it better matches specific products. Example of this products are found in references i.e., mutual funds; economic damages valuation; financial decisions; stock returns; futures markets; hedge funds; stock prices; adoption of emerging technologies under uncertainty; optimal response under uncertainty; cell phone companies; households decisions; etcetera.
[0008] Probable uses of the invention: This invention could be use by: Farm associations; state governments; consulting firms; Wall Street; commercial banks; Federal Reserve; national governments; classroom teaching; etcetera.
SUMMARY OF THE INVENTION
[0009] In summary, this system and method helps individual farmers and/or economic agents and also different aggregations of them; state government and nations to analyze their current situation by giving them statistic tools and econometric models that allows them to take grounded i.e., food-crop decisions.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] For what follows and for the understanding of the present invention, it will be more readily apparent from the following detailed description of drawings with respect to the invention embodiments:
[0011] FIG. 1 is a flow chart of a method for an embodiment to assign initial number of observations and values for the random variables in accordance with the present invention;
[0012] FIG. 2 is a flow chart of a method for an embodiment to generate synthetic data based on descriptive statistics and the uniform distribution in accordance with the present invention;
[0013] FIG. 3 is an illustration of a Weibull distribution function drawing for the error term with shape 3.8 and scale 1.3. The center of the boxplot displays the median;
[0014] FIG. 4 is a flow chart of a method for an embodiment to compute standard errors in accordance with the present invention;
[0015] FIG. 5 is Table 4: ML Estimates of Weibull Parameters;
[0016] FIG. 6 is equation 11 in Saha;
[0017] FIG. 7 is Table 3. Summary Statistics;
[0018] FIG. 8 is a flow chart of a method for an embodiment for the first stage on Saha CDE non random part estimation method in accordance with the present invention;
[0019] FIG. 9 is the output of the first stage on Saha estimation CDE non random part method. A stands for technology; a 1 stands for the elasticity coefficient of capital; a 2 stands for the elasticity coefficient of materials and h stands for hat;
[0020] FIG. 10 is a flow chart of a method for an embodiment for the second stage on Saha CDE random part estimation method: G stands for the log of the square error term in accordance with the present invention;
[0021] FIG. 11 is the output of the second stage on Saha CDE random part estimation method: m 1 stands for the elasticity coefficient for input not risk reducing; m 2 stands for the elasticity coefficient for inputs risk reducing and h stands for hat in accordance with the present invention;
[0022] FIG. 12 is a flow chart of a method for an embodiment for the wealth function computation in accordance with the present invention;
[0023] FIG. 13 is the wealth function computation output: alpha is the expo-power utility parameter; beta is the expo-power utility parameter and h stands for hat;
[0024] FIG. 14 is the partial production elasticities output: mmiu 1 stands for the partial production elasticity of ×1; mmiu 5 stands for the partial production elasticity of ×2 and h stands for hat;
[0025] FIG. 15 is a flow chart of a method for an embodiment to compute Only CDE in accordance with the present invention;
[0026] FIG. 16 is the output for Only CDE: A stands for technology; a 1 stands for the elasticity coefficient of capital; a 2 stands for the elasticity coefficient of materials; m 1 stands for the elasticity coefficient for input not risk reducing; m 2 stands for the elasticity coefficient for inputs risk reducing; mmiu 1 stands for the partial production elasticity of ×1; mmiu 5 stands for the partial production elasticity of ×2; m and b stands for only CDE and h stands for hat;
[0027] FIG. 17 is a flow chart of a method for an embodiment to compute the second estimation method under CARA in Table (5) in accordance with the present invention;
[0028] FIG. 18 is the output part of the second estimation method under CARA in Table (5): A stands for technology; a 1 stands for the elasticity coefficient of capital; a 2 stands for the elasticity coefficient of materials; m 1 is stands for the elasticity coefficient for input not risk reducing; m 2 stands for the elasticity coefficient for inputs risk reducing; mmiu 1 stands for the partial production elasticity of ×1; mmiu 2 stands for the partial production elasticity of ×2;
[0029] FIG. 19 Table 5. Parameter estimates of EP Utility and CDE Production Function;
[0030] FIG. 20 is a flow chart of a method for an embodiment to compute Table 6 in accordance with the present invention;
[0031] FIG. 21 is Table 6. Arrow-Pratt Risk Aversion Measures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Manual
[0032] In the following manual, it is used a sample problem input based on Saha, A., R. Shumway and H. Talpaz. 1994. “Joint Estimation of Risk Preference and Production Technology Using the Expo-Power Utility Function” American Journal of Agricultural Economics 76, 173-184, during the rest of the manual this paper would be referring as Saha or authors indistinctly.
[0033] 1. Generate the random data for the experiment using a Monte Carlo simulation, emulating the variables use in Saha. To simplify things you can use the Matlab integrated modules that provide already random number generators. From the sample problem input, take the mean and standard deviation to generate the input variables as follows:
[0034] 1.a. Assign initial values for the random variables. Please note that in this system and method sample problem input, the names, values, and functions match with those in Saha. Take into consideration the number of observations i.e., all farms are 15 and the number of years are four, so it gives back 60 observations, 15 times four (Step 10 ). To assign the started values pick the ones already published in Table 5 in Saha (Step 12 ). See FIG. 1 .
[0035] 1.b. Once you completed the above step, proceed to generate the input variables. Be careful not to hit negative values. Remember than in economics negative prices and quantities do not have meaning.
[0036] To generate the synthetic data reported in Table 3, see FIG. 2 , it was used the random number generator with a uniform distribution (Step 22 ), taking into account the mean and standard deviation in Saha (Step 20 ). Although, it seems that the correct way to proceed is by using a random Weibull distribution. This characteristic seems to come from the fact that given the mean and standard deviation from the raw data, a symmetrical distribution around the mean reaches negative numbers. Therefore, the standard deviations have to be adjusted accordingly. That is to say, instead of allowing the data dispersion to be within two standard deviation range away from the mean and reach negative values, take different factors among one and two standard deviations. In consequence, it is generated the independent variables using a random number generator (Step 24 ).
[0037] 2. Error term generation. Follow Saha to generate the Weibull error term, with b scale parameter and c shape. Take initial values those coming from Table 4 of the paper, and call it (ε_). The graph of this distribution is presented in FIG. 3 .
[0038] In FIG. 3 , you can see that the Weibull distribution for the error term only takes positive values and it is skewed to the left. This made economics sense as described above.
[0039] The standard errors were calculated with based on the Marquardt-Lavenberg gradient expansion algorithm (Step 42 ), where the diagonal terms of the curvature matrix are increased by a factor that is optimized in each search step for optimum values (see Bevington and D. K. Robinson (1992), also see Patel, J. K., C. H. Kapadia, and D. B. Owen (1976)). The asymptotic variance-covariance matrix of the parameter estimates for maximum likelihood is the matrix computed as the inverse of the Fisher's information matrix (Step 40 ), which is obtained after running max. likelihood regression. The corresponding system and method are reported in FIG. 4 .
[0040] The tables in Saha are referred by their numbers, herein reproduced along with the report of the synthetic variables and estimates values. The standard errors for the maximization of the log-likelihood Weibull are reported in Table 4, in here reproduced along with the corresponding simulation estimates b and c. Besides, the estimated mean and standard deviation of Weibull e (error) are reported. The sample standard for epsilon es (error from the sample) was simulated, along with its mean and standard deviation. See FIG. 5 .
[0041] The variance of the estimated epsilon (e_) is 1.1322 and for (es) is 0.3284 (i.e. every time you hit the run button it changes, because a new random number is generated). However, the variance coming from these trials keeps a close resemblance to the one herein mention. Also, the variable Q 1 is generated with the corresponding formula taken from Saha, see FIG. 6 .
[0042] In what follows, it is presented the summary statistics reported in Table 3, along with those generated from this simulation, see FIG. 7 .
[0043] 3. According to Saha, the complexity of the estimation of equation (14) can be substantially reduced if prior parameters b and c estimates of the Weibull p.d.f in equation (15) are used in the estimation of equation (14).
[0044] 3.1. Estimate b and c for equation (15) and call them bh and ch i.e., bh=1.2976 and ch=3.7357, see the above estimation description in the first part for a refresher on how these parameters are estimated.
[0045] For the parameter starting values, according with Saha, they can be provided through prior estimation using a Just-Pope method with some modifications to address the fact that ε, the stochastic yield variable has a Weibull distribution. Saha mentions that the starting values for the production function parameters proceed in two stages.
[0046] Thus, implement the first stage following Saha estimation method description as: “In the first stage, the production function is estimated through nonlinear least squares on (16) . . .”. Having this purpose in mind, use the Levenberg-Marquardt algorithm for non-linear least squares (see Seber, G. A. F., and C. J. Wild (2003)) (Step 80 ). This algorithm does not compute robust fits. For robust fits, you need to use an algorithm (see DuMouchel, W. H., and F. L. O'Brien (1989)) that iteratively refits a weighted nonlinear regression, where the weights at each iteration are based on each observation's residual from the previous iteration. For the estimation of the nonrandom part, equation (16) through non-linear least squares gives, take starting values from the published ones (Step 82 ), see FIG. 8 . Not traces of endogeneity are detected. The corresponding system and method are reported in FIG. 8 (Prajnesgu (2008), retrieved from http://ageconsearch.umn.edu/bitstream/47684/2/16-Prajneshu.pdf):
[0047] Thus, the corresponding output for the above defined variables is reported in FIG. 9 .
[0048] where the h stands for hat; se stands for standard error. These results are also reported in their corresponding tables.
[0049] 3.2 The second stage corresponds with the estimation of the random part of equation (16), see FIG. 10 . A specific structure in the random part is to be imposed, in the same manner mention by Saha (Step 100 ). The corresponding parameters for this stage are the conditional mean of G or log of the square error term: (According with Just, R, and J. David (2011, p. 10) E(ε)=0, the expected value of the error is zero or the expected mean value for the error term is zero. Although, for this case this assumption is not quite correct).
[0050] So, the output values corresponding with the variables of interest from the above system and method embodiment of FIG. 10 are reported in FIG. 11 .
[0051] 4. According to Saha after estimating M=[m 1 h m 2 h], the starting values for EP utility parameters alpha and beta can be found through a suitable grid search.
[0052] In the above respect, the grid search would be faster if you optimize and found the maximum value, see FIG. 12 . Thus, since the parameters and independent random variables needed for computing wealth are already estimated (called W), proceed through the optimization path (Step 120 ). Performing this evaluation on a complete grid, as required by the max function, will be much less efficient since it samples a small subset of grid discrete points. Optimization algorithms could be used for continuous grid search.
[0053] Note that the profit function does not include the output price, because Saha has normalized with respect to it. Thus it becomes the unit. Also, with this procedure the joint estimation is integrated in W computation. Moreover, this computation integrates the Cobb Douglas and exponential forms previously obtained through equation (16) in its two stages. To be more explicit about computing W, use the independent random variables generated and the parameters already determined in previous optimizations (Step 122 ), plus the published alpha value as an initial starting value.
[0054] Therefore, the above simulated output parameters of interest are presented in FIG. 13 .
[0055] The partial production elasticities at the sample mean are reported in Table 5, see FIG. 14 .
[0056] 5. In here Saha Empirical Model section finishes. Is in this section where it is described the estimation procedure, which corresponds to this manual with the estimation part. In addition, there is a system and method to simulate all the parameters reported in Table 5 for the method corresponding to joint estimation. Remember that there is not needed for computing r 1 (capital input prices) and r 2 (material input price), since they are given as independent variables since the beginning (their mean and standard deviation are reported in Table 3). In other words, there is no need to solve equation (14) to obtain the input prices.
[0057] Thus, the (2n+5)×1 φ vector is computed with all the above mentioned system and method. The interpretation on the number of parameter in the φ vector is (2 for alpha and beta, n for 15 farms); 5 (for A, a 1 , a 2 , m 1 and m 2 ), which are reported already as output from the non-linear least squares implementation. In this way all the estimations needed in equation (14) are already simulated, thanks to the implemented models embodiments presented in this invention.
[0058] Moreover, in the identity expressed in equation (6) on Saha, which could be worded as follows: optimal input levels are identical to maximize expected utility. In other words, this invention works in the left hand side of identity (6) in order to find the optimal input levels. Therefore, the simulated procedure implemented for obtaining the vector φ is by finding the optimal input levels. This procedure is endorsed by Saha equation (6) identity. Therefore, by taking the optimization procedure that is used and the identity in (6) altogether, it is also maximizing the expected utility.
[0059] In this final part the sensitivity estimates are simulated and compared with those reported in Saha. To implement this analysis, follow Saha: “Comparison of the three sets of estimation results underscores the sensitivity of estimates to alternative assumptions” p. 182.
[0060] Later on, the authors mention that efficiency gain can be assessed by comparing standard errors of the three sets of estimations reported in Table 5. Also, comparisons are considered for m coefficients and SSE.
[0061] 5.1 In order to carry over this task, it is required to proceed in a similar way as explained in Part 2 to estimate the third method of Table 5: Only CDE, see FIG. 15 . Thus, construct the risk scenario only CDE, change ×1; ×2 and the error distribution parameter b (Step 150 ). Take starting values from the published ones and repeat the process of FIGS. 8 and 10 (Step 152 ).
[0062] So, after changing ×1, ×2; error distribution parameter: b. The corresponding estimates are reported in FIG. 16 .
[0063] 5.2. For the second method estimation in Table (5), see FIG. 17 . Thus construct the risk scenario under CARA, change alpha; beta and the error distribution parameter b (Step 170 ).
[0064] Take the starting values from the published ones and rename them A=AA; risk aversion parameters: alpha, beta; risk distribution parameters: m 1 =n 1 , m 2 =n 2 ; and error distribution parameter: b. and repeat the process of FIG. 8 and FIG. 10 (Step 172 ). The corresponding estimates are reported in FIG. 18 .
[0065] In Table 5 the published and simulation estimates are provided, see FIG. 19 .
[0066] As it can be seen the convergence between A; a 1 and a 2 for the simulation model and the authors publish estimates is achieved. Nonetheless, the standard errors for the simulation are very small with respect to the ones reported. A similar pattern is emulated for the methods Under CARA and Only CDE. When looking only at the standard errors for the corresponding simulation, they present the same pattern as the reported ones. Please note that the smallest simulation standard errors belong to Joint estimation, follow by Under CARA and Only CDE. These characteristics in Saha words are expressed as follows: “. . . a prominent feature of these results is that the standard errors of estimates under the joint estimation procedure are consistently and considerable lower than those under alternative settings. This suggests that there is indeed a substantial efficiency gain in joint estimation, corroborating similar findings by Love and Buccola.”
[0067] For m 1 and m 2 coefficients convergence are also achieved. The standard errors for the simulation are small when compared to those from the reported estimation. Input 2 materials, is risk reducing, in joint estimation and Under CARA. For the column. Only CDE convergence is not achieved between reported and simulated estimates, however, they keep the same positive sign with respect to its publish analog. Overall, regarding m 1 and m 2 simulation behavior it is concluded as Saha does: “. . . when jointly estimated, coefficient m 2 is negative and significant, suggesting that ×2 is a risk reducing input: the same parameter is positive and significant when non-jointly estimated. This suggests that estimation from the utility functions—as is prevalent in a considerable body of applied research—may lead to serious errors in inference.”
[0068] Regarding the SSE, taking into account its different qualifications, are smaller for the joint estimation, than for Under CARA and Only CDE. Therefore, globally, this statistic indicates that the best model is the joint estimation (although SSE for Only CDE cannot be compared with the rest of columns or methods. This happens because this method considers different variables).
[0069] The partial production elasticities, keep similar values across methods. The partial production elasticity for materials takes values in the interval [0.52 0.70]. This behavior is consistent with empirical observation, according with Saha. In other words: “. . . it should be recalled that the materials category include a large array of inputs such as fertilizer, seed, machinery operating inputs, and miscellaneous purchased inputs.” This mention material input diversity could explain, interalia, why they find ×2 as risk reducing.
[0070] 5.3 Next, system and method for computing Table 6 and Table 6 are presented. In FIG. 20 , Step 200 it is constructed the risk sensitivities for the mean wealth; absolute risk aversion and relative risk aversion by using linear least squares regression. For Step 202 take the starting values from the published ones or construct their numeric values by running linear least squares for each corresponding optimization i.e., mean wealth. In FIG. 21 the corresponding output is reported as the Arrow-Pratt Risk Aversion Measures.
[0071] The first row of Table 6 belongs to the a parameter, which is already reported in Table 5 for all farmers. Convergence between the model and the reported estimates are achieved for all farmers and large farmers, with the exception of small farms. An analog case is presented in the estimation of the mean wealth, where all and large farmers achieved convergence, while small farmers do not. The absolute risk aversion estimates maintain consistency regarding a positive sign. The coefficient convergence is achieved with the second decimal.
[0072] The reported behavior for small and large farmers with respect to A( W ) and R( W ) are mimicked by the simulation. Also, in the preceding paragraph was explained why small farmers have a somehow different trend. For instance, the bigger dispersion between simulation and reported estimates is found for small farms. Perhaps, this is due to its relative smaller size in the overall sample and thus to its implicitly diminishing representativeness in the whole sample. Thus, it could be concluded as the authors do: “Arrow-Pratt estimates for both groups are consistent with DARA and IRRA. The small farmers do show a higher level of A( W ) and a lower level of R( W ) than do the larger farmers.”
[0073] The simulation of the null hypothesis of risk neutrality has achieved convergence in all three cases. Then, they also present a similar pattern as the published null hypothesis values. Therefore, it could be used the author's explanation for this case: “. . . the hypothesis of risk neutrality is clearly rejected in favor of risk averse preference structure. Further EP utility parameter estimates provide evidence of decreasing absolute risk aversion (DARA) because {circumflex over (α)}<1, and increasing relative risk aversion (IRRA) because {circumflex over (β)}>0.” This last quote is taken from the conclusions presented by Saha: “The empirical findings clearly rejected the null hypothesis of risk neutrality in favor of risk aversion among Kansas farmers. We also found evidence of decreasing absolute and increasing relative risk aversion.”
[0074] It is used Saha's conclusion and explanations to present a panoramic view about what the reported simulation estimates imply, in terms of methodology and risk assessment, thanks to their close resemblance with the published paper's results.
[0075] In general, the implemented models and their simulated parameters have achieved convergence with the results reported in the selected paper Saha et al. (1994). All the data use in this simulation is synthetic and the inventor does create all the econometric models.
[0076] End of the Manual. | This is an invention implying a system and method to construct synthetic data of said financial variables i.e., prices and quantities and to construct sophisticated econometric models that achieve convergence with related estimations already published. These system and method is abled to run under different risk scenarios and input settings; they also allow lower costs by simulating time frequencies, variables and factors of economic activity, through the use of random number machines and Monte Carlo simulations. This invention furnishes risk sensitivities based on sophisticated econometric models and mathematical not lineal models and a set of behavioral and statistic assumptions by using the synthetic data herein constructed. Great results in providing criteria for risk management and decision making with 99% of statistical significance. Modifications of this invention can generate a multiplicity of applications by those skilled in the art. Thus, the input problem treated should be taken as illustrative and not restrictive. | 6 |
CROSS REFERENCE
[0001] The present invention is a continuation of co-pending U.S. patent application Ser. No. 09/005/932, filed on Jan. 12, 1998 entitled “Method and Apparatus for Image Capture, Compression and Transmission of a Visual Image over Telephonic or Radio Transmission System,” and is assigned to the Assignee of the co-pending application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is generally related to image capture and transmission systems and is specifically directed to an image capture, compression and transmission system specifically designed for field applications with wired, wireless and/or synchronous serial devices.
[0004] 2. Discussion of the Prior Art
[0005] Industry has developed and continues to develop and enhance techniques for scanning, compressing, transmitting, receiving, decompressing and printing documents. This technology, encompassing the full body of facsimile transmission and reception, is currently in widespread use. The current standards, CCITT Group III and Group IV, define methods to scan and transmit high quality, bi-level images with a high degree of success and has become commercially acceptable throughout the world. However, gray scale documents and images are not easily transmitted because the scanners and algorithms are not tailored to the function. Three dimensional objects will not fit into the flat document scanners and cannot be transmitted.
[0006] Examples of systems that have addressed some of these issues are shown in U.S. Pat. No. 5,193,012 which shows a video to facsimile signal converter, and U.S. Pat. No. 3,251,937 which discloses a system for transmitting still television pictures over a telephone line.
[0007] Vie photography, and its extension, radio photography, have long been used by the news media. The most common form involves an input device that converts photographs into encoded signals for communication over telecommunications facilities or radio. At the receiving end, reproducing equipment reconverts the encoded image signals by exposing photographic film or other sensitized paper. The term facsimile is often use with these products.
[0008] Still video equipment has recently become available from vendors such as Canon and Sony, and is again primarily used by the television and print media, although applications are expanding rapidly in such areas as insurance investigations and real estate transactions. A still video camera that captures a full color still video image can be reproduced using a special video printer that converts the still video image data into hard copy form. For applications requiring communication of the still video image, transmit/receive units are available wherein the image begins and ends as a video image.
[0009] The PhotoPhone from Image Data Corporation is an example of a specialty product that combines a video camera, display and storage facility in a terminal package. One terminal can send a real time or stored still video image to another for display or storage, or printing on special video printers. Again, the signal begins and ends as a video image.
[0010] Another example of a specialty product is peripheral equipment available for personal computers that enables the input/output, storage and processing of still video images in digitized formats. For instance, the Canon PV-540 is a floppy disk drive that uses conventional still video disks, digitizing and a still video image using a conventional format, and communicates with the computer through a standard communications I/O port.
[0011] U.S. Pat. No. 5,193,012 discloses a still-video to facsimile conversion system for converting the still-video image frame into a half-tone facsimile reproduction without having to store an entire intermediated gray scale image frame by repeatedly transmitting the still-video image frame from a still-video source to an input circuit with a virtual facsimile page synchronization module . This system permits image to facsimile conversion by utilizing a half tone conversion technique.
[0012] While the various prior art systems and techniques provide limited solutions to the problem of transmitting visual images via a facsimile transmission system, all fall short of providing a reliable method and apparatus for readily capturing, storing, transmitting and printing visual images in a practical manner.
[0013] An example of a system that addresses many of these problems is shown and described in the copending application of David A. Monroe and John _. Frassanito, filed on ______, 1997, and entitled: APPARATUS FOR CAPTURING, CONVERTING AND TRANSMITTING A VISUAL IMAGE SIGNAL VIA A DIGITAL TRANSMISSION SYSTEM. The system described therein provides the apparatus for capturing, compressing, converting, transmitting and receiving a facsimile using digital transmission techniques and protocols.
SUMMARY OF THE INVENTION
[0014] The subject invention is an image capture, compression and transmission system that is specifically designed to permit reliable visual image transmission over land lines or cellular communications using commercially available data transmission techniques. The preferred embodiment captures the high-resolution (640×480) full color images from any NTSC source like video cameras, monochrome image intensifiers, monochrome night visions devices (such as FLIRs) and the like. Depending on application, medium and low resolution may also be selected based on user selection. The system can be operated locally or remotely through the host interface software. In the remote mode, the image can be captured, stored and/or transmitted by remote “dial up” using land line telephone or cellular systems, or other communications systsems such as radio or the like. In the preferred embodiment, the system firmware may be loaded and accessed for troubleshooting via remote access as well.
[0015] The system of the present invention is specifically designed to operate over the public switched land line telephonic systems (POTS) and cellular services. The invention is designed with a hardware port for digital radio operation, as well.
[0016] Operating in correlation with a PC running WIN '95 or NT4.0 or the equivalent, the system of the present invention provides a complete imagery communication system for commercial communications networks, providing a versatile remote imagery terminal for radio, cellular or land line based telephone systems. The preferred embodiment of the invention is fully compatible with and integrates with a standard AMP cellular phone such as by way of example, a Motorola flip phone, and supports NTSC monochrome composite and S-video sources including video cameras, camcorders, VCRs, still image cameras, image intensifiers and FLIR-night vision devices. In the preferred embodiment, all of the circuitry for the system is on a card or slice which is inserted between the battery pack and the body of a standard Motorola cellular phone. Full isolation of the system circuitry is provided, permitting power preservation for cellular telephone use when data transmission is not activated.
[0017] The present invention, permits a still frame visual image to be captured at a remote location and either stored locally or sent immediately, over land line or wireless communication systems, to a remote location such as, by way of example, a computer system wherein the image could be merged directly into newsprint. The image may also be printed as a hard copy using any Windows based printer or Group-III facsimile machine, anywhere in the world. Where desired, the images may be stored in memory for later recall, and may be archived on a portable medium such as a memory card or the like. In addition to multiple resolution capability, the system may be used with multiple compression algorithms such as JPEG, wavelet and other compression schemes.
[0018] In the preferred embodiment of the invention, the controller is programmed to permit smart addressing of the video RAM, allowing for row or column access to the image data, decimation and non-linear, sequential pixel access.
[0019] The system of the subject invention is particularly useful for applications where immediate transmission of visual images are desirable and sophisticated equipment is not always available for receiving the information. The system also provides a unique and reliable means for transmitting visual data from remote locations, such as, by way of example, construction sites, law enforcement and emergency vehicles and the like.
[0020] It is, therefore, an object and feature of the invention to provide an apparatus for capturing, converting and transmitting a visual image over land line or wireless telephone systems, such as cellular, or private wireless radio systems.
[0021] It is another object and feature of the invention to provide an apparatus for compressing the visual image data in order to minimize the capacity requirements of the data capture and storage system and to minimize the transmission time over the transmission media.
[0022] It is an additional object and feature of the invention to provide an apparatus for capturing converting and transmitting images over other wireless transmission systems such as radio and satellite.
[0023] Other objects and features will be readily apparent from the drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a perspective view of a typical hand held cellular telephone with the image transmission system of the subject invention integrated therein.
[0025] [0025]FIG. 2 is a side view of the transmission system, showing the side not visible in FIG. 1.
[0026] [0026]FIG. 3 is an exploded view of the assembly for the preferred embodiment of the subject invention.
[0027] [0027]FIG. 4 is a block diagram of the circuitry of the preferred embodiment of the subject invention.
[0028] [0028]FIG. 5 is a schematic diagram of an exemplary-embodiment of the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] The image capture and transmission system of the subject invention is suited for capturing a single frame analog image signal and transmitting the captured signal via either a cellular or land line telephone system. The preferred embodiment is shown and described and is particularly well suited for use in combination with a standard Motorola flip phone. The camera is not part of the system and the image captured by the camera is introduced into the system via standard cable, as will be described.
[0030] Turning now to FIG. 1, a: hand held cellular telephone 10 is shown with the image transmission system 12 mounted integrally therein. A standard Motorola FlipPhone® is shown. However, it will be readily understood by those who are skilled in the arts that the invention can be readily adapted to other telephone configurations. The cellular telephone includes a flip cover 14 , and LED panel 15 , a keypad 16 and an antenna 18 , as is standard. The battery pack 20 is normally secured directly to the phone body 11 . In the preferred embodiment of the invention, the transmission system 12 is inserted between the battery pack 20 and the body 11 , as shown. The battery pack 20 provides the power for both the telephone and die transmission system. The standard connectors between the battery pack and the phone body are utilized to couple the transmission system 12 to the standard battery pack and the phone. The cable 22 and connector 24 are used to connect the system 12 and phone 10 . The connector 24 is connected to the phone via the standard phone hands free (or data) port 25 . The various control buttons, status readouts and ports for operating the transmission system 12 with the telephone 10 are located on the opposite side panels 26 (FIG. 1) and 28 (FIG. 2) of the transmission system housing.
[0031] An exploded view of the assembly of the image facsimile transmission system 12 of the present invention is shown in FIG. 3. The housing 30 is an open topped box of standard construction, typically an unitary member of high impact plastic or similar material. The housing may be custom molded in the well known manner. Seated in the housing 30 is the processor board 32 , containing the processor 34 and other circuitry, as more fully shown in block diagram form in FIG. 4. The modem board 36 is placed over the processor board 32 . The housing cover 38 fits over the entire assembly and sits on the top edges of the sidewalls of the box 30 to close the unit. The processor board 32 is seated directly on pads 40 provided in the box and held in place by standoff screws 42 . The modem board 36 is seated directly on the stand off posts 42 and the cover 38 is placed over the modem board 36 . The assembly is then secured in assembled relationship by screws 44 . A window 46 provides an opening in alignment with the power connectors on the telephone 10 , permitting the power interface 46 mounted on board 36 to communicate directly with the cellular telephone 10 . Also mounted on the modem board 36 is a RJ-11 switch 50 for switching between POTS and cellular or radio and an insulated mini-phono jack 52 for video input and remote trigger signals.
[0032] The landline hook-up can be used whether or not the system is installed on the cellular telephone 10 . A latch 54 is installed in the latch recess 55 provided in the box 30 , and is spring loaded in the latched position by spring 56 . The latch 55 permits the entire assembly to be secured to the flip phone 10 in the same manner as the battery pack 20 would be secured in a non-modified phone configuration. The battery pack 20 is mounted on the outside of the bottom 58 of the box 30 , with the power connections being interfaced to the phone 10 via the interface window 60 in the box 30 , and interface circuitry 62 in the processor board 32 and 48 in the modem board 36 . The displays and control button switches are mounted in openings provided in the side walls of the box 30 , as better seen in FIGS. 1 and 2.
[0033] As shown in FIGS. 1 and 2, a series of LED readout lamps 64 a - d are provided on side 26 , 28 of the box 30 . The control switches or buttons 66 a - h are also located on the two sides of 26 , 28 of the box 30 . In the preferred embodiment, the lamp 64 a indicates a busy processor signal, the lamp 64 b indicates when the system is in a sending mode. Button 66 d controls selection of the send mode. The lamps 64 c indicate image storage capacity level. The button switches 66 e and 66 f controls the abort mode and erase mode, respectively. The control buttons 66 a - c are on the opposite side panel 26 of the box 30 and include video input format switch 66 a, resolution select button 66 b an ON/OFF button switch 66 c. High medium and low resolution indicator lamps 64 e are also on this side panel. Switch 66 h is the data capture switch.
[0034] The circuitry housed on the processor board 32 and the modem board 36 is shown in FIG. 4. The circuitry is partitioned into distinct functional areas, as follows: DC/DC convertor power supply 70 ; push button control switches 66 ; lamps 64 ; the video decoder circuit 72 ; video buffer 74 ; frame and video buffer controller 76 ; image and program store 78 ; data Ram and program store 80 ; digital signal processor 82 ; RS-232 level synchronous and asynchronous ports 84 ; modem 86 ; RJ-11 presence switch (see FIG. 3); and the I/O decoder 88 .
[0035] The system is a battery operated frame grabber, video compressor, image transmission device adapted for accepting NTSC, composite or S-video as an input. In the preferred embodiment, it has a Harvard architecture DSP engine for compression and transmission. Transmission is accomplished via several methods, the asynchronous RS-232 port, the synchronous RS-232 port a cellular phone compatible modem or a land line modem interface. The modem 86 is implemented on the daughter board 36 (FIG. 3). The daughter board interface (not shown) allows other optional functions to be designed in place of the modem in the well-known manner.
[0036] The system memory is separated into two access areas: the program and data memory 80 , each of which is 64K words; and the memory 78 accessed by a decode of the DSP address bus and the I/O instructions. A separate I/O address is implemented to allow contiguous memory blocks of greater than 64K words as is required for the large number of words in a frame of video. A programmable logic device (PLD) 76 provides the registers, extended I/O address and additional “glue logic” required.
[0037] The power supply 70 is adapted to receive between 5.5 Vdc and 8.2 Vdc which can be accepted as input to the DC/DC converter for providing output voltage of 5.0 VDC. The video format selection is controlled by a combination of a single three conductor video input jack, and a slide switch 66 a (FIG. 1) to indicate either S-video/monochrome or composite. The video inputjack is a mini-phono jack 52 , which will have the sleeve connected to ground. The tip contact is Y (luma) and the ring contact is C (chrominance) if the input is S-video. For composite or monochrome video inputs, the tip contact is the video. The Remote Capture Interface is a mini-phone jack 50 , which provides both capture functions and busy LED feedback. The slide switch 66 a provides a status bit to be read by the software. This bit is assigned to a bit position 10 in the general status register. For example, in the composite position the switch 66 a is open and this is read as logic one in the register.
[0038] The video decoder 72 may be adapted to accept both S-video or composite PAL, NTSC OR SECAM signals. The video is input through the mini-phono jack 52 and is detected and available to the processor 82 via the video status bits in the system status register. In the preferred embodiment the decoder 72 is a Brooktree Bt829 which automatically detects PAL/SECAM and NTSC video standards. The format detected is available in the register set. The device features an extensive set of registers accessible via its I 2 C interface. These registers may be used to program the decoder to any of a variety of formats, as more fully described in the Bt829/Bt827 VideoStream II Decoders Manual, September, 1996, incorporated by reference herein. The decoder may be programmed to produce either 640×480 YcrCb images from an NTSC source or 768×576 YcrCb images from a PAL source. The decoder is powered on by a command from the processor 82 prior to capture of a frame and off by a command from the processor 82 upon completion of the capture of a frame. The decoder is isolated from the rest of the system by zero load buffers and isolation switches to allow power control. In the preferred embodiment, the decoder takes approximately 0.5 seconds to lock onto a valid video source. The decoder may be programmed 10 milliseconds after the decoder on command is initiated.
[0039] The video decoder 72 is controlled by an I 2 C Bus interface, which is implemented in the PLD 76 and accessed by software using bit positions 0 and 1 , for SDA and SCL, respectively, in the I 2 C control register. A third bit, bit 2 , is available for changing between master and slave mode. The default position is slave. This is further described in the Brooktree BT829/BT827 data sheet, incorporated by reference herein.
[0040] The video buffer 74 is a 16 bits wide by 512K deep buffer. The buffer holds one complete frame of NTSC square pixel imagery. The video buffer is written to by the video controller 76 which conditions the control signals provided by the video decoder 72 . The buffer 74 is read by the processor 82 via the controller 76 which also conditions the control signals provided by the processor during an I/O operation. The video buffer is mapped into the processor I/O space. An extended I/O address is generated in a PLD. When the most significant bit extended i/o address 31 (MSB ElOAD31) of the I/O address bus is 0, the video buffer is selected.
[0041] The frame detector, extended address and video controller circuitry 76 identifies the start of a frame and initiates the capture of that frame. Image capture is initiated under software control by writing a logic 1 to bit position 6 (SNAP) of the power management and command register. The controller will issue a HOLD to the processor 82 , and upon receipt of the acknowledge (HOLDA), takes control of the processor data bus. The controller waits for the odd field to start and then saves two consecutive fields in contiguous memory. As part of the capture sequence, this circuitry resets the extended address bus to all zeroes as the location of the first pixel data, auto increments the address and generates the write strobe for the video buffer 74 in response to the control inputs from the decoder 72 . Upon completion of the frame, HOLD is released. The software is responsible for clearing the SNAP bit after released and before commanding another capture.
[0042] The controller 76 also provides the control signals and extended I/O address bus for reading the image in response to I/O operations by the processor 82 . The extended I/O address bus operation is programmable by the processor. Three registers control operation of this bus. The first two set the base address used as the starting address. Since the address bus is 20 bits wide, two I/O locations are used to write the base address from the processor's 16 bit data bus. The third register is the offset register. The offset is added to the base address after each read or write to generate the next address to be accessed. This permits convenient traversing either across a line of pixels or down a column of pixels. During boot by the processor 82 the extended address bus will initialize to 0000H and the increment by one after each read strobe of the processor. This requires that the module to be loaded be located at the bottom of the image/program store 78 . Since the processor 82 uses only the least significant byte when booting, this section of code requires two memory locations for each word of executable code. Each word of the program must be divided into two bytes and loaded upper byte lower byte in that order into successive memory locations. Location 0000H must have the upper byte of the destination in program memory, and location 0001H must have the lower byte of the destination. The next two locations 0002H and 0003H must contain the upper byte and lower byte of the length in bytes to be loaded. This is more fully covered in the Boot Loader section of the TMS320C2xx User's Guide, incorporated by reference herein. Wait states for all memory accessed via the extended address bus will be controlled by the extended address bus controller.
[0043] The image and program storage 80 is a 16 bit×1 M flash file memory, providing lifetime up to 1 million erase cycles per block. Addresses are generated by the controller PLD 76 and the DSP 82 . The image and program storage is mapped into I/O space except at processor boot. At power up, the designated boot block will be mapped into program space and the boot program loaded from the program storage FLASH RAM ( 78 ) into the program RAM 80 . Upon completion of the boot operation, the program storage will revert to I/O space. The image and program store is selected in extended I/O memory space by setting the MSB EIOAD31, of the extended address to 1. Two wait states will be required for access to this memory. The number of wait states is controlled by the extended address bus controller. In the preferred embodiment, an Intel 28F016SV flash memory is used. Programming is controlled by the register set on the flash chip and the busy signal it provides. The busy signal RY/BY is inverted and connected to INT3 of the processor 82 . This flash part features a 128 word buffer to allow writing of a page of data at a time. Complete details of this device are further described in the Intel data sheet, July, 1995 and the Specification Update, July, 1996, incorporated by reference herein.
[0044] The data and program run RAM 80 are each 64K words. The software will be responsible for controlling the software wait state register in the processor 82 for data and program ram access.
[0045] The data signal processor (DSP) 82 of the preferred embodiment is a Texas Instruments TMS320LC203 and has an advanced Harvard architecture, software programmable wait states, a synchronous serial port, and an asynchronous serial port. On board RAM, 544 words, is accessible as either data or program ram. A 20 MHz oscillator will be used which results in single cycle instructions taking 50 ns. The processor monitors the control switches 66 , interprets the commands and performs the tasks commanded, which include: (1) powering up and down; (2) loading the boot code; (3) initiating video capture; (4) video compression; (5) image transmission over the modem a) to wireless telephone; b) to landline; (6) image transmission over the RS-232 port; (7) reprogramming the flash memory; and (8) COMSEC interface over the RS-232 port. More complete details of the processor 82 are included in the Texas Instruments Data Sheet and Users Guide, incorporated by reference herein.
[0046] The on board cellular phone compatible modem 86 is set to interface to the cellular phone 10 through the cellular line interface drivers and receivers. The drivers and receivers provide any required level translation and connect to the cellular phone connector. An isolation circuit 87 is utilized before the cellular phone interface. This is accomplished by using an FET pack that is switched active and non-active by the RJ11 selection circuit: (1) Async with DTR data terminal ready; and or (2) Sync radio interface cable ID/DTR; or (3) Branch telephonic DAA, (a) RJ-11 switch or (b) cellular.
[0047] The modem provides a host interrupt to the processor 82 , assigned to INTP of the processor A. DAA (Direct Access Arrangement) circuit is provided for connection to the POTS telephone line. The isolation circuit is adapted to power down the entire data capture and transmission module whenever a data input signal is not present, preserving battery power. The system powers up only when the user engages the capture sequence by depressing the capture switch and begins transmission. In the preferred embodiment, the power up sequence takes 0.5 second.
[0048] [0048]FIG. 5 is an exemplary schematic of one embodiment of the invention, incorporating the features shown and described in FIG. 4. The pin and wire numbers are shown in the drawing. Viewing part A of the drawing from left to right, module 101 provides cellular phone power “on” “off”. The microcontroller unit 103 is the modem controller. Module 104 is a crystal circuit for the modem 105 . Amplifier 106 is a speaker amplifier. Part B shows the modem RAM 107 and the modem program storage memory 108 . Part C is the cell phone interface section of the circuit. The amplifier 109 is the D.C. reference buffer. Amplifier 110 is the modem RX signal amplifier and signal conditioner. Amplifier 111 is the POTS landline RX amplifier and signal conditioner. Switches 112 are the cell phone isolation switches. The blocked area 113 provide cell phone EMI filters. Part D is the POTS direct access arrangement, with signal level clamping circuitry 114 , with an isolation transformer at 115 . AC isolation is provided by the capacitor network 116 comprising capacitors C 26 and C 27 . The blocked area 117 is the POTS line loading current control. The diode bridge 118 provides a polarity bridge. Switch 48 at 119 provides “off hook” or open line switch and a ring detection circuit. A surge protector is provided at 121 , and an EMI filter networks provided at 122 . Part E is the power management circuitry. Circuit 123 is the battery voltage sensor. The power switch is provided at 125 , with the power-up process status driver at 125 , the processor power on switch at 126 and the main power switching circuit at controller 129 . Switch 130 is the video decoder power.
[0049] Part F is the Processor 131 , with the oscillator at 132 . Part G shows the program and data RAM 133 and connectors 134 . Part H shows the video buffer RAM 135 and 136 . The program and image storage flash RAM is shown at 137 . Part I includes the video oscillator 138 and video input and conditioning circuitry 139 for managing input into the video decoder 140 . The video decoder isolation switches are shown at 141 ; the video address generator PLP 1142 ; the videotiming and glue logic PLP 143 ; the PLD bootstrap logic 144 and the serial PROM (1×256K) boot program module 145 for PLD 144 .
[0050] Part K includes the remote trigger jack 146 , the radio keying FET (PTT) 147 ; the radio digital mode keying transistor or digital data mode control (DDMC) 148 and the serial I/O drivers and receivers 149 . The data port is designated as 150 . Part L is the LED array 151 ; the composite/s-video switch 1152 and the push button array 153 .
[0051] The preferred embodiment captures the high-resolution (640×480) full color images from any NTSC source like video cameras, monochrome image intensifiers, monochrome night visions devices (such as FLIRs) and the like. Depending on application, medium and low resolution may also be selected based on user selection. The system can be operated locally or remotely through the host interface software. In the remote mode, the image can be captured, stored and/or transmitted by remote “dial up” using land line telephone or cellular systems, or other communications systsems such as radio or the like. In the preferred embodiment, the system firmware may be loaded and accessed for troubleshooting via remote access as well.
[0052] The system of the present invention is specifically designed to operate over the public switched land line telephonic systems (POTS) and cellular services. The invention is designed with a hardware port for digital radio operation, as well.
[0053] The preferred embodiment of the invention is fully compatible with and integrates with a standard AMP cellular phone such as by way of example, a Motorola flip phone, and supports NTSC monochrome composite and S-video sources including video cameras, camcorders, VCRs, still image cameras, image intensifiers and FLIR-night vision devices. In the preferred embodiment, all of the circuitry for the system is on a card or slice which is inserted between the battery pack and the body of a standard Motorola cellular phone. Full isolation of the system circuitry is provided, permitting power preservation for cellular telephone use when data transmission is not activated.
[0054] The present invention, permits a still frame visual image to be captured at a remote location and either stored locally or sent immediately, over land line or wireless communication systems, to a remote location such as, by way of example, a computer system wherein the image could be merged directly into newsprint. The image may also be printed as a hard copy using any Windows based printer or Group-III facsimile machine, anywhere in the world. Where desired, the images may be stored in memory for later recall, and may be archived on a portable medium such as a memory card or the like. In addition to multiple resolution capability, the system may be used with multiple compression algorithms such as JPEG, wavelet and other compression schemes.
[0055] In the preferred embodiment of the invention, the controller is programmed to permit smart addressing of the video RAM, allowing for row or column access to the image data, decimation and non-linear, sequential pixel access.
[0056] Other configurations are contemplated and are within the teachings of the invention. While specific embodiments have been shown and described herein, it will be understood that the invention includes all modifications and enhancements within the scope and spirit of the claims. | An image capture, conversion, compression, storage and transmission system provides a data signal representing the image in a format and protocol capable of being transmitted over any of a plurality of readily available transmission systems and received by readily available, standard equipment receiving stations. The system is adapted to be installed in a standard cellular phone configuration, providing a portable, hand held, wireless transmission system for transmitting video image signals to a remote receiving station. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of German patent application 10146608.0,filed Sep. 21, 2001, herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an air-spinning arrangement having an opening device for opening a sliver.
BACKGROUND OF THE INVENTION
[0003] In connection with open-end spinning processes such as rotor spinning, a sliver is opened into individual fibers by means of an opening roller. For preventing fiber compressions in connection with air-spinning, or with open-end spinning methods, such as friction spinning, it is customarily desired that the fiber material can be continuously accelerated over the entire path from the feeding device of the opening roller to the yarn withdrawal device. In this way, the fibers remain stretched.
[0004] A spinning process is known from German Patent Publication DE 196 01 038 A1 in which several slivers are conducted to an opening roller. The opened fibers are removed from the opening roller by means of a perforated removal roller, to which suction is applied. The individual fibers are not to be slowed at the transfer points, but ideally are to be accelerated in order to prevent the compression of the fibers. The removal roller acts together with a friction roller. The fibers, while spinning, are withdrawn transversely in the conveying direction in the nip between the removal roller and the friction roller. A false twist is generated by the spin creation, which is turned out of the fiber structure downstream of the nip. In order that the fiber structure has stability, a pneumatic spin nozzle is arranged downstream of the nip. Fiber ends that have been released are to be wound around the fiber core in the spin nozzle. However, the release of fiber ends is made more difficult by the dissolving false twist. The yarn stability that can be achieved in this way is low.
[0005] German Patent Publication DE 196 10 960 A1 discloses a method for air-spinning, wherein slivers are also opened into individual fibers by an opening roller. Yarn formation occurs by means of a spinning device for twisting the yarn to be spun. A thin fiber fleece is to be formed from the opened individual fibers and the fibers of the thin fiber fleece are to be fed to a collecting surface extending transversely with respect to their direction of movement, from which they enter immediately thereafter into the spin device. In this case, the distance viewed over the working width, between the collecting surface and the previous fiber-conducting surface is not always constant. In connection with one embodiment, in which the collecting surface directly follows the opening roller, the fibers are hurled off the circulating combing elements and travel the distance to the collecting surface in an uncontrolled free flight. The fibers conveyed along with the combing elements can be located anywhere between the surface of the opening roller, or the base of a saw-toothed fitting, and the tip of the combing elements at a place that is mainly determined by accident. The release from the fittings of the opening roller takes place in free flight, wherein the distance traveled is a function of the initial position of the fibers in the fittings.
[0006] Free flight of the fibers to the collecting surface also takes place in the exemplary embodiment of German Patent Publication DE 19610 960 A1, in which the collecting surface does not immediately follow the opening roller, but where the fibers are transferred from the opening roller to a removal roller, and are only fed to a collection surface from the removal roller. Viewed across the working width, the distance between the fiber-conducting surface of the removal roller and the following collecting surface is not constant. Thus, paths of different lengths for the fiber transfer result. The distance over which the fibers move in free flight can be relatively long. An uncontrolled free flight of the fibers holds the danger that a compression or random orientation of the fibers can result. This hampers the yarn formation, and lack of quality of the finished yarn occurs. The application of suction to the collecting surfaces leads to an additional use of air that, in spinning frames with a multitude of spinning stations, constitutes a considerable disadvantage.
[0007] German Patent Publication DE 197 46 602 A1, which defines the species, shows a spinning process in which slivers are opened by an opening roller, the individual fibers are taken over by a removal roller, and a thin fiber fleece is formed and combined on the removal roller. A slubbing-like fiber structure is intended to be created in the process, that is passed through a nip formed with the aid of the removal roller and fed to a pneumatically operating spinning nozzle. The combination of the thin fiber fleeces is achieved by means of an appropriate embodiment of the suction insert in the removal roller. The area of the removal roller to which suction is applied tapers in the conveying direction of the fibers. The combination of the thin fiber fleeces performed in this way only has a chance of success if a path of sufficient length is available for the combining. In order to obtain the required circumferential length, the combination of the thin fiber fleece has been parceled out to two successive suction rollers. Combining the thin fiber fleece in accordance with this process contains disadvantages since individual fibers can be sucked into the perforation of the removal roller and are not released at the edges of the area to which suction is applied as is required for functioning. They then remain attached to the removal roller in the form of so-called circulating fibers and often prevent other fibers from being released in the desired manner from the removal roller. Circulating fibers can result in yarn defects which are created in that the caught fiber is only released after several fibers have collected and adhere to it. The result is a slub in the yarn. Adhering fibers can also cause fiber windings on the removal roller and because of this can considerably interfere with the functioning of the spinning device, or can even stop it. A large consumption of suction air is created by the extensive areas to which suction is applied, in particular with two removal rollers to which suction is applied, which decisively interferes with the efficiency of the spinning process.
[0008] A friction spinning method is known from Japanese Publication JP (A) 3-15 2223, in which a belt is employed as the collecting surface. No speed conditions or distance settings are provided in this publication in connection with the working together of the individual elements. No air aspiration, wherein air is sucked off through the belt, can be seen, nor is it provided. Even though no additional extensive suction air consumption is created, the disclosed arrangement has disadvantages. The fiber structure formed from the collected fibers is given a twist by the friction belt, which goes counter to the use of the device in an air-spinning process, because the twisting interferes with air-spinning, and the yarn stability which can be achieved would be kept low. The friction belt clamps the fibers arriving at the collecting line, so that the withdrawal of the fiber structure, which is subjected to twisting, is made difficult.
SUMMARY OF THE INVENTION
[0009] It is accordingly an object of the present invention to improve the known arrangements for air-spinning.
[0010] According to the present invention, this object is addressed by an air-spinning arrangement comprising: an opening device having a feed device and an opening roller for opening a sliver into individual fibers; a perforated removal roller rotatable in a direction of revolution for receiving the opened fibers at a feeding zone adjacent the opening roller and transporting the opened fibers therefrom in the direction of revolution of the removal roller; a conveying device for transporting the fibers from the removal roller to a nip at a downstream located air-spin nozzle for forming a yarn, wherein the conveying device comprises a conveyor belt arranged downstream of the feeding zone and driven in axially parallel relation with the removal roller at a sufficiently close spacing to the removal roller for picking up the fibers from the removal roller by mechanical contact and deflecting the fibers by approximately 90° for delivery to the nip.
[0011] In accordance with the present invention, the conveyor belt surprisingly neither imparts a twist to the fiber structure formed in the nip and consisting of fibers taken over from the opening roller nor does the withdrawal of the fiber structure entail any difficulties. Following the deflection by 90°, the fibers lie stretched and parallel in the strand-like fiber structure. This position of the fibers is maintained during their conveyance through the following nip to the air-spin nozzle, and makes possible very good spinning of the fiber structure by means of an air-spinning process.
[0012] No additional application of suction is required for the functioning of the conveyor belt as the collecting surface for the fibers. Therefore, corresponding additional suction air consumption is avoided, and the efficiency when using the air-spinning arrangement in accordance with the present invention is not hampered.
[0013] In connection with a conveyor belt that is arranged tangentially in relation to the removal roller, the transfer of the fibers from the removal roller to the conveyor belt is aided. An air flow coming from below is generated in the lower nip between the removal roller and the conveyor belt by means of applying suction to the perforated removal roller that aids in the release of the fibers from the removal roller.
[0014] If, as in one embodiment of the present invention, a sufficiently close spacing of 0.2 mm to 0.7 mm is selected as the smallest distance, on the one hand the surface of the conveyor belt is positioned close enough to the removal roller for picking up the fibers conveyed on the removal roller by means of a mechanical contact and to prevent the free uncontrolled flight of the fibers, on the other hand is the surface of the conveyor belt sufficiently far removed from the removal roller to prevent the application of a spin generated by friction to the fiber structure, or to make the fiber removal from the nip more difficult.
[0015] In another embodiment of the present invention, a conveyor belt with a microscopically roughened surface, or made of a material with a high coefficient of friction improves the pickup and conveyance of the fibers by the conveyor belt without interfering with the release from the conveyor belt.
[0016] In yet another embodiment of the present invention, a conveyor belt that is impermeable to air prevents undesired interference with the air flow directed to the nip from below and increases the dependability of the release process of the fibers from the removal roller.
[0017] In still yet another embodiment of the present invention, a layout of the conveyor belt drive mechanism wherein the speed of the conveyor belt is slightly greater than or equal to the circumferential speed of the removal roller aids in the prevention of compression of the fibers.
[0018] The air-spinning arrangement in accordance with the present invention permits the efficient and unhampered production of a yarn in accordance with the air-spinning process and overcomes disadvantages of known arrangements.
[0019] Further details of the present invention can be gathered from a non-limiting exemplary embodiment presented in the following description with reference made to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a lateral view of an air-spinning arrangement having a conveyor belt running along the removal roller.
[0021] [0021]FIG. 2 is an overhead view of a simplified version of the air-spinning arrangement of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The air-spinning arrangement 1 represented in FIG. 1 has a fiber opening device 2 with a draw-in roller 3 , feeding trough 4 and opening roller 5 . A material feed consisting of several slivers 6 passes through a nip formed by the draw-in roller 3 and the feeding trough 4 and is conveyed to the opening roller 5 . Three slivers are fed in next to each other in the represented exemplary embodiment, seen in FIG. 2. The draw-in roller 3 is driven in the customary way by a motor 7 via a toothed belt 8 , wherein the number of revolutions can be set in an infinitely variable manner. On its circumference, the opening roller 5 is equipped with combing elements in the form of needles 9 . In an alternative embodiment (not shown), the opening roller is constituted by a saw-toothed wire fitting. After passing through the nip, the fed-in fiber material is grasped by the needles 9 of the rotating opening roller 5 and is taken along. The surface of the opening roller 5 has a multitude of bores 10 , each arranged between two needles 9 . A stationary, unmoving suction insert 11 is arranged in the opening roller 5 , which is connected to a vacuum source (not shown). A vacuum is applied by means of the suction insert 11 over an area that includes approximately a quarter of the circumference of the opening roller 5 and extends from the combing location as far as the transfer location, or the feeding zone of the fibers, to the removal roller 12 . The fibers grasped by the needles 9 and released out of the fiber structure of the material feed are aspirated by the vacuum existing at the bores 10 . The combing of the fibers out of the fiber structure of the material feed is intensified because of this and the take-along of the fibers by means of friction, even at slow combing speeds, is improved. The immediate take-along of the combed-out fibers is intended to prevent that the fibers lose their stretched position, or are compressed by the needles 9 . For improving the opening of the slivers, it is, for example, alternatively possible to equip the fiber opening device 2 with a support roller that meshes with the opening roller 5 , or with other means, such as known from German Patent Publication DE 198 50 518 A1, for example.
[0023] The surface 13 of the removal roller 12 that rotates in a counterclockwise direction in the representation in FIG. 1 is perforated. The suction insert 14 that is fixedly arranged inside the removal roller 12 is also connected to the previously mentioned vacuum source. A vacuum is applied to the surface 13 of the removal roller 12 with the aid of the suction insert 14 in the area between the spot in which the fibers are transferred from the opening roller 5 to the removal roller 12 , and the spot where the fibers are removed from the removal roller 12 to the conveyor belt 15 . The cutout 16 in the suction insert 14 is connected via the air conduits 17 and 18 and via the vacuum chamber 19 with the vacuum source. The air flowing to the air conduit 17 aids the transfer of the fibers from the opening roller 5 to the removal roller 12 , and the air flowing to the air conduit 18 aids the release of the fibers from the removal roller 12 . The conveyor belt 15 extends in an axially-parallel manner and tangentially in relation to the removal roller 12 at a distance of 0.4 mm.
[0024] A portion of the air aspirated by the air conduit 18 flows from below into the nip between the surface 13 and the conveyor belt 15 . Here, this airflow aids the release of the fibers from the removal roller 15 . The fibers are caught by the conveyor belt 15 , are deflected by 90° into the conveyance direction of the conveyor belt 15 and taken along by it. The conveyor belt 15 has a slightly higher speed than the circumferential speed of the surface of the removal roller 12 . To increase the dependability of the transfer process, the conveyor belt 15 has a microscopically roughened surface and is made of soft caoutchouc. The fibers that are taken along form a strand-like fiber structure of parallel arranged fibers on the conveyor belt 15 . After the deflection by 90°, the fiber structure passes through a nip and thereafter passes through the air-spin nozzle 20 .
[0025] It is achieved by means of the air-spin nozzle 20 that the fiber structure is charged with an air flow which rotates around the passing fiber strand. In the process, the fiber ends are spread away from the fiber structure and are wound around the so-called core fiber. The principle of such air-spinning processes is known from German Patent Publication DE 197 46 602 A1, for example.
[0026] After the air-spin nozzle 20 , the yarn 21 passes through a withdrawal device 22 , wherein the withdrawal rollers 23 and 24 form a nip point. The yarn 21 spun in this manner is wound on a cheese (not shown). The driving of the opening roller 5 and the removal roller 12 is provided by the motor 25 and via the belt 26 . The belt 26 drives the conveyor belt 15 via the gear arrangement 27 , and by means of the belt 28 the withdrawal rollers 23 and 24 . From the opening roller 5 to the withdrawal device 22 the opening roller 5 , the removal roller 12 , the conveyor belt 15 and the withdrawal rollers 23 and 24 each have a slightly rising circumferential speed. The gear ratios remain the same for each spinning speed.
[0027] It can be seen in the simplified view from above on the air-spinning arrangement 1 in FIG. 2 that the toothed opening roller 5 is relatively wide in comparison with opening rollers, such as are used with rotor spinning. Matched to this width, three slivers 6 placed next to each other are simultaneously fed to the draw-in roller 3 .
[0028] The conveyor belt 15 runs over deflection rollers 29 and 30 and is arranged in such a way that it extends along the entire perforated working width of the removal rollers 12 . The resiliently seated gripping roller 31 presses against the deflection roller 29 , or the conveyor belt 15 . The fibers are released from the removal roller 12 , are deflected in their movement direction by 90° by the conveyor belt 15 and are collected into a strand-like fiber structure. The fiber structure follows the deflection of the sliver 15 at the deflection roller 29 as far as to the nip line between the deflection roller 29 and the gripping roller 31 . The air-spin nozzle 20 projects into the nip formed by the deflection roller 29 and the gripping roller 31 . The air-spin nozzle 20 is connected via the connector 32 with a compressed air source (not shown). The compressed air is used for generating the rotating air flow with which the fiber structure is charged in the air-spin nozzle 20 . During the spinning operation the air pressure is 5 to 9 bar. The connector 33 is connected with a vacuum source. Fibers that are released during piecing or spinning are aspirated by means of the connector 33 . The vacuum for aspirating the fibers that are individually released from the fiber structure is approximately 20 mbar. A higher vacuum of approximately 100 mbar is applied during piecing, by means of which the fibers are aspirated off the conveyor belt 15 when the compressed air supply to the air-spin nozzle 20 is interrupted. In the course of this, the gripping roller 31 is lifted off the conveyor belt 15 . The suction flow causes the fibers to initially follow the deflection of the conveyor belt 15 around the deflection roller 29 , after which they are aspirated by the air-spin nozzle 20 . At the start of piecing, a piecing yarn, which is first guided around the lifted gripping roller 31 , is drawn into the air-spin nozzle 20 , which was drawn out of the nip. When the fiber structure aspirated off the conveyor belt 15 passes through the air-spin nozzle 20 together with the piecing yarn, the gripping roller 31 is placed against the conveyor belt 15 , the compressed air supply for charging the fiber structure with a rotating air flow is turned on, and the vacuum from the vacuum source is set to approximately 20 mbar instead of 100 mbar.
[0029] The fibers are combined with the piecing yarn. Feeding of the piecing yarn is stopped after the spinning process has been started. The narrow sliver is still further drawn into the air-spin nozzle 20 after the gripping roller 31 has again been placed against the conveyor belt 15 . The fibers follow the deflection of the conveyor belt 15 even without suction air, because the deflection track is considerably shorter than the staple length of the fibers. Therefore, shortened fibers contained in the fiber structure also follow the deflection, because they are guided, or supported, by the longer fibers. The withdrawal device 22 is activated synchronously with the application of the gripping roller 31 to the conveyor belt 15 in that the withdrawal roller 23 is placed against the driven withdrawal roller 24 .
[0030] After passing through the withdrawal device 22 , the yarn 21 is conducted to a winding arrangement (not shown) for producing a cheese.
[0031] It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | An air-spinning arrangement has an opening device having a feed device and an opening roller for opening a sliver into individual fibers. A perforated removal roller receives the opened fibers from the opening roller in the circumferential direction. A conveyor belt conveys the fibers from the removal roller to a nip with a following air-spin nozzle for forming a yarn. The conveyor belt is arranged axially-parallel with the removal roller. A sufficiently close spacing of the conveyor belt from the removal roller is selected such that the fibers conveyed to the removal roller can be picked up by mechanical contact, and the conveyor belt is driven such that it deflects the fibers by approximately 90° and conveys them to the combing location. The air-spinning arrangement allows the formation of a fiber structure that is well suited to the air-spinning process. | 3 |
BACKGROUND OF THE INVENTION
This invention relates generally to carrier signal recovery loops located at a receiver for the reception and demodulation of quadraphase shift keyed (QPSK) signals, and more particularly to such a carrier recovery loop for the demodulation of QPSK signals which are received intermittently in a burst mode. Such carrier recovery is one of several functions which together comprise the demodulation process by which signals received on a radio frequency carrier are detected and converted to baseband frequencies.
In some prior art methods of recovering the carrier at the receiver for demodulating a QPSK signal the frequency f c of the carrier signal e c of the QPSK signal is multiplied by four to remove the four phase modulation, leaving a line frequency sine wave component of 4f c . This sine wave signal is then employed as one input to the phase detector of a phase locked loop (PLL) circuit to become phase locked with the phase of a multiplied-by-four frequency (4f vco ) of a locally generated carrier signal e vco of a frequency f vco and generated in a voltage controlled oscillator (VCO).
The recovered carrier e vco of frequency f vco will then have one of four phase relationships, 0°, 90°, 180°, or 270° with the phase of the received carrier e c of frequency f c . In a subsequent step in the demodulation process (not a part of the present invention) this phase ambiguity is resolved to obtain bit synchronization and detection.
In applications employing bursts of QPSK transmission, the received carrier will generally deviate from the phase locked condition between bursts so that when the next burst occurs the locally generated carrier signal is no longer phase locked with the carrier of the received signal and accordingly must be phase corrected before the demodulation of the next transmission burst can be accomplished.
When the system is operated in the burst mode of operation, it is assumed herein that each transmission burst will begin with a synchronizing preamble as is normally done in time division multiplex access (TDMA) transmissions. For the purpose of this invention it is further assumed that a portion of the burst preamble will consist of a sequence modulated by alternating symbol phases of zero and π radians. Such a two valve sequence produces a line frequency component at 2f c after frequency doubling (or 4f c after frequency quadrupling) and permits the phase locked loop to initiate synchronization in the present invention.
As an example of the problem that can be encountered between transmission bursts assume that the phase of the VCO signal has wandered off the phase locked value by some phase between 0° and 360° of a cycle of the desired frequency f c . As will become clearer later herein, the worst possible phase shifts that can occur between transmission bursts are even multiples of 45° of a cycle of f c which would establish a phase relation between the quadrupled (x4) frequency 4f vco of the locally generated signal e vco and the quadrupled (x4) frequency 4f c of the received carrier signal e c at phase angles of either 45°, 135°, 225° or 315°, relative to f c . All of these phase relations represent an unstable null point at the output of the phase detector which compares the phases of the quadrupled frequencies 4f c and 4f vco of e c and e vco . Thus, the phase of the quadrupled frequency 4f vco of the local VCO signal e vco must be shifted by a full 180° of a cycle in order to become phase locked with the quadrupled frequency 4f c of received signal e c at one of the four possible stable null points which occur at any one of the phase relations 0°, 90°, 180° or 270° between e vco and e c .
The amount of time required for the quadrupled frequencies of e c and e vco to become phase locked at one of the above-mentioned four stable null points presents the specific problem which is met and solved by the present invention, particularly when the loop is initially near an unstable null. More specifically, it is a substantial reduction in the time required to acquire phase lock starting from the vicinity of one of the four unstable null points that the present invention achieves.
It should be specifically noted, as mentioned above, that the resolution of the ambiguity presented by the four stable null points, i.e., the selection of the proper one of the four stable null points, is not a part of the present invention. This problem is solved using such well-known techniques as differential coding of the transmitted data or the detection and correlation of coded words that are a part of the burst preamble mentioned above and which also serve to provide word synchronization.
The above-mentioned techniques are discussed in detail in the following three publications, all of which are incorporated in full herein by reference.
1. "Digital Communications--Satellite/Earth Station Engineering", pp 306-7, 385-6, Prentice-Hall 1983.
2. "Preamble Requirements for Burst-Type QPSK Satellite Communications under Low Es/No Conditions", by S. A. Rhodes, Proceedings of 1977 National Telecommunications Conference, pp 05:3-1 to 05:3-7.
3. "Phase-Ambiguity Resolution in a Four-Phase PSK Communication System", by E. R. Cacciamani and C. J. Wolejsza Jr., IEEE Trans. on Comm. Technology, Vol. COM-19, No. 6, Dec. 1971, pp 1200-1210.
After correction of the output of the local VCO to the proper one of the four possible stable null points of the x4 frequencies, the output e vco of the local VCO is compared with e c for the demodulation function.
An unstable null point derives its label of instability from the fact that any change in the phase difference between the two signals being phase compared will produce a change in voltage at the output of the phase detector of a polarity which will increase such change in phase difference between the two signals, thereby increasing the phase difference until the phases of the two signals coincide, i.e., until a stable null point is reached, as at 0°. At a stable null point, any change in phase between the two signals from the stable null point will result in an output voltage from the phase detector which will cause the phase of the output of the VCO to change in a direction as to close the phase difference between the two signals, i.e., to return to the stable null.
SUMMARY OF THE INVENTION
In one form of the invention there is provided a QPSK signal source of frequency f 1 , first and second x2 frequency multipliers to produce a signal of 4f 1 with the QPSK modulation thereby removed. Also provided are first and second phase locked loops comprising a common voltage controlled oscillator (VCO), and separate ones of first and second phase detectors, respectively, with each detector having a characteristic output which varies substantially sinusoidally with linear variation of the phase difference of the two signals supplied thereto and with the negative-going cross-over transitions of the characteristic output being an unstable null, a third x2 frequency multiplier connecting the VCO output to the first phase detector, and a fourth x2 frequency multiplier connecting the output of the third x2 frequency multiplier to the second phase detector. A comparator compares the output signals of the phase detectors to generate a control signal indicating when the output of the second phase detector is near an unstable null at which time a switch responds to the control signal to connect the output of the first phase detector to the input of the VCO.
DESCRIPTION OF THE DRAWING
In the drawings:
FIG. 1 is a combination block and logic diagram of one embodiment of the invention; and
FIGS. 2(A and B) show characteristics curves of the output signals of phase detectors shown in FIG. 1, both in noninverted and inverted form.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, the received signal e 1 , defined below in Expression 1, is supplied to the multiply-by-two (x2) frequency multiplier 102 to produce the signal e 2 defined below in Expression 2 which, in turn, is supplied to a second x2 frequency multiplier 106 and to a phase detector 104. The output e 3 of the x2 multiplier 106 is defined in Expression 3 and is supplied to a second phase detector 108.
e.sub.1 =A cos (2πf.sub.1 t+θ.sub.i) (Exp. 1) ##EQU1##
It can be seen that the X2 input signal e 2 of Expression 2 is supplied to the input of phase detector 104 and the X4 input signal e 3 of Expression 3 is supplied to the input of phase detector 108. The multiplication by 4 of input signal e 1 removes all of the quadra-phase modulation thereon so that the signal supplied to phase detector 108 no longer contains any of the phase modulation of the received signal e 1 and is, in fact, a sinusoidal line component of 4f 1 .
The ouput e vco (shown in Expression 4 below) of VCO 116 is also multiplied by two in the X2 frequency multiplier 120 to produce an output signal e' vco (shown in Expression 5 below) whose output, in turn, is supplied to the second input of phase detector 104 and also to the input of the second X2 frequency multiplier 122. The output e" vco of the second X2 multiplier 122, which is a X4 multiplication of the frequency f vco of the output of VCO 116, and shown in Expression 6 below, is supplied to a second input of phase detector 108.
e.sub.vco =B sin (2πf.sub.vco t+θ.sub.o) (Exp. 4) ##EQU2##
Thus, phase detector 104 receives a X2 frequency input signal (e 2 ) derived from e 1 and a X2 frequency input signal e' vco derived from VCO 116 and phase detector 108 receives a X4 frequency input signal e 3 derived from e 1 and the X4 frequency input signal e" vco derived from e vco .
The output of each of the two phase detectors 104 and 108 is a voltage whose amplitude varies around zero as the phase difference of the two input signals supplied thereto change. Thus, for example, the output e 4 of phase detector 104 (shown in Expression 7 below), is represented by the waveform 160 of FIG. 2A and the output e 5 of phase detector 108 (shown in Expression 8 below) is represented by the waveform 162 of FIG. 2A. ##EQU3##
It is to be understood that waveforms 160 and 162 are sine wave signals only in the sense that they represent the output of the two phase detectors 104 and 108 as the difference in the phases θ i and θ o of the two signals supplied to each of the phase detectors varies, noting that the phase variation due to the carriers, 2πf 1 t and 2πf vco t cancels itself at loop equilibrium. Thus, for example, if the phase angles θ i and θ o of the two signals e 2 and e' vco supplied to phase detector 104 of FIG. 1 remain at some fixed value, then the output of phase detector 104 will be a steady state voltage whose amplitude will depend upon the sine of the fixed phase difference between the two signals supplied thereto. If the phases of the two signals supplied to detector 104 are coincident, i.e., have a zero phase difference, then the output of phase detector 104 will be a zero value as represented by the point 172 of FIG. 2A and will be a stable null point.
On the other hand, if the phase difference between the two signals e 2 and e' vco supplied to phase detector 104 were initially 180° out of phase, the output of phase detector 104 would be the null point as represented at point 170 of FIG. 2A. However, this null point 170 is an unstable null point and the phase of the X2 output signal e' vco of VCO 116 from X2 multiplier 120 would change (either increase or decrease) until the phases of the two signals supplied to phase detector 104 were coincident, as represented by either point 172 or point 173 of FIG. 2A.
The foregoing can perhaps be better understood by the following explanation. If the phases of the two signals e 2 and e' vco supplied to phase detector 104 (FIG. 1) are initially coincident, as represented at point 172 of FIG. 2A, then if some pertubation should occur to cause a phase difference to develop between such two signals, the voltage generated at the output of phase detector 104 would be of such a polarity that when supplied through loop filter 110 and switch 114 to the input of VCO 116 it would cause the frequency of the output signal e vco of VCO 116 to change in that direction which will cause the phase difference to be reduced, thereby resulting in a return to a coincident phase condition between the two signals e 2 and e' vco supplied to phase detector 104.
Conversely, if the phases of the two signals e 2 and e' vco supplied to phase detector 104 were 180° different, and having an output as represented at the unstable null point 170 of FIG. 2A, a change in the phase difference between such two signals would result in a voltage generated at the output of phase detector 104 which would be supplied through loop filter 110 and switch 114 to the input of VCO 116 to cause the frequency f vco of the output signal e vco of VCO 116 to move farther away from the unstable null point 170. This process would continue until the phases of the two signals e 2 and e' vco supplied to phase detector 104 had become coincident and the output of phase detector 104 would then be either at point 172 or point 173 of FIG. 2A.
In a similar manner and for similar reasons, the stable null points of the phase detector 108, which compares the X4 frequencies of the input and VCO signals e 1 and e vco , will occur at points 172, 170 and 173 and the unstable null points will occur at points 166 and 168. The output of phase detector 108 will pass through loop filter 112 and selector switch 114 to the input of VCO 116 when switch 114 makes contact with the output of filter 112 to cause the output of VCO 116 to shift in phase until the phases of the two signals e 3 and e" vco supplied to phase detector 108 are coincident so that one of the null points 172, 170, or 173, is attained.
As can be seen from FIG. 1, selector switch 114 can connect the output of loop filter 110 or the output of loop filter 112 to the input of VCO 116. The state of switch 114 is under control of the output of comparator 134. It can be assumed arbitrarily that the output of comparator 134 is either a high level signal or a low level signal depending upon whether the output of full wave rectifier 130 is greater or less than the output of full wave recitifier 132.
Selector switch 114 will be in its up position in FIG. 1 to connect the output of loop filter 110 to the input of VCO 116 when the output of comparator 134 is a high level signal as the result of the output of rectifier 130 being greater than the output of rectifier 132. When the output of full wave rectifier 132 becomes greater than that of full wave rectifier 130 the output of comparator 134 becomes a low level signal to cause switch 114 to connect the output of loop filter 112 to the input of VCO 116.
It is apparent from FIG. 1 that if switch 114 connects loop filter 110 to the input of VCO 116 a closed phase locked loop is then established which includes VCO 116, X2 frequency multiplier 120, phase detector 104 and loop filter 110. When the switch 114 is in its lower position to connect loop filter 112 to the input of VCO 116 then a second phase locked loop is established which includes VCO 116, X2 frequency multipliers 120 and 122, phase detector 108 and loop filter 112.
The determination of which of the two phase locked loops is closed depends upon the relative magnitudes of the outputs of full wave rectifiers 130 and 132 which in turn depend upon the outputs of phase detectors 104 and 108.
Referring now to the curves of FIG. 2B, there is shown the output of full wave rectifiers 130 and 132 with the curve 160' representing the output of full wave rectifier 130 and curve 162' the output of full wave rectifier 132. It will be observed that curve 160' corresponds to curve 160 of FIG. 2A but fully rectified. Similarly, the curve 162' of FIG. 2B corresponds to the curve 162 of FIG. 2A but fully rectified.
Further examination of FIG. 2B shows that during the phase intervals Δφ 1 , Δφ 3 , and Δφ 5 the amplitude of the output of full wave rectifier 132 is greater than that of full wave rectifier 130 and that during phase intervals Δφ 2 and Δφ 4 the output of full wave rectifier 130 is greater than that of full wave rectifier 132. Thus, during phase intervals Δφ 2 and Δφ 4 the selector switch 114 will connect the output of loop filter 110 to the input of VCO 116 so that the phase locked loop including phase detector 104 and loop filter 110 will control the input to VCO 116 and will cause the phase of the output of VCO 116 to shift towards a stable null point as defined in the X2 phase locked loop including loop filter 110.
More specifically, the phase of the output of VCO 116 will shift in such a direction that the output of phase detector 104 will shift toward either the stable null point 172 or the second stable null point 173 in FIG. 2B. Assume, for purposes of discussion, that the initial phase relation between the outputs of the X2 frequency multipliers 120 and 102, as supplied to phase detector 104, is as indicated at point 181 in FIG. 2B. The output of phase detector 104 will then shift towards the stable null point 172 under control of the X2 phase locked loop which includes loop filter 110. However, when point 181 moves past the point 180 (to the left of point 181 in FIG. 2B) the output of phase detector 108 will exceed the output of phase detector 104 so that the output of full wave rectifier 132 will become greater than that of full wave rectifier 130. The comparator 134 will then generate a low level output signal to cause switch 114 to connect the output of loop filter 112 to the input of VCO 116 to pass control of the system to phase detector 108 and loop filter 112.
The output of phase detector 108 will then shift along its output characteristic curve 162' (FIG. 2) towards a stable null point (point 172) which can be seen to represent a higher voltage than the output of phase detector 108, thereby providing a fast transition of the phase of VCO 116 to the desired stable null point 172.
The foregoing is important since it is the increased speed with which the logic finds one of the four possible stable null points that forms the essence of the invention. In particular the loop will never be under control of the low level signals associated with unstable null positions of the phase detectors.
Should the initial phase relation between the received signal e 1 and the output e vco of the VCO be as represented at point 183 of FIG. 2B, then the output of phase detector 108 will control since it is larger than the output of phase detector 104. Thus point 183 of waveform 2B will shift towards the stable null point 175 of FIG. 2B. Point 175 is a stable null point since it is the positive going cross-over of signal 162 of FIG. 2A which is the output of phase detector 108 of FIG. 1.
As another example, if the initial condition is as represented by point 185 of FIG. 2B, such point 185, which is the output of phase detector 108 and filter 112, will shift towards the stable null point 175.
As still another example, should the initial phase relationship be as represented by point 187 of FIG. 2B, then the output of phase detector 104 will move towards the stable null point 173 of FIG. 2B. However, when it reaches point 186 of FIG. 2B control of the change of phase of VCO 116 will pass to the phase locked loop including loop filter 112 whose output is represented by the curve segment 189 of FIG. 2B. Point 187 will continue to move toward point 173 until it reaches such point 173 which is a stable null point of the output of phase detector 108. | A carrier recovery loop for a burst type QPSK system. A QPSK signal source of frequency f 1 has its output frequency doubled and then doubled again to produce a signal of 4f 1 with the QPSK modulation thereby removed. Also provided are first and second phase locked loops comprising a common voltage controlled oscillator (VCO), and separate ones of first and second phase detectors, respectively, with each detector having a characteristic output which varies sinusoidally with linear variation of the phase difference of the two signals supplied thereto and with the negative-going cross-over transitions of the characteristic output constituting unstable nulls. A third x2 frequency multiplier connects the output of the VCO to the first phase detector, and a fourth x2 frequency multiplier connects the output of the third x2 frequency multiplier to the second phase detector. The output signals of the phase detectors are compared to generate a control signal indicating when the output of the second phase detector is near an unstable null at which time a switch responds to the control signal to connect the output of the first phase detector to the input of the VCO. | 5 |
This application is a continuation-in-part of application Ser. No. 682,798, filed Dec. 18, 1984, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a method for the preparation of a polyarylene sulfide or, more particularly, to a method for the preparation of a polyphenylene sulfide having an outstandingly small content of salt in a process by which the polymer product can readily be separated from the reaction mixture.
Polyarylene sulfide or, typically, polyphenylene sulfide, which is referred to as PPS hereinbelow, is a partially heat-curable thermoplastic resin having excellent characteristic properties as a so-called engineering plastic in respect of the remarkable resistance against various chemicals, good mechanical properties retained over a wide range of temperature, heat-resistant rigidity and others.
PPS is usually prepared, as is described in Japanese Patent Publication No.52-12240, by the reaction of 1,4-dichlorobenzene and sodium sulfide in an organic amide as the solvent in the presence of a metal carboxylate as the catalyst. This method is, however, disadvantageous due to the high production cost of the PPS because the amount of the relatively expensive metal carboxylate required for sufficiently accelerating the reaction is very large in the range, for example, from 0.7 to 4 moles per mole of the sodium sulfide. Moreover, the PPS product unavoidably contains as much as 1000 to 3000 ppm of sodium chloride as an impurity produced by the reaction as a byproduct. Such a high content of the sodium chloride impurity is of course detrimental in the PPS polymer, especially, when the polymer is used in applications in the fields of electric and electronic technologies due to the possible decrease in the insulation of the circuit in a humid condition to cause errors in the operation of the circuit. Therefore, such a PPS polymer of high impurity content must be purified again before it is used.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a novel and improved method for the preparation of a polyarylene sulfide or, in particular, PPS without using an expensive alkali metal salt of carboxylic acid as the catalyst so that the production cost of the polymer can remarkably be reduced.
Another object of the invention is to provide an industrially advantageous method for the preparation of a polyarylene sulfide or, in particular, PPS containing a much smaller amount of the impurity salt than in conventional polymers as a result of the outstanding ease in the separation of the polymer from the reaction mixture.
Thus, the method of the present invention for the preparation of a polyarylene sulfide comprises reacting an alkali metal sulfide and a polyhalogenated aromatic compound in a heterogeneous reaction mixture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One of the starting reactants used in the inventive method is an alkali metal sulfide represented by the general formula M 2 S, in which M is an alkali metal such as sodium, potassium and lithium. Particularly preferable is sodium sulfide of the formula Na 2 S.
The other starting reactant to be reacted with the alkali metal sulfide is a polyhalogenated aromatic compound which is a compound having at least 2 halogen atoms or, typically, chlorine and bromine atoms directly bonded to an aromatic nucleus from, for example, benzene or naphthalene represented by the general formulas ##STR1## respectively, in which X is a halogen atom, R is a halogen atom or an alkyl group having from 1 to 20 carbon atoms and n is zero or a positive integer of 1 to 4. Examples of such a polyhalogenated aromatic compound include 1,2-dichlorobenzene, 1,3-dichlorobenzene, 1,4-dichlorobenzene, trichlorobenzenes, tetrachlorobenzenes, dibromobenzenes, tribromobenzenes, dichloronaphthalenes, trichloronaphthalenes, dichlorodiphenyl sulfones, dichlorobenzophenones, dichlorodiphenyl ethers, dichlorodiphenyl sulfide and the like. Two kinds or more of these compounds may be used as a mixture according to need.
The reaction of the above described alkali metal sulfide and polyhalogenated aromatic compound should be performed in a heterogeneous reaction mixture or, preferably, in a two-phase mixture. A typical and preferable example of such a reaction in a heterogeneous reaction mixture is the reaction of the above described starting reactants in the presence of water and polyethyleneglycol. In this case, the polyethyleneglycol should have an average molecular weight in the range from 2000 to 20,000 or, preferably, from 4000 to 15000 or, more preferably, from 6000 to 10,000. Polyethyleneglycols having an average molecular weight in this range are not freely miscible with water at elevated temperature so that a mixture thereof with water is separated into two phases while a polyethyleneglycol having an average molecular weight smaller than 2000 is miscible with water at all temperatures to form a homogeneous solution. Polyethyleneglycols having an excessively large average molecular weight are undesirable usually because such a polyethyleneglycol is so viscous that difficulties are encountered in handling thereof and process control of the reaction. This is the reason for the upper limit of 20,000 for the average molecular weight of the polyethyleneglycol used in the inventive method. The weight proportion of water to polyethyleneglycol in the reaction mixture should be in the range from 25:1 to 1:10 or, preferably, from 15:1 to 1:3 or, more preferably, from 10:1 to 1:1. When the amount of water in the reaction mixture is larger than 25 parts by weight per part by weight of polyethyleneglycol, the productivity of the desired polymer is decreased while a blend of water and polyethyleneglycol in which the amount of water is smaller than one tenth by weight of the polyethyleneglycol is not separated into two phases but forms a homogeneous solution.
The above-noted average molecular weights are number average molecular weights. The molecular weight measurement was obtained by gel permeation chromatography using benzene as a solvent at 30°C.
In practicing the method of the invention, a polyethyleneglycol having a low average molecular weight added to the reaction mixture may serve as an interphase transition catalyst. The polyethyleneglycol to exhibit such a catalytic activity should have an average molecular weight in the range from 100 to 1500 or, preferably, from 100 to 1000 or, more preferably, from 100 to 600. Also, as the molecular weight of the polyethyleneglycol decreases, the catalytic activity increases. When the average molecular weight thereof is larger than 1500, the polyethyleneglycol has a decreased solubility in water so that a lower catalytic activity is exhibited thereof as a result of the decrease in the interphase transition. The amount of the low-molecular polyethyleneglycol to serve as a catalyst should be 300 g or smaller or, preferably, in the range from 10 to 150 g per mole of the polyhalogenated aromatic compound.
In addition to the above mentioned low-molecular polyethyleneglycol, several inorganic and organic basic compounds may serve as a catalyst for the reaction of the inventive method including alkali metal hydroxides such as sodium and potassium hydroxides, alkali metal carbonates such as lithium, sodium and potassium carbonates and amides and related compounds such as N-methylpyrrolidone, N,N-dimethyl formamide, N-methyl caprolactam, tetramethylurea, 1,3-dimethyl-2-imidazolidine and the like.
The reaction of the alkali metal sulfide and the polyhalogenated aromatic compound according to the inventive method should be performed at a temperature in the range from 200 to 350°C. or, preferably, from 240 to 330°C. and the reaction is continued usually for 5 hours or longer or, preferably, for a length of time from 6 to 80 hours. To obtain good color product polyarylene sulfide, it is preferable to deaerate the reactor and water before dissolving the alkali metal sulfide at the start of reactor charging.
The reaction of the alkali metal sulfide and the polyhalogenated aromatic compound performed in the above described manner leads to the formation of the desired polyarylene sulfide or, typically, PPS. When the reaction mixture after completion of the reaction is kept at a temperature greater than 150°C., phase separation is maintained, consisting of an aqueous phase and a phase of the polyethyleneglycol containing powdery precipitates of the polyarylene sulfide of high molecular weight. In this case, water-soluble byproducts such as sodium chloride are dissolved and contained in the aqueous phase so that the content of the salt impurities in the polyarylene sulfide product is greatly decreased. The powdery precipitates of the high-molecular polyarylene sulfide contained in the phase of the polyethyleneglycol are collected by filtration and freed from the polyethyleneglycol by washing with water or an organic solvent such as methylene chloride, acetone and the like. The filtrate of the polyethyleneglycol phase is a mixture of the polyethyleneglycol and polyarylene sulfide of a relatively low molecular weight. The high-molecular polyarylene sulfide is further purified to be freed from impurities such as the unreacted starting reactants by washing with water, acetone and the like.
As is described above, the present invention provides a method for the preparation of a polyarylene sulfide or, typically, PPS with outstandingly low production costs because the reaction of the inventive method is performed without the use of an expensive alkali metal carboxylate indispensable in the prior art methods. Furthermore, the inventive method has an advantage that the polymer product can readily be separated from the reaction mixture because the reaction is performed in a heterogeneous reaction system comprising the specific two phases. In addition, the extremely low content of the salt impurities in the polymer product gives a possibility that the polymer product can be used for specific applications in the fields of electric and electronic technologies without disadvantages caused by the presence of salt impurities. Therefore, the polyarylene sulfide products such as PPS obtained by the method of the present invention are very useful as a class of engineering plastics.
In the following the method of the present invention is described in more detail by way of examples.
EXAMPLE 1
Into an autoclave of 2-liter capacity equipped with a stirrer were introduced with agitation an aqueous solution of 72.050 g (0.3 mole) of sodium sulfide nonahydrate (Na 2 S.9H 2 O) dissolved in 600 ml of distilled water, 200 g of a polyethyleneglycol having an average molecular weight of about 8000 and 44.103 g (0.3 mole) of 1,4-dichlorobenzene to form a reaction mixture, in which the weight ratio of water to the polyethyleneglycol was 3:1. Nitrogen gas was gently blown into this reaction mixture for about 30 minutes.
The reaction mixture was heated and stirred at about 80°C. to allow uniform mixing and the autoclave was closed under pressurization with nitrogen gas at a pressure slightly higher than the atmospheric. Under continuous agitation with the stirrer driven at 300 rpm, the temperature of the reaction mixture was increased to 275°C. while the pressure inside the autoclave increased to 430 psig to effect the reaction which was continued for about 20 hours at the same temperature. After completion of the reaction in this manner, agitation and heating of the reaction mixture were discontinued and the mixture was kept standing to be cooled to room temperature.
The aqueous solution of about 575 ml volume forming the upper layer in the autoclave was transferred into a jar by siphon and 100 ml of toluene were added thereto and blended by use of a roll mill. When the liquid mixture in the jar had been settled and separated into two phases, the organic upper layer of toluene was a clear reddish solution while the aqueous solution forming the lower layer was yellowish brown in color with turbidity. No solid precipitates were found on the bottom of the jar. The light yellowish brown product suspended in the aqueous solution was collected by filtration and washed twice with water and further twice with acetone to be freed from the unreacted sodium sulfide and 1,4-dichlorobenzene.
The polyethyleneglycol solution left in the autoclave was admixed with 500 ml of water and 100 ml of toluene and the mixture was agitated for 3 hours and then transferred into a jar of 1-gallon capacity by siphon from the autoclave. About 3.0 g of yellowish brown precipitates were found on the bottom of the autoclave and recovered. This material was a PPS of low molecular weight dissolved in the polyethyleneglycol.
When the liquid mixture in the jar had been stabilized and separated into two phases, the toluene solution forming the upper layer was clear and red in color while the lower layer was formed of a yellowish brown aqueous suspension containing black solid particles on the bottom. The toluene solution was separated by decantation and evaporated and the aqueous suspension was filtered by use of a medium-fast flow filter paper with suction by a water-jet aspirator. No particulate product was found in the aqueous phase.
The light yellowish brown solid product thus collected by evaporation of the toluene was washed first with water and then with acetone and combined with the solid material recovered from the bottom of the autoclave followed by drying for 16 hours under reduced pressure. The overall yield of the thus obtained PPS was 0.28 g. The infrared absorption spectrum of this product was identical with that of an authentic poly(1,4-phenylene sulfide). The product was washed with hot water and analyzed by the atomic absorption spectrometry for the content of chloride impurities to find a content of 10 ppm while the value in the same PPS before washing with hot water was 400 ppm.
EXAMPLE 2
The experimental procedure was substantially the same as in the preceding example excepting the following modifications. In this case, the amounts of the sodium sulfide and 1,4-dichlorobenzene were each 0.5 mole and the weight proportion of water to polyethyleneglycol as the reaction medium was 1:1. The reaction temperature was 300°C. instead of 275°C. The product was found to be suspended in one phase indicating the importance of the weight proportion of water to polyethyleneglycol in the reaction medium. The overall yield of the product was 1.41 g and the product was identified to be a PPS by the infrared absorption spectroscopy. The balance of the product was in an emulsified state in the phase of water and polyethyleneglycol.
EXAMPLE 3
The experimental procedure was also substantially the same as in Example 1 except that the polyethyleneglycol used here was a mixture of 100 g of a first polyethyleneglycol having an average molecular weight of about 8000 and 10 g of a second polyethylene glycol having an average molecular weight of about 400 with the weight proportion of water to polyethyleneglycol equal to 6:1 and the conduit pipe to the pressure gauge was closed to prevent sublimation of 1,4-dichlorobenzene.
Thus, an aqueous solution of 72.054 g of sodium sulfide Na 2 S.9H 2 O dissolved in 600 ml of water, 44.103 g of 1,4-dichlorobenzene, 100 g of a first polyethyleneglycol having an average molecular weight of about 8000 and 10 g of a second polyethyleneglycol having an average molecular weight of about 400 were introduced together into a reaction vessel to form a reaction mixture which was homogenized by heating at about 80°C. under agitation with simultaneous blowing of nitrogen gas thereinto.
Thereafter, the reaction vessel was hermetically closed and the temperature of the reaction mixture was increased to 275°C. to effect the reaction at the same temperature for 24 hours. After the end of this reaction time, a small portion of the reaction mixture was taken out of the vessel and diluted with acetone to be analyzed by the gas chromatography which indicated the presence of unreacted dichlorobenzene in the reaction mixture.
The reaction mixture was allowed to cool with the rotation of the stirrer discontinued and the thin aqueous solution of 625 ml in volume forming the upper layer of the reaction mixture separated into two layers was discharged out of the reaction vessel by suction through the opening provided on the wall of the vessel. The remaining mixture in the vessel, which was mainly composed of the polyethyleneglycol and yellowish brown precipitates of PPS suspended therein as the product, was admixed and agitated with 150 ml of methylene chloride and the mixture was extracted repeatedly with water followed by evaporation of the solvent to leave 3.01 g of a brown solid as the product. The theoretical yield of the product in this case was 32.4 g.
EXAMPLES 4 to 6
The experimental procedure in each of the Examples was substantially the same as in Example 3 excepting the modification of the reaction conditions as indicated in the table given below which also includes the results obtained in each of the Examples.
EXAMPLE 7
Into a 2-liter stirred autoclave was charged, 675 ml of a 360 mg/ml Na 2 S.9H 2 O solution (1.01 mole, determined by iodimetric assay) with 147.01 g of p-dichlorobenzene (1.00 mole). Also added were 200 g of a polyethylene glycol with a molecular weight of 8000, 50 g of a polyethylene glycol (PEG) with a molecular weight of 400, and 10 g of potassium hydroxide.
The mixture was melted by heating to approximately 80°C., the autoclave sealed off under slight nitrogen pressure, and the ingredients stirred at 300 rpm. After 42 hours at 275°C., the stirrer and heater were turned off, and the reaction mixture was allowed to cool to room temperature, vented, and opened.
A two phase system had been established and 675 ml of the top aqueous phase was siphoned from the reactor and filtered. There was no PPS present in the top layer.
To the sediment remaining in the reactor was added 200 ml methylene chloride, and hand stirred for approximately three minutes. After the mixture was siphoned from the reactor, it was filtered using a water aspirator vacuum, and a medium-fast flow filter paper. The product was extracted repeatedly with distilled water and acetone, and vacuumed dried to obtain 26.59 g of a tan-brown solid, which was determined to be PPS by IR analysis.
The filtrate from this filtration procedure was extracted with 800 ml of a 10% hydrogen chloride solution in a separatory funnel. The acid solution was then decanted off, and the methylene chloride layer washed until neutral with distilled water.
The neutral methylene chloride phase was then transferred into a 500 ml l-neck boiling flask, and by rotary evaporation, 76.52 g of a dark brown, waxy solid was obtained. IR analysis of this waxy solid revealed a mixture of PPS and PEG.
The theoretical yield from this experiment was 108.1 g. The actual yields were 26.59 g PPS or 24.6%, and 76.52 g of the PPS-PEG mixture or 70.8%. Thus the total yield was 95.4 percent. Since the molar extinction coefficient (infrared absorption intensity) of PEG is one-hundred times greater than that of PPS, the weak absorption due to PEG is attributed to a very small percentage of PEG. Thus, the 76.52, of the mixture is mostly PPS.
TABLE__________________________________________________________________________Molar ratio of Weight ratio of Reaction Reaction Yield of PPS ResidualExampleNa.sub.2 S/dichloro- H.sub.2 O/high mole- Catalysts tempera- time, Insoluble.sup.(a) Soluble.sup.(b) % of content ofNo. benzene cular PEG (g) ture, °C. hours g g retical NaCl,__________________________________________________________________________ ppm1 0.3/0.3 600/200 -- 275 20 0.28 3.0 10.3 4002 0.5/0.5 600/600 -- 300 24 1.41 5.0 11.9 --3 0.3/0.3 600/100 Low mole- 275 24 3.01 16.0 59.3 310 cular PEG (10)4 1/1 795/200 Low molecular 275 24 24.46 37.54 57.4 -- PEG (10)5 1/1 675/200 Low molecular 275 24 35.33 32.3.sup.(c) 44.5 -- PEG (50)6 1.3/1 830/200 Low molecular 275 24 7.80 25.67.sup.(c) 30.9 -- PEG (50)7 1/1 675/200 Low molecular 275 42 26.59 76.52.sup.(c) 95.4 -- PEG (50) + KOH (10)__________________________________________________________________________ .sup.(a) insoluble in methylene .sup.(b) soluble in methylene .sup.(c) extracted with dilute HCl | The invention provides a novel efficient method for the preparation of a polyarylene sulfide or, typically, polyphenylene sulfide by the reaction of an alkali metal sulfide, e.g. Na 2 S, and a polyhalogenated aromatic compound, e.g. 1,4-dichlorobenzene. The improvement in the inventive method comprises performing the reaction in a heterogeneous reaction mixture comprising water and a polyethyleneglycol having a relatively high molecular weight, namely an average molecular weight of from 2,000 to 20,000, and not freely miscible with water. The product polymer is outstandingly free from salt impurities, e.g. sodium chloride, as a byproduct of the reaction. When a low molecular polyethyleneglycol is added to the reaction mixture in combination with the above mentioned high molecular polyethyleneglycol, a remarkable catalytic effect is obtained to accelerate the reaction and increase the yield of the desired polymer product. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of Federal Republic of Germany Application No. P 39 28 835.8 filed Aug. 31st, 1989, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an opening apparatus for opening fiber bales, that is, for removing fiber tufts from top faces of fiber bales. The apparatus is of the type which has a single, rapidly rotating opening roll which is composed of axially side-by-side arranged, sawtooth edged opening discs or which has a cylindrical surface provided with opening spikes or needles. The opening roll cooperates with a grate whose grate bars extend between the opening discs or circumferential rows of opening needles. The opening apparatus is arranged for travel above stationarily supported fiber bales and the teeth of the opening roll penetrate from above into the upper fiber bale surface.
A known opening apparatus of the above type comprises a tower which travels on horizontal rails and a cantilever projecting generally horizontally from the tower and adjustable to various angles to the longitudinal tower axis. In such a known arrangement, no bale support elements are provided so that the fiber bales may, during the opening operation, yield to operational pressing forces and thus shift or tip over. Further, turning the cantilever together with the opening device is structurally complex and expensive.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved opening apparatus of the above-outlined type which, in particular, ensures the stability of the fiber bales and has a simpler construction than prior art devices.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the opening roll is flanked on either side as viewed in the direction of travel, by a bale supporting element such as a bale pressing roll and further, setting means are provided for vertically shifting the bale support elements simultaneously in opposite directions.
By providing bale supporting elements such as bale pressing rolls, sliding shoes, inclined wall elements, pivotal plates or the like, pressure is exerted on the bales from above, as a result of which the bales are supported and cannot shift or tip over during the opening process. By virtue of the fact that, according to the invention, the bale support elements may be adjusted vertically simultaneously in opposite directions, a fiber tuft removal from the bale series may be performed in a plane which is inclined to the horizontal. It is a particular advantage of such an arrangement that only the bale supporting elements need to be shifted relative to the opening roll to achieve in a simple manner an opening process which progresses under different angles to the horizontal (obliquely oriented plane of removal). Thus, the cantilever, together with the opening device, need not be turned for achieving this purpose.
According to a further feature of the invention, the bale pressing rolls are vertically linearly adjustable. According to a further feature of the invention, the bale pressing rolls may be shifted arcuately about an axis of rotation. Expediently, pneumatic, hydraulic or electric power means (cylinders) may be used as power sources for effecting the vertical adjustment of the bale pressing elements.
The setting means are preferably form-fitting setting elements, such as chains or sprockets, tooth belts and belt sprockets, gears or toothed racks, and the like.
According to another preferred embodiment in which the vertical feed of the cantilever arm and the travel motion of the tower are determined and coordinated by a control device, the shift of the bale pressing rolls is effected as a function of a preset angular position which is stored in a memory.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a schematic side elevational view, with block diagram, of a preferred embodiment of the invention.
FIG. 2a is a schematic sectional side elevational view of another preferred embodiment of the invention illustrating a horizontal operational position.
FIG. 2b is a view similar to FIG. 2a, illustrating an operation along an inclined plane.
FIGS. 3 and 4 ar schematic end elevational views of two further preferred embodiments of the invention.
FIG. 5 is a schematic side elevational view of still another preferred embodiment of the invention.
FIG. 6 is a schematic top plan view of a component of the preferred embodiments.
FIGS. 7a and 7b are schematic side elevational views of two further preferred embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, there is illustrated therein a first preferred embodiment of the invention incorporated in an otherwise known bale opener which may be a BLENDOMAT BDT model, manufactured by Tretzschler GmbH & Co. KG, Monchengladbach, Federal Republic of Germany. The bale opener removes fiber tufts from the top faces of serially arranged fiber bales 1 as the bale opener travels therealong. The bale opener comprises a carriage 17 which is travelling horizontally back and forth on rails 17a. On the carriage 17 a vertically adjustable opening device is mounted which comprises a housing 2, a suction hood 3, a grate 4 and a rapidly rotating opening roll 5. The bale opener travels back and forth as indicated by arrows A and B.
The opening roll 5 is provided with teeth 5a which are arranged in circumferential series axially spaced from one another. The grate bars of the grate 4 extend in the axial clearance between the tooth series, so that the teeth 5a extend downwardly between the bars of the grate 4 to penetrate into the upper face 1a of the bales. The grate 4 lies on the surface 1a of the fiber bales whereby the latter are being held down and thus stabilized.
In front of and behind the opening roll 5 axially parallel bale pressing rolls 6a, 6b are provided which press down on the surface 1a of the fiber bales 1. In this manner, and by the penetration of the teeth 6' of the pressing rolls 6a and 6b the fiber bales are immobilized and are thus secured against shifting or tipping over as they are exposed to the operating forces of the bale opener. Further, the grate 4 secures the fiber layers of the fiber bales against a horizontal tearing or shifting by forces exerted by the opening roll 5.
The suction hood 3 is situated above the opening roll 5. In operation, the opening device travels with the opening roll 5 above the free-standing fiber bales 1, while the teeth 5a of the opening roll 5 tear fiber tufts from the surface 1a of the fiber bales 1 and throw the fiber tufts directly into the suction air stream 24 travelling in the suction hood 3. The fiber tufts are removed from the bale opener by a suction duct (not shown).
Also referring to FIG. 6, the grate 4 is formed of a plurality of grate bars 4a spaced from one another in a direction transverse to the travelling direction, that is, along the width of the fiber bale series. Each grate bar 4a essentially consists of three parts: first: and second ends 4a' as well as an intermediate mid zone 4a". The first and second ends 4a' of each grate bar are oriented at an oblique angle to the bale surface 1a; the mid zone 4a" of each grate bar is oriented substantially horizontally and lies on the bale surface 1a. The terminus of the first and second ends 4a' is secured to respective holding elements 8a, 8b.
The rotatable pressing rolls 6a, 6b are carried at opposite ends of a switchable, two-armed rocker 9 supported in a bearing 10 which has a shaft 11 attached to the rocker 9 to thus permit swinging motions of the rocker 9 as indicated by arrows E and F. In FIG. 1, the pressing rolls 6a, 6b and the rocker 9 are illustrated in a horizontal orientation at the beginning of a fiber bale opening operation. At this time, the bale surface 1a is essentially horizontal. By rotating the rocker 9 about the shaft 11, a vertical displacement of the pressing rolls 6a, 6b occurs in mutually opposite directions so that the opening roll 5, the pressing rolls 6a, 6b and the grate 4 move along a working plane which is inclined to the horizontal. The grate 4 too, may be arranged for pivotal motion about a horizontal rotary axis which is oriented transversely to the travelling direction of the bale opener.
Also referring to FIG. 3, there is shown therein a bale opener tower 18 mounted on the carriage 17 and a cantilever 19 which contains the opening roll 5 and which may be raised or lowered in a vertical direction relative to the tower 18. Considering FIGS. 1 and 3 together, to the rocker 9, at a distance from the pivot shaft 11, there is attached one end of the piston rod of a pneumatic cylinder 12 which, at its opposite end is secured to an inner wall 2a of the housing accommodating the opening device. The cylinder 12 is connected, through a transducer 13, with a control device 14 which, in turn, is connected to a hoisting motor 15 for the cantilever 19 and the motor 16 for driving the carriage 17. A memory 20 and an inputting device 21 are connected with the control device 14. The memory 20 and the inputting device 21 apply predetermined signals to the control device 14 for the stepwise adjustment of the vertical setting of the bale supporting elements (such as the pressing rolls 6a, 6b) as well as the vertical feed motion of the cantilever 19 by means of the hoisting motor 15 and the travel motion of the carriage 17 by means of the motor 16.
Turning to FIGS. 2a and 2b, to the pressing rolls 6a and 6b there are connected respective pneumatic cylinders 12a and 12b which exert vertical forces to roll supporting bars 12c, 12d in the direction of arrows G, H and I, K, respectively. In FIG. 2a the pressing rolls 6a, 6b are arranged in a horizontal plane a, while in FIG. 2b the pressing roll 6a has been displaced in the direction of the arrow G downwardly such that the lowest point of the pressing roll 6a is at a level below the lowest point of the opening roll 5, whereas simultaneously, the pressing roll 6b has been raised vertically in the direction of the arrow K such that the lowest point of the pressing roll 6b is at a level above the lowest point of the opening roll 5. By such a shift in opposite directions, the pressing rolls 6a, 6b are oriented in an oblique plane b forming an angle α with the horizontal plane a. The opening roll 5 need not be displaced to obtain such an oblique plane. A and B indicate the travelling direction (working direction) of the bale opener.
The opening roll 5 has, on a central core member, a plurality of axially spaced annular toothed discs. The teeth 5a and 5b of consecutive discs are oriented in opposite directions of rotation. By virtue of such an arrangement, the opening process can be performed by a single opening roll 5 in the one and the other working direction A, B to thus remove fiber tufts from the upper bale surface 1a. The grate 4 has a slightly curved mid zone underneath the opening roll 5 making possible a smooth adaptation during transition from the horizontal plane a to the inclined plane b.
As illustrated in FIG. 3, the cantilever 19 is, together with the opening roll 5, horizontally shiftable in the direction of the arrows L and N towards and away from the opener tower 18 by means of a shifting device 25. As an alternative, with a similar, non-illustrated, shifting device mounted on the carriage 17, the tower 18 is, together with the cantilever 19 horizontally shiftable relative to the carriage 17 in the direction of arrows O, P transversely to the direction of travel, as illustrated in FIG. 4. As a further alternative, the rails 17a, 17b may be shiftable in the directions O', P' to effect a horizontal transverse shift of the bale opener. By virtue of the above-described transverse shift of the opening roll 5 after each pass to an extent which is one-half the distance between grate bars, burrows and ridges formed during the opening operation in the fiber bale surface can be compensated for.
Turning to FIG. 5, there are illustrated therein fiber bales 1 positioned on a conveyor belt 26 movable in the direction of the arrows R, S. As the opening operation progresses along an inclined plane, new, full-height fiber bales are added to the series in the direction T in a continuous manner. In the suction hood 3 a routing plate 22 is arranged which is pivotal about a pin 23 and which is switchable from one of its limit positions (solid-line illustration) to the other (dash-dotted position 22a) as the direction of travel is reversed. The grate 4 and/or the opening roll 5 may be shiftable beyond the vertical end faces 1b and 1c of the fiber bale series.
Turning once again to FIG. 6, the adjoining toothed opening discs 5', 5" are shown with right-hand and, respectively left-hand turns; the teeth 5a and 5b in the adjoining respective discs 5' and 5" are oriented in opposite directions of rotation as shown in FIGS. 1, 2a and 2b.
Turning to FIGS. 7a and 7b, the opening roll 5, irrespective of the travelling direction A or B, rotates at all times in the same direction as indicated by the arrow D. The pressing rolls 6a, 6b rotate inthe direction V when the opening device travels in direction A and they rotate in the direction U when the opening device travels in the direction B. The opening roll 5 is, in the travelling direction A (FIG. 7) displaced by means of a non-illustrated setting motor in the direction of the arrow W downwardly so that the distance of the outermost points of the teeth 5a is at a distance x from the lowermost point of the grate 4. According to FIG. 7b, the opening roll 5 is, when travel is in the direction B, moved vertically upwardly as indicated by the arrow Z to change the distance of the points of the teeth 5a from the lowermost point of the grate 4 to the distance y. Distance x being smaller than distance y, the quantity of the removed fiber tufts remains the same in the travelling directions A and B in case all teeth in the opening roll are uniformly oriented, that is, they point in the same direction as the direction of rotation D.
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 bale opener arranged for travel along a series of fiber bales for removing fiber tufts from top surfaces thereof. The bale opener includes a toothed opening roll supported in an orientation transverse to a direction of travel and a grate formed of grate bars spaced in a direction transverse to the direction of travel and arranged for engaging the top surfaces of the fiber bales. The teeth of the opening roll extend between the grate bars for penetrating into the fiber bales during travel. There are further provided bale pressing elements supported by the bale opener on opposite sides of the opening roll spaced therefrom parallel to the direction of travel. The bale pressing elements are arranged to engage and press down the fiber bales during travel of the bale opener. A setting arrangement simultaneously vertically adjusts the bale pressing elements in opposite directions. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrolytic capacitor having a low equivalent series resistance and a low impedance capable of being satisfactorily used at a high frequency range.
2. Description of the Prior Art
The use of an electrolytic capacitor in a filter for a D.C. power supply has often been observed.
A high frequency control system such as a switching type D.C. power supply has been recently used frequently. Particularly, at a low voltage and high power D.C. power supply, an electrolytic capacitor of a high capacitance is required. Since such an electrolytic capacitor uses a long anode foil and a long cathode foil, it exhibits a high inductance at a high frequency and cannot present a sufficient filtering action, and hence the improvement of its characteristic has been strongly desired.
SUMMARY OF THE INVENTION
An electrolytic capacitor capable of being used at the high frequency must have a sufficiently low equivalent series resistance to reduce power loss due to a large ripple current which flows at a low frequency and to suppress heat generation, and at the same time it must have a sufficiently low inductance to assure sufficient filtering action at a high frequency.
An object of the present invention is to provide an electrolytic capacitor which meets the above requirements for use at the high frequency, is a cheap and easy manner.
The present invention is directed to an electrolytic capacitor wherein capacitor elements each comprising an anode foil, a separator and a cathode foil laminated one on the other and wound, are used to eliminate the instability of interelectrode spacing and the inefficiency in operability which have been encountered in a stacked foil type capacitor while maintaining a low equivalent series resistance resulting from the multiplicity of leads which is a merit of the stacked foil type capacitor, four such capacitor elements being used, and is order to enhance ripple performance and improve high frequency characteristic, a pair of lead plates which serve as leads to the anode and cathode, respectively, are arranged to intersect perpendicularly to each other and said four capacitor elements are arranged at the four corners defined by said lead plate pair, the leads of the capacitor elements being connected to said lead plates, and the resultant capacitor elements are then impregnated with electrolyte and sealed in a casing. The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG.1 is a perspective view of one embodiment of an electrolytic capacitor of the present invention.
FIG. 2 is a sectional view thereof.
FIG. 3 is a perspective view of an elementary unit thereof.
FIG. 4 is a top plan view of the elementary unit.
FIG. 5 is a developed view of a capacitor element.
FIG. 6 is a perspective view of the capacitor element.
FIG. 7 is a perspective view showing an assembly of lead plates.
FIGS. 8A to 8C illustrate manufacturing steps of the lead plates.
FIG. 9 is a perspective view of another embodiment.
FIG. 10 is a top plan view thereof.
FIG. 11 is a perspective view of a lead plate used in the capacitor of FIG. 9.
FIG. 12 is a sectional view of other embodiment.
FIG. 13 is a perspective view of lead plates used in the capacitor of FIG. 12.
FIG. 14 is a perspective view of a sealing member for the capacitor of FIG. 12.
FIG. 15 is a perspective view of still other embodiment.
FIG. 16 is a perspective view of lead plates used in the capacitor of FIG. 15.
FIG. 17 is a perspective view of lead plates in other embodiment.
FIG. 18 is a perspective view showing an assembly of the lead plates in the other embodiment.
FIG. 19 is a top plan view thereof.
FIG. 20 is a sectional view showing the mount of capacitor elements.
FIG. 21 is a perspective view showing a combination of lead plates in other embodiment.
FIG. 22 shows a comparison of frequency-impedance characteristic of prior art and present electrolytic capacitors.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment shown in FIGS. 1 through 8 is first explained.
Housed in a casing 1 formed by a metal such as aluminum are four divided capacitor elements 2a, 2b, 2c and 2d, which are mounted at four corners defined by an anode lead plate 3 and a cathode lead plate 4 coupled to intersect perpendicularly to each other. At the tops of the lead plates 3 and 4, a sealing member 5 made of resin is fastened, which is sealingly attached to an opening of the casing 1 via a rubber packing by means of contraction and bending. Those upper portions of the lead plates 3 and 4 which extend above the sealing member 5 are used as external terminals.
The capacitor element 2 comprises, as shown in FIG. 5, an anode foil 8 of aluminum having an anode internal lead 7 attached thereto so that it extends in the direction of width of the anode foil 8, and a cathode foil 10 of aluminum having a cathode internal lead 9 attached thereto in the same way. The anode foil 8 and the cathode foil 10 are stacked on each other with a separator 11 being interposed therebetween, and the lamination are wound to form a wound element as shown in FIG. 6. The anode internal lead 7 and the cathode internal lead 9 extend beyond the opposite ends of the capacitor element 2.
The lead plates 3 and 4 are constructed by plates of aluminum or the like, as shown in FIG. 8. Slits 12 having width wider than thickness of the lead plates 3 and 4 are formed, on the one hand in the lead plate 3 extending from an intermediate point to the bottom end thereof and on the other hand in the lead plate 4 extending from an intermediate point to the top end thereof. Insulating layers 13 are formed on center zones of the lead plates 3 and 4 except in the area of the slit 12, and the lead plates 3 and 4 are assembled to intersect perpendicularly to each other as shown in FIG. 7 by making use of the slits. When the lead plates 3 and 4 are assembled to intersect perpendicularly to each other, they are electrically isolated from each other by virtue of the slits 12 and the insulating layers 13. The insulating layers 13 should be formed at the inner deepest portions of the slits 12 which cross to each other.
By perpendicularly assembling the lead plates 3 and 4 in this manner, four corners are defined, at which the capacitor elements 2a, 2b, 2c and 2d are arranged. The anode internal leads 7 and the cathode internal leads 8 of the capacitor elements 2 are coupled to the lead plates 3 and 4, respectively, by means of welding or caulking using rivets.
In the state of assembling as shown in FIGS. 3 and 4, the capacitor elements 2 are impregnated with electrolyte and the assembly is sealed in the casing 1.
Connecting apertures 14 for external lead wires are formed at the upper ends of the lead plates 3 and 4.
Alternatively, the upper end of the lead plate 3 may be formed with a notch 15 as shown in FIG. 11, and the lead plate is mounted so that the upper end thereof extends above the sealing member 5 and the upper end is bent to present the external terminals as shown in FIGS. 9 and 10.
Referring now to FIGS. 12 to 14, when the sealing member 5 having external terminals 16 inserted therein is used, the notch 15 is formed at the top of the lead plate 3 so that both lead plates 3 and 4 can be divided into two sections at their respective upper ends, and the tops of the lead plates 3 and 4 are bent to form bends 17, to which the external terminals 16 may be electrically and mechanically connected by means of welding or caulking using rivets.
When it is desired to form only two external terminals as shown in FIG. 15, cutouts 18 are formed at portions of upper ends of the lead plates 3 and 4 while the remaining portions thereof extending above the sealing member 5, and the extending portions being thereafter bent to form the external bent terminals. When it is desired to form two terminals on each of the opposite ends of the casing 1, cutouts 18 are formed at upper and lower ends of the lead plates 3 and 4 and the remaining end portions are arranged to extend beyond the opposite ends of the casing.
Furthermore, in order to enhance the insulation at the inner deepest crossing areas of the slits 12 of the lead plates 3 and 4, the slits 12 may be formed longer as shown in FIG. 17 so that a gap having a width a is presented between the end surfaces of the slits 12 when the upper ends of the lead plates are held by the sealing member 5.
Alternatively, as shown in FIGS. 18 through 20, instead of mounting the capacitor elements 2 on the lead plates 3 and 4, the lead plates 3 and 4 may be arranged to intersect perpendicularly to each other only at the upper portions of the capacitor elements 2 or at the area of the sealing member, and any number such as two, three, four, five, six, . . . of the capacitor elements 2 may be connected to the lead plates 3 and 4.
Referring to FIG. 21, the lead plate 4 is provided with a bend 19 at its intermediate area with the bend 19 perpendicular to the lead plate 3 while the other portion of the lead plate 4 is in parallel with the lead plate 3, to allow mounting of two capacitor elements 2. Lugs 20 to which the anode internal leads 7 of the capacitor elements 2 are connected are formed at opposite lower ends of the lead plate 3 while lugs 21 to which the cathode internal lead 9 of the capacitor elements 2 are formed at opposite upper ends of the lead plate 4. In this manner large size of capacitor elements 2 may be used to form a small size electrolytic capacitor and the manufacture of the capacitor elements 2 is facilitated.
A specific example of the present invention is given below.
The anode foil 8 and the cathode foil 10 are made of high purity aluminum, and the anode foil 8 is formed at a predetermined voltage to form an oxide coating thereon in the same manner as in the prior art. The cathode foil 10 may also be subjected to formation to make it non-polarized.
The thickness of the foils is in the order of 0.02 to 0.1 mm. The separator 11 is made of a kraft paper or manila paper of 0.02 to 0.1 mm thickness.
The anode foil 8 is sized to have the width of 82 mm and the length of 500 mm, to which the anode internal lead 7 is attached. On the anode foil 8, two separators 11 in the form of tape having 86 mm width and the cathode foil 10 of 82 mm width and 500 mm length having the cathode internal lead 9 attached thereto are stacked and the resulting lamination is wound to form the capacitor element 2.
Four such capacitor elements 2 are prepared. On the other hand, the lead plates of 40 mm × 140 mm made of high purity aluminum of 15 mm thickness are formed in a manner shown in FIG. 8, which lead plates are then assembled in a manner shown in FIG. 7 and the sealing member 5 is mounted thereon to form an integral unit. The internal leads 7 and 9 of the capacitor elements 2 are welded to the lead plates 3 and 4 to complete the elementary unit shown in FIGS. 3 and 4. A tape or the like is wound thereon to fasten the assembly, which is then impregnated with electrolyte and housed in the casing 1 and the sealing member 5 is sealed thereto via the packing 6 by contracting or bending the casing 1.
In this manner, an electrolytic capacitor of 16 Volts, 60,000 μF was provided.
The below list gives a comparison of the characteristics of the present electrolytic capacitor, a prior art wound electrolytic capacitor and a stacked foil electrolytic capacitor.
______________________________________ Packing Capacitance Loss Index______________________________________Prior Art 60,000 μF 400 Ω μF 1 (Wound type)Prior Art 60,000 μF 200 Ω μF 2.3(Stacked foil type)Present 60,000 μF 200 Ω μF 1.5 invention______________________________________
The frequency-impedance characteristics of those products are shown in FIG. 22, wherein A, B and C represent those for the prior art wound type, the prior art stacked foil type and the present invention, respectively.
With the construction of the electrolytic capacitor of the present invention described above, the capacitor elements are divided into four so that the number of the internal leads can be increased and the heat dissipation can be easily effected, and consequently the capacitor can withstand a large ripple current and can exhibit a low equivalent series resistance. Furthermore, the perpendicular lead plates are effective in reducing the inductance at the high frequency region (several tens of KHz to several MHz), and the lead may extend in one direction by virtue of the lead plates.
Thus, the present capacitor provides sufficient functions in various respects as an electrolytic capacitor used at high frequency, and it has great industrial value. | An electrolytic capacitor comprises a pair of lead plates of electrically conductive metal electrically isolated from each other and arranged to intersect perpendicularly to each other, and a plurality of divided capacitor elements connected to said lead plates to attain a low equivalent series resistance and a high ripple performance, whereby the electrolytic capacitor is adapted to be satisfactorily used at a high frequency range. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to an automatic combinatorial weighing apparatus.
Automatic combinatorial weighing devices operate by supplying articles to be weighed to a plurality of weighing machines, effecting a combinatorial arithmetic operation based on weights detected by the weighing machines, selecting an optimum weight combination with a combined weight equal or closest to a target weight, and discharging the articles from only those weighing machines which give the optimum weight combination, thereby obtaining a group of articles having their combined weight equal or closest to the target weight.
One such automatic combinatorial weighing apparatus will be described with reference to FIG. 21 of the accompanying drawings. The automatic combinatorial weighing apparatus, generally denoted at 1, has a frame 2 and a subframe 3 disposed above the frame 2 and supported thereon by a plurality of legs 2a. A distributing or dispersing table 4 is mounted centrally on the subframe 3 using an electromagnetic three-dimensional vibrator 5. The weighing apparatus 1 includes a plurality (14, for example) of heads comprising respective radial troughs 6 disposed around the distributing table 4 and mounted on the subframe 3 by respective electromagnetic vibrators 7. A plurality of pool hoppers 8 are positioned respectively outside and below the radial troughs 6, and a plurality of weighing hoppers 10 are disposed below the pool hoppers 8, respectively, the weighing hoppers 10 being supported by a plurality of weighing devices 9, respectively. The pool hoppers 8 and the weighing hoppers 10 have respective lids which can be opened and closed by link mechanisms 16 through push rods 14 of opening and closing devices 13 mounted on the lower surface of the subframe 3. The opening and closing devices 13 can be actuated through a gear transmission device 12a by a motor 12 mounted centrally on the lower surface of the subframe 3.
Collection chutes 11 are mounted on the frame 2 below the weighing hoppers 10 for collecting the articles discharged from the weighing hoppers 10 and discharging the collected articles to a packaging device (not shown).
The automatic combinatorial weighing apparatus thus constructed operates as follows: Articles to be weighed are dropped from an article feeder (not shown) onto the distributing table 4 and distributed thereby into the radial troughs 6, from which the articles are supplied to the pool hoppers 8, respectively. The articles are then fed from the pool hoppers 8 into the respective weighing hoppers 10 and weighed therein by the weighing devices 9, respectively. Weight signals from the weighing devices 9 are applied to an arithmetic control unit (not shown), which effects a combinatorial arithmetic operation based on the weight values represented by the applied weight signals. The arithmetic control unit then selects an optimum weight combination with a combined weight equal or closest to a target weight, and controls the opening and closing devices 13 to open the lids of those weighing hoppers 10 which contain the articles giving the optimum weight combination, thereby discharging the articles from the selected weighing hoppers 10. The weighing hoppers 10 from which the articles have been discharged are then supplied with articles from the corresponding pool hoppers 8, which are in turn supplied with articles from the corresponding radial troughs 6.
The arithmetic control unit comprises a microcomputer for effecting the combinatorial arithmetic operations necessary to enable the automatic combinatorial weighing apparatus 1 to weigh articles at high speed.
To assist the automatic combinatorial weighing apparatus 1 in operating at high speed the electronic controls, the pool hoppers 8 and the weighing hoppers 10 are arranged in a circular pattern of a small diameter around the central vertical axis of the apparatus 1, i.e., the apparatus 1 has a reduced diametrical size, so that the aritcles will fall and slide along a short path and at high speed. The vertical dimension of the apparatus 1 is also reduced to shorten the path along which the articles fall through the apparatus 1.
As illustrated in FIG. 21, the pool hoppers 8 and the weighing hoppers 10 are arranged such that the collection chutes 11 for delivering the articles fed from the weighing hoppers 10 through timing hoppers 110 to the packaging process are of the greatest size among other components. Since the hoppers 8 and 10 are circularly arranged, the diameter of the collection chutes 11 can not be reduced beyond a certain limit. In addition, if the collection chutes 11 were excessively reduced in their height, their slide surfaces have too a small gradient and impose a large resistance to the sliding movement of the articles thereon, thus preventing higher-speed operation.
Since the lids of the weighing hoppers 10 are openable outwardly and inwardly as shown in FIG. 21, one of the collection chutes 11 is positioned as an inner collection chute for receiving articles through the inwardly openable lids of the weighing hoppers 10 and the other as an outer collection chute for receiving articles through the outwardly openable lids of the weighing hoppers 10. The lids of the weighing hoppers 10 are opened alternately inwardly and outwardly to supply articles to the double collection chute assembly for higher-speed operation.
One requirement for achieving higher-speed operation and removing obstacles against such higher-speed operation in the double collection chute assembly is that the articles discharged from the weighing hoppers 10 be fed along straight paths of least resistance to their sliding movement in the inner and outer collection chutes.
The inner and outer collection chutes are coaxially arranged and required to have their own outlets or timing hoppers 110. Various improvements have heretofore been made to shorten the path of sliding movement of the articles down the inner and outer collection chutes toward their lower outlets.
There has been developed a double collection chute assembly as shown in FIG. 22 of the accompanying drawings. The double collection chute assembly, generally designated at 11 in FIG. 22, has an inner collection chute 111 in the form of a truncated cone and outer collection chutes 112 each in the form of a substantially semicircular cone, the outer collection chutes 112 being symmetrical with respect to a plane S passing through the center of the inner collection chute 111. The inner collection chute 111 has an outlet 113 offset or displaced from the central axis and connected to inclined off-center discharge chutes 114, 115. The outer collection chutes 112 and the inner collection chute 111 create discharge clearances 116 therebetween, which are connected to outlets 117 joined to a downwardly tapered discharge chute 118 having an outlet 120. The inner collection chute 111 has an outlet 119 which is disposed as closely to the outlet 120 as possible. The shapes, sizes, and positions of the inner and outer collection chutes 111, 112 are substantially similar such that the articles falling down the inner collection chute 111 and discharged into the clearances 116 will slidingly drop as quickly as possible over the shortest distance.
With the double collection chute assembly 11, the articles are theoretically assumed to fall quickly down the inner and outer collection chutes 111, 112 and reach the outlets 119, 120 at the same speed in the same period of time. However, the articles tend to hit each other and be caused to jump and flow in meandering or roundabout paths because the slanted surfaces of the chutes 111, 112 are curved. Particularly, while the articles falling in the clearances 116 drop through the discharge chute 118 beneath the outlets 117 to the outlet 120, the articles are forced to flow in a curved path on the inner side of the discharge chute 118, with the result that the articles are caused to flow around about and are apt to be disturbed just before the outlet 120. Therefore, the articles falling down the discharge chute 118 are more likely to flow down at irregular speeds in uneven times than those falling down the discharge chutes 114, 115 of the inner collection chute 111 in which the articles fall more smoothly.
The outer collection chutes 112 are not symmetrical with respect to a plane P normal to the plane S. Therefore, the articles falling on the opposite sides of the plane P fall in different paths and at different speeds in different time periods.
A number of such combinatorial weighing apparatus 1 are generally employed in a packaging center or the like, where mainly foods are processed by the weighing apparatus 1 and where the building of the packaging center is closed to the exterior. When all of the combinatorial weighing apparatus 1 are operated at the same time, much noise is produced by the vibration of the combinatorial weighing apparatus 1 and noise is also produced in a high-frequency range due to hitting engagement of the articles with panels and plates of the apparatus 1 and the resonating vibration of these panels and plates. The combined noise level is intolerably high in the building and hence the working environment is poor. At times, accurate measurements and communications are hindered by such a high noise level.
More specifically, the articles supplied onto the distributing table 4 of the automatic weighing apparatus 1 are delivered from the radial troughs 6 to the pool hoppers 8 to the weighing hoppers 10 to the collection chutes 11. Since the lids of the hoppers 8, 10 are intermittently opened and closed, the articles are caused to follow stepped, irregular and curved paths such as zigzag paths as the articles are charged and discharged.
Since there are many heads in the combinatorial weighing apparatus 1, the articles are caused to flow through the stepped, irregular and curved paths while the heads are operated in and out of synchronism. Accordingly, a considerably high degree of noise is produced in an area where many combinatorial weighing apparatus 1 are arranged in an array.
The higher the speed of delivery of the articles through the apparatus 1, the larger the noise produced thereby. The noise becomes much larger if the collection chutes are improved for higher speed of flow of the articles through the apparatus 1.
One known approach to solving the noise problem has been to line or coat the surfaces of the pool hoppers 8 hit by the articles as they are disharged radially outwardly from the radial troughs 6 and also to coat surfaces of the lids of the weighing hoppers 10 hit by the articles as they are discharged downwardly obliquely from the pool hoppers 8, with urethane layers or urethane sheets for cushioning the articles to attenuate the noise produced thereby.
However, the sound-insulating materials used in the above arrangement are not sufficiently capable of against insulating noise. To prevent the lining or coating layers from being peeled off when the weighing apparatus 1 are cleaned or operated highly frequently, the lining or coating layers should be of a considerable thickness. These thick layers are practically unacceptable in recent weighing apparatus which are required to be compact and complex in their internal structure. In addition, the cost of attaching the lining or coating layers to the complex structural members is prohibitively high.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an automatic combinatorial weighing apparatus having inner and outer collection chutes disposed in the delivery paths for passage of articles and capable of equalizing the times in which the articles flow down the chutes as much as possible and also of increasing the speeds of flow of the articles down the chutes as much as possible.
Another object of the present invention is to provide an automatic combinatorial weighing apparatus capable of suppressing vibration arising from hitting engagement of articles flowing in delivery paths through the apparatus, thereby reducing noise produced by the apparatus.
According to the present invention, there is provided an automatic combinatorial weighing apparatus including delivery paths for passage of articles to be weighed and a collection chute assembly disposed in and defining the delivery paths. The collection chute assembly includes an inner collection chute in the form of a truncated cone having an outlet, a pair of outer collection chutes disposed outwardly of the inner collection chute and having respective outlets, and plurality of timing hoppers connected to the outlets, respectively, of the inner and outer collection chutes. Also included are a discharge chute having an outlet and coupled to the timing hopper connected to the outlet of the inner collection chute, and a common discharge chute having a single outlet and coupled to the timing hoppers connected to the outlets of the outer collection chutes.
The collection chute assembly also includes a vibration damper having vibration-restriction damping capability and disposed in an area of the delivery paths for damping vibration of the area arising from hitting engagement with the articles.
The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a half of a collection chute assembly;
FIG. 2 is a perspective view of lower inner and outer collection chutes;
FIG. 3 is a plan view of an upper outer collection chute;
FIG. 4 is a plan view of the lower outer collection chute;
FIG. 5 is a plan view of the lower inner collection chute;
FIG. 6 is a plan view of an upper inner collection chute;
FIG. 7 is a side elevational view of the upper outer collection chute;
FIG. 8 is a side elevational view of the lower outer collection chute;
FIG. 9 is a side elevational view of the upper inner collection chute;
FIG. 10 is a side elevational view of the lower inner collection chute;
FIG. 11 is a plan view of a quarter of the collection chute assembly where the chutes are superimposed;
FIG. 12 is a plan view of the quarter of the collection chute assembly;
FIG. 13 is front elevational view of the quarter of the collection chute assembly;
FIG. 14 is a front elevational view of connected timing hoppers of the outer and inner collection chutes;
FIG. 15 is a side elevational view of the connected timing hoppers of the outer and inner collection chutes;
FIG. 16 is a plan view of discharge chutes connected to inner and outer outlets;
FIG. 17 is a front elevational view of the discharge chutes;
FIG. 18 is a side elevational view of a pool hopper employed in an automatic combinatorial weighing apparatus according to the present invention;
FIG. 19 is an enlarged fragmentary cross-sectional view of an encircled area X in FIG. 18;
FIG. 20 is an enlarged fragmentary cross-sectional view of a pool hopper according to another embodiment of the present invention;
FIG. 21 is a side elevational view of a general arrangement of an automatic combinatorial weighing apparatus; and
FIG. 22 is a schematic perspective view of a conventional double collection chute assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 through 17 illustrate a collection chute assembly for use in an automatic combinatorial weighing apparatus according to the present invention.
A collection chute assembly 200 is designed for use in an automatic combinatorial weighing apparatus having 14 heads. The collection chute assembly 200 is composed of an inner collection chute 201 having the shape of a truncated pyramid and an outer collection chute 202 also having the shape of a truncated pyramid, the inner and outer collection chutes 201, 202 being shown in their halves in FIG. 1. The collection chute assembly 200 is therefore shown as having partition sides for 7 heads. The inner collection chute 201 comprises an upper inner collection chute 203, a lower inner collection chute 204, and a discharge chute 205 in the form of a 14-sided tubular prism having an outlet 206. The outer collection chute 202 has a pair of upper outer collection chutes 207 and a pair of lower outer collection chutes 208 having respective square outlets 209. The halves of the outer collection chute 202 and the inner collection chute 201 are joined to each other by upper and lower vertically elongate flat panels or partitions 210, 211 which define a discharge clearance 212 between the inner and outer collection chutes 201, 202.
Articles discharged from the inwardly opened lids of the weighing hoppers 10 (FIG. 21) fall through the upper and lower inner collection chutes 203, 204, the discharge chute 205, and the outlet 206. Articles discharged from the outwardly opened lids of the weighing hoppers 10 fall through the discharge clearance between the inner and outer collection chutes 201, 202, i.e., through the upper and lower outer collection chutes 207, 208, and the square outlets 209. The discharge clearances 212 in the halves of the collection chute 200 are separated from each other by the upper and lower partitions 210, 211. The inner and outer collection chutes 201, 202 are symmetrical with respect to two mutually perpendicular planes extending diametrically across the collection chute assembly 200.
The lower inner collection chute 204 and the upper outer collection chutes 207 are shown in perspective in FIG. 2. The lower inner collection chute 204 and its outlet 213 are axially symmetrical. Although not shown in FIG. 2, the lower outer collection chutes 208 having the outlets 209 are connected to the upper outer collection chutes 207, respectively. The outlet 213 of the lower inner collection chute 204 is connected to the discharge chute 205.
FIGS. 3 and 4 show, in plan, a quarter of one of the upper outer collection chutes 207 and a quarter of one of the lower outer collection chutes 208, respectively. FIGS. 5 and 6 illustrate, in plan, a quarter of the upper inner collection chute 203 and a quarter of the lower inner collection chute 204. FIGS. 7 and 8 show, in side elevation, the quarters of the upper and lower outer collection chutes 207, 208. FIGS. 9 and 10 show, in side elevation, the quarters of the upper inner collection chute 23 and the lower inner collection chute 204.
FIG. 11 shows, in a plan view, the superimposed quarters of the upper and lower outer collection chutes 207, 208 and the upper and lower inner collection chutes 203, 204. FIG. 12 shows the same superimposed chute quarters in side elevation, and FIG. 13 shows the same superimposed chute quarters in front elevation.
Each of the collection chutes 203, 204, 207, 208 comprises a number of flat panels 214 joined through bent edges and lying in different angular planes. The partitions 210, 211 have portions held against the inner and outer collection chutes 201, 202.
As shown in FIGS. 14 and 15, timing hoppers 215 are connected to the outlets 209 of the lower outer collection chutes 208 and the outlet 206 of the discharge chute 205 coupled to the lower inner collection chute 204. The timing hoppers 215 are coupled to mechanisms (not shown) actuated by pneumatic cylinders for opening and closing the timing hoppers 215.
More specifically, one timing hopper 215 is joined to each of the lower outer collection chutes 208, and one timing hopper 215 is connnected to the discharge chute 205, as shown in FIG. 14. Therefore, a pair of timing hoppers 215 is coupled to the outer collection chute 202, whereas one timing hopper 215 is coupled to the inner collection chute 201. In FIGS. 14 and 15, the outer and inner collection chutes 202, 201 have the same paths for flow of articles, or the same article delivery paths, from the weighing hoppers 10 (FIG. 21) down to the lower timing hoppers 215 in areas defined by symmetrical planes which intersect at 90°. The article delivery paths through the inner collection chute 201 are axially symmetrical.
In each of the inner and outer collection chutes 201, 202, the surfaces along which the articles flow are defined by the angularly arranged flat panels 214 from the upper end to the lower end of the article delivery paths for the respective heads of the apparatus. Since the flat panels are joined by bent edges or valleys, the articles flowing down the delivery paths tend to go down the valleys while being forcibly guided thereby through the shortest distance along the delivery paths.
Therefore, the flat panels 214 between the bent edges serve to prevent the articles from flowing in roundabout paths.
As illustrated in FIGS. 16 and 17, a discharge chute 216 connected to the timing hopper 215 of the inner collection chute 201 extends downwardly and is offset or displaced to one side of the plane with respect to which the outer collection chutes 202 are symmetrical, the discharge chute 216 having an outlet 218 connected to a nozzle of a packaging machine (not shown). A common discharge chute 217 connected to the timing hoppers 215 of the outer collection chute 201 extends downwardly and has an outlet 219 offset or displaced to the other side of the symmetry plane, the outlet 219 being connected to another nozzle of the packaging machine. Therefore, the inner outlet 218 and the outer outlet 219 are positioned symmetrically with respect to a point. Each of the discharge chutes 216, 217 is composed of a plurality of angularly joined flat panels.
As shown in FIG. 16, the paths extending from the timing hoppers 215 of the outer collection chute 202 toward the outlet 219 of the discharge chute 217 are slightly differently slanted. However, the lengths of these paths are substantially the same, and these timing hoppers 215 can electrically be controlled for opening timing to discharge the articles from the timing hoppers 215 and pass through the outlet 219 simultaneously. Therefore, there is no time delay in discharging the articles from the outlet 219, and hence the subsequent packaging process is not substantially affected.
The outlet 218 of the discharge chute 216 which is offset from the timing hopper 215 of the inner collection chute 201 is substantially free from any undesirable effects based on that timing hopper 215.
Articles discharged from the upper article feeder are fed by the distributing table 4 (FIG. 21) via the radial troughs 6 and the pool hoppers 8 into the weighing hoppers 10, in which the articles are weighed by the weighing devices 9. Weight signals from the weighing devices 9 are applied to an arithmetic control unit comprising a microcomputer which selects the weighing hoppers 10 that gives a weight combination equal or closest to a target weight. Then, the arithmetic control unit alternately opens the inner and outer lids of the selected weighing hoppers 10 to discharge the articles into the inner and outer collection chutes 201, 202. The articles discharged into the inner collection chute 201 flow uniformly therethrough toward the outlet 206 since the inner collection chute 201 is axially symmetrical. Inasmuch as the flat panels 214 are separated by the edges therebetween, the articles are guided to flow in the shortest delivery paths through the inner collection chute 201 and then discharged from the outlet 206 into the timing hopper 215 at the same timing. As the timing hopper 215 is opened, the articles are delivered through the discharge chute 216 and its outlet 218 into the nozzle of the packaging machine.
When the outer lids of the weighing hoppers 20 are opened, articles are discharged into the clearances 212 between the outer and inner collection chutes 202, 201. The articles are then allowed to flow down the flat panels 214 of the outer collection chutes 202. Since the flat panels 214 are bounded by the edges therebetween, the articles as they flow down the flat panels 214 can be supplied smoothly without going round about and jumping into the lower outer collection chutes 208, from which the articles are supplied through the outlets 209 into the respective timing hoppers 215.
The outer collection chutes 202 are symmetrical with respect to a pair of planes crossing at 90°. The articles as they flow down the outer collection chutes 202 are guided by the edges between the flat panels 214 to flow smoothly without passing through roundabout paths. Consequently, the articles follow the same delivery paths without being disturbed and without jumping and reach the timing hoppers 215 at the same time.
Then, the articles are supplied from the timing hoppers 215 into the common discharge chute 217. Since the delivery paths from the timing hoppers 215 to the outlet 219 are different as shown in FIG. 16, the timing hopper 215 connected to the longer delivery path is controlled to open at a faster timing, and the timing hopper 215 connected to the shorter delivery path is controlled to open at a later timing. The articles supplied from the outer collection chutes 202 into the common discharge chute 217 arrive at the outlet 219 at the same time, and then are discharged therefrom into the nozzle of the packaging machine in which they are packaged.
As seen from above the inner and outer collection chutes 201, 202, the articles flowing therethrough follow straight delivery paths led to the timing hoppers 215.
The present invention is not limited to the illustrated embodiment. The delivery paths in the inner and outer collection chutes may be defined by any shapes which have some kinds of valleys, rather than sharp edges, and which prevent articles from flowing in roundabout paths. The pair of outer collection chutes may be spaced from the inner collection chute by any distance which can appropriately be designed.
FIGS. 18 and 19 illustrate a sound-insulating structure in the automatic combinatorial weighing apparatus. The sound-insulating structure can be employed on any wall surface upon which articles will impinge violently, such as of the pool hoppers 8, the inner collection chute 201, the outer collection chute 202, the lower inner collection chute 204, the lower outer collection chute 208, and the timing hoppers 215. In the illustrated embodiment, the sound-insulating structure is incorporated in each of the pool hoppers 8. As shown in FIG. 18, relatively hard articles Z such as candies or beans drop from the radial trough 6 into the pool hopper 8 along a parabolic path. The articles Z falling off the radial trough 6 would impinge upon an outer panel 81 of the pool hopper 8 and produce noise due to vibration of the outer panel 81. According to the illustrated embodiment, a vibration damper 82 is attached to the inner surface of the outer panel 81.
The vibration damper 82 which is commercially available comprises a base 83 and a viscoelastic member 84 applied as a tape to the base 83 and made of macromolecular material capable converting vibratory energy into thermal energy. The vibration damper 82 is attached to the panel 81 such that the viscoelastic tape 84 is applied by an adhesive to the panel 81 with the base 83 positioned inwardly away from the panel 81. The vibration damper 82 and the panel 81 are then lined with a urethane coating 85 so as to be covered therewith.
The urethane coating 85 extends sufficiently to cover the edges of the base 83 so that the base 83 will be prevented from peeling off at its edges by being hit by the solid articles. The panel 81 serves as a vibration-restricting plate.
Many panels employed in the combinatorial weighing apparatus 1 are made of stainless steel, and their outer surfaces should preferably be shiny and flat from a hygienic design standpoint. Since the vibration damper 82 is mounted on the inner surface of the panel 81, the outer surface thereof remains flat and shiny as it is free from surface irregularities, poor appearance, and color differences which would otherwise result from a urethane coating on the outer panel surface.
The vibration damper 82 prevents articles Z from directly hitting the inner surface of the panel 81. The articles Z are instead caused to hit the urethane coating 85 and then drop into the pool hopper 8. At this time, the base 83 is caused to vibrate and the vibratory energy produced by the base 83 is converted by the viscoelastic tape 84 into thermal energy. Due to this vibration-restricting damper effect, the panel 81, as a vibration-restricting plate is prevented from inducing resonant vibratng and hence from producing noise. The pool hopper 8 therefore operates very quietly.
Even if articles Z are directed to hit an edge of the base 83, the edge covered with the urethane coating 85 is protected against wear and serves to cushion the articles Z, which are therefore protected from damage.
A vibration damper of the same construction may be attached to the inner surface of each of the lids of the weighing hoppers 10 upon which articles from the pool hoppers 8 tend to impinge, or to each of the inner surfaces of the collection chutes against which articles are directed from the weighing hoppers 10, or to the inner surface of each of the radial troughs 6 against which articles from the distributing table 4 are discharged.
It is possible to attach a vibration damper to the outer surface of the panel 81 for the purpose of attenuating noise, and also to a surface on which articles are likely to roll and slide. It is not necessary to apply a urethane coating to such a vibration damper on the outer panel surface which is not exposed to direct external view.
FIG. 20 shows a vibration damper according to another embodiment of the present invention. The vibration damper, generally designated at 821, is assembled as a unit comprising a base 83 in the form of a commercially available vibration damping steel sheet, a vibration-restricting plate 86, and viscoelastic tape 84 interposed therebetween. The vibration damper unit 821 is applied by an adhesive to the inner surface of the panel 81, and the vibration damper unit 821 and the panel 81 are covered with a urethane coating 85. The vibration damper 821 is as advantageous as the vibration damper 82 shown in FIGS. 18 and 19.
Although certain preferred embodiments have been shown and described, it should be understood that many changes and modifications may be made therein without departing from the scope of the appended claims. | An automatic combinatorial weighing apparatus includes a double collection chute assembly disposed in delivery paths for passage of articles to be weighed. The double collection chute assembly includes an inner collection chute having an outlet and a pair of outer collection chutes having respective outlets, the outlets being connected to timing hoppers, respectively. Articles flow down the inner and outer collection chutes at as equal speeds and in as equal times as possible, the speeds being increased as much as possible, due to valleys created by flat plates which form the chutes. To prevent an increase in noise produced by hitting engagement of the articles with the chutes as the articles flow down the chutes at high speeds, a vibration damper having a vibration-restriction damping capability is disposed in an area of the delivery paths for damping the vibration to suppress the noise. | 8 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a device which will help children and others tie their shoelaces properly and/or improve their shoelace tying skills. The device will help shoe wearers become more proficient at tying their shoelace knots securely, particularly but not exclusively using the conventional bow-type knots.
BACKGROUND OF THE INVENTION
[0002] Tying shoelaces is generally a two-step process. First, the laces are tied tightly into a crossover knot that is meant to hold down the tongue of the shoe and hold the laces threaded through the shoe tightly. Second, the shoe wearer will generally form a loop with each lace and tie those loops together on top of the first crossover knot, to make a bow-type knot. There are, of course, other methods known for tying a bow-type knot, but they have at least one thing in common: tying the knot securely is a two-step process. The crossover knot must first be secured, and then the bows for the bow-type knot must be tied together. Certain segments of the population, including young children, the elderly, and individuals with certain disabilities often have problems learning and/or performing these steps satisfactorily.
[0003] A common difficulty encountered by children is that their shoelaces are not tied tightly enough, so they come undone unintentionally. Shoelace knots that are tied too loosely can result in injury. Children's feet can slip out of their shoes because their shoelaces are not tied tight enough, or loose shoelace knots could come completely undone and increase the likelihood that a child will trip over the untied laces.
[0004] The genesis of these problems is oftentimes a crossover knot that is too loose. In the process of tying a shoe, sometimes the crossover knot comes loose or undone while the shoe wearer is trying to complete the second, bow-type knot.
[0005] A class of technology exists which contains devices for securely holding laces already tied in a bow-type knot. These devices secure the finished bow-type knot so that the laces do not come undone until the wearer removes the device—i.e., they are designed to secure a bow-type knot after it is securely tied in the first place. These devices, however, are not designed or concerned with ensuring that the crossover knot is created correctly and tied tightly in the first place. None of the devices known to the applicants assist with tying the first, crucial crossover knot properly, or keeping that knot securely tied until the shoe wearer has successfully made the bows and tied the bow-type knot over the crossover knot.
[0006] Thus, there is a clear need for a device which can assist children and others in tying their shoelace knots properly, so that their shoelaces are tied firmly around their feet and their shoelace knots are tight.
SUMMARY OF THE INVENTION
[0007] The present invention consists of a means for securing the shoelaces in the middle of the tying process. As previously discussed, the process of tying conventional bow-type knots is composed of two steps. The user must first assemble a crossover knot, then the user must form loops from the shoelace ends and tie these loops over the crossover knot to form a bow-type knot. As previously discussed, there are various known methods for completing the second step. The present invention will hold the crossover knot in place while the laces are being manipulated in preparation for and during the tying of the bow-type knot.
[0008] Though the primary objective of the present invention is to aid children in tying shoelaces properly, the device could be used by any person who is having difficulties tying shoelace knots, such as persons with certain disabilities. The use of the term “child” or “children” is not meant to limit the application of the device to certain users. Any mention of children in conjunction with the present invention is only for convenience and clarity, and is meant to serve as a reference for people who may be challenged by tying shoelace knots. In addition, the term “shoe” is meant to include every type of footwear that includes laces which need to be tied. Any mention of the terms “shoe” or “shoes” in conjunction with the present invention is only for convenience and clarity.
[0009] The present invention will assist children by securing the crossover knot in the middle of the tying process, allowing the children to complete tying the second step of the bow-type knot tightly, no matter how long it takes or how much they squirm in their shoes. This will lead to fewer instances of dangerously loose shoelaces or insecure shoelace knots. The shoelace knot assisting device will help children confidently complete the bow-type knot without having to worry about their crossover knot coming loose or undone. The invention is directed towards a method and means to help children and others tie shoelaces properly by securing the shoelaces in the middle of the tying process (i.e., after the crossover knot has been made), which will allow individuals to perform the final steps (creating and tying the bows for the bow-type knot) more easily.
[0010] Thus, it is an object of the present invention to help people tie their shoelace knots properly.
[0011] These and other objects will become apparent to one skilled in the art after review of the following description, figures, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A preferred embodiment of the present invention is illustrated in the accompanying drawings in which:
[0013] FIG. 1 shows the device before it has been attached to a shoe.
[0014] FIG. 2 shows the device attached to the tongue of a shoe before the shoelaces have been tied.
[0015] FIG. 3 shows the device after the crossover knot has been tied.
[0016] FIG. 4 shows the device securing the crossover knot in place so that the bow-type knot can be tied properly.
[0017] FIG. 5 shows the completed bow-type knot with the device in place.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] As required, a detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, systems and operating structures in accordance with the present invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific structural and functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein which define the scope of the present invention. The following presents a detailed description of a preferred embodiment (as well as some alternative embodiments) of the present invention.
[0019] Referring now to the drawings in greater detail, FIG. 1 illustrates the shoelace knot assisting device alone. The device is composed of a first tab 100 and a second tab 110 which both have an outer and inner surface. The two tabs are attached to each other by a cord 120 . The cord could be composed of various materials such as elastic fabrics, rubber materials, leather, canvas, or other textile materials. Elastic and non-elastic materials are both contemplated. Also, tensioning means, such as buckles, could be employed to ensure a secure hold.
[0020] The outer surface 101 of the first tab 100 is secured to the tongue of the shoe. The device of the present invention can be attached to the tongue of the shoe through various means. If the device is sold together with a shoe, then the first tab of the device could be sewn, stapled, or glued directly onto the tongue of the show. If the device is sold separately from a shoe, then there are various methods for attaching the first tab of the device to a shoe tongue after sale. These methods could include adhesive materials (such as cyanoacrylate, methacrylate, epoxy, or acrylic adhesives), a sewing means, or various types of staples, fasteners, clips, clamps, or tying devices. Therefore, tabs could be secured to the tongue permanently (through sewing or other means) or tabs could be less fixably attached so that they can be removed and reattached to the tongue at will.
[0021] The inner surface 102 of the first tab 100 contains an adhesive material or device (such as, for example, a VELCRO®-like hook material) so that it is facing away from the tongue of the shoe. The inner surface 112 of the second tab 110 contains a material or is otherwise designed to receive the adhesive material from the inner surface of the first tab (for example, a VELCRO®-like loop material) so that the inner surfaces of the two tabs fasten securely to each other when brought into contact. Means for securing the two tabs could include buttons, snaps, latches or any other suitable means known in the art of fastening. To increase the appeal of the device to children, a decorative element may be attached to the outer surface 111 of the second tab 110 , facing away from the shoe when the two tabs are connected. The decoration could include almost any design, such as cartoon images, flowers, sports items, stars, animals, words, logos, or a happy face.
[0022] FIG. 2 shows the shoelace knot assisting device attached to the tongue of a shoe before the shoelaces have been tied. The first tab 100 of the device is secured to the shoe tongue so that it cannot be lost even when the shoelaces have been untied. The dotted region 200 illustrates the area hidden from view where a means of securing the outer face of the first tab 100 can be applied to secure the device to the tongue of a shoe. The adhesive material or device is attached to the inner surface 102 of the first tab 100 , so that the adhesive material or device will not come in contact with the shoelaces and damage their fabric. The receiving material or device is attached to the inner surface 112 of the second tab 110 .
[0023] FIG. 3 shows the device in the middle of the shoelace tying process, but before the device has been put to use. The crossover knot 300 (i.e., the first step in tying the completed bow-type knot) has been completed.
[0024] FIG. 4 shows the device as it is about to secure the shoelaces in the middle of the shoelace tying process. The first tab 100 and second tab 110 of the device are about to be connected so that the cord will hold the crossover knot 300 in place. Once the crossover knot has been fastened, the child can concentrate on completing the bow-type knot without worrying about the crossover knot coming undone. If the crossover knot is not loose to begin with, it will be less likely to come undone later.
[0025] The cord 120 of the device is preferably thin enough to allow the bow-type knot to be tied on top of it. Most of the existing shoelace fastening devices of which the applicants are aware are concerned with further securing an already-tied bow-type knot, and they contain elastic bands or strips which are too thick to securely tie a bow-type knot on top of them. Therefore, they cannot be used to secure knots in the middle of the tying process.
[0026] FIG. 5 shows the completed bow-type knot 500 with the shoelace knot assisting device in place. The outer surface 111 of the second tab 110 can contain a decorative element which can accommodate various types of artwork, or may contain no artwork at all. A decorative element may make the device more attractive to children, some of whom might otherwise prefer not to use the device.
[0027] While the present invention has been described with reference to a preferred embodiment (as well as some variants thereof), which have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, such embodiment is merely exemplary and is not intended to be limiting or to represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims as attached or as subsequently amended. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention. | The present invention is a device for assisting users in tying their shoelaces properly. The device will help users tie bow-type knots by securing the initial crossover knot in place while the complete bow-type knot is being tied. The device can be used by children learning how to tie shoelace knots or by any person who is having difficulty tying shoelaces. | 3 |
BACKGROUND OF THE INVENTION
The invention concerns a method for the production of weather- and corrosion-resistant formed metal parts of aluminium or an aluminium alloy with decorative surface.
In the production of decorative formed parts of aluminium such as e.g. trim strips, in a conventional method the parts are first punched out of a strip and formed. The pre-treatment and application of further surface coatings are performed on the already formed parts. This procedure is very costly and associated with complex handling, as the metal parts to be treated in different baths are placed on holders and must often be transferred from one holder to another.
EP-A-1 154 289 discloses a coil coating process for production of reflector plates of aluminium or an aluminium alloy. However, the protective coating on the reflector plates which are produced with this method has a tendency to form cracks when the plates are formed so that the weather- and corrosion-resistance of the formed metal parts is no longer guaranteed.
The invention is based on the object of creating a method for production of formed metal parts of aluminium or an aluminium alloy with decorative surface using a coil coating process with better weather- and corrosion-resistance than known processes.
SUMMARY OF THE INVENTION
The solution according to the invention leads to a method which comprises in succession the following steps:
provision of a strip of aluminium or an aluminium alloy,
where applicable continuous degreasing of the strip,
where applicable electrochemical, chemical or mechanical polishing of the degreased strip,
continuous pre-treatment of the degreased and/or polished strip to produce a pre-treatment coating which is suitable as an adhesion base for a lacquer coating,
continuous lacquering of the pretreated strip with a sol-gel lacquer of polysiloxane to generate a first protective coating,
continuous drying and hardening of the first protective coating in a belt oven,
production of the metal parts by
a. forming the strip with the first protective coating and trimming the metal parts that may be formed further, or
b. cutting the metal parts out of the strip with the first protective coating and forming of the cut metal parts,
lacquering of the formed metal parts with a sol-gel lacquer of a polysiloxane to generate a second protective coating,
drying and hardening of the second protective coating in an oven.
DETAILED DESCRIPTION
The layer thickness of the hardened sol-gel lacquer of the first protective coating is preferably at least 1 μm and preferably between 1 and 1.5 μm, in particular between 1 and 3 μm. If the sol-gel lacquer also contains dye pigments, the layer thickness can be up to 10 μm.
The layer thickness of the hardened sol-gel lacquer of the second protective coating is preferably at least 0.5 μm and preferably between 1 and 3 μm.
Generation of a second protective coating on the surface of the formed metal parts leads to the desired weather- and corrosion-resistance.
The sol-gel lacquer preferably comprises a polysiloxane made from an alcoholic silane solution, preferably an alkoxysilane solution, and a watery colloidal silicic acid solution, and in particular comprises cross-linked inorganic polysiloxanes with organic groups, in particular alkyl groups, bonded to the silicon by way of carbon bonds. Polysiloxane is a term for polymers of cross-linked siloxanes.
The strip material for production of the formed parts can be conventional aluminium with a purity of 98.3% or higher, depending on the requirements imposed on surface quality, e.g. aluminium with a purity of 99.0% and higher, where applicable also with a purity of 99.5%. In particular cases a purity of 99.8% and higher may be indicated. As well as aluminium of the said purities, aluminium alloys can also be used. Preferred alloys are those of series AA 1000, AA 3000 and AA 5000. Further possible alloys contain for example 0.25 to 5 w. %, in particular 0.5 to 4 w. % magnesium, or 0.2 to 2 w. % manganese, or 0.5 to 5 w. % magnesium and 0.2 to 2 w. % manganese, in particular 1 w. % magnesium and 0.5 w. % manganese, or 0.1 to 12 w. %, preferably 0.1 to 5 w. % copper, or 0.5 to 6 w. % zinc and 0.5 to 5 w. % magnesium, or 0.5 to 6 w. % zinc, 0.5 to 5 w. % magnesium and 0.5 to 5 w. % copper, 0.5 to 2 w. % iron and 0.2 to 2 w. % manganese, in particular 1.5 w. % iron and 0.4 w. % manganese, or AlMgSi or AlFeSi alloys. Further examples are AlMgCu alloys, such as AlMg0.8Cu or AlMg alloys such as AlMgl or AlFeMn alloys such as AlFeMn1.5.
The metal parts can be formed for example by bending, deep drawing, cold extrusion or roll forming, but also by other forming methods.
The pre-treatment layer can for example be a coating which is produced by chromatisation, phosphatisation or anodic oxidation. Preferably the pre-treatment layer is made of anodically oxidised aluminium.
The pre-treatment layer can have a thickness of for example at least 10 nm, preferably at least 20 nm, in particular at least 50 nm and advantageously at least 100 nm. The maximum thickness of the pre-treatment layer is for example 5000 nm, preferably 1500 nm and in particular 300 nm.
The pre-treatment layer is preferably an anodically generated oxide layer which is constructed in a non-redissolving or redissolving electrolyte. The pre-treatment layer is preferably a porous anodically generated oxide layer.
Anodisation preferably takes place in an acid electrolyte from the series of phosphoric acid, citric acid, tartaric acid, chromic acid electrolyte and in particular the series of sulphuric acid electrolytes. Anodisation takes place in AC or DC methods.
The pre-treatment layer can also be a yellow chromate coating, a green chromate coating, a phosphate coating or a chromium-free pre-treatment layer which is formed in an electrolyte containing at least one of the elements Ti, Zr, F, Mo or Mn.
Furthermore, the aluminium surface for pre-treatment can be polished in a chemical or electrochemical method or subjected to an alkali pickling process. Such polishing or pickling processes are performed before anodisation.
Before application of the pre-treatment layer or performance of a first pre-treatment step, the strip surface is suitably de-greased and cleaned. Pre-treatment can also comprise solely degreasing and cleaning of the strip surface. The strip surface can be cleaned in a known manner e.g. chemically and/or electrochemically and by acid or alkali. Its purpose is the removal of foreign substances and where applicable the naturally occurring oxide layer on the aluminium surface. Suitable cleaning agents are e.g. acid, watery degreasant, alkali degreasant based on polyphosphate and borate. Cleaning with moderate to severe material removal is achieved by pickling or etching by means of strong alkali or acid pickling solutions, such as e.g. caustic soda lye or a mixture of nitric acid and hydrochloric acid. The existing oxide layer and its contaminants are removed. With highly aggressive alkali pickling, where applicable acid post-treatment may be required.
The strip surface can also be cleaned using known electrochemical, chemical or mechanical polishing methods. The polishing process can also influence the optical appearance of the strip surface on the end product.
As part of the method according to the invention, in a preferred embodiment the pre-treatment layer can for example be applied to the aluminium strip while observing the following process conditions:
a) degreasing at pH 9-9.5 at around 50° C.,
b) rinsing with tap water (room temperature),
c) electrochemical polishing
d) rinsing with tap water (room temperature),
e) anodising in 20% H 2 SO 4 at around 25° C. and 20V voltage,
f) rinsing in tap water at around 50° C. and
g) rinsing in de-ionised water at around 85° C.
The aluminium strip passes continuously through the various treatment baths with a speed for example of 40 m/min.
The protective coating and where applicable further coatings can then be applied to the pre-treatment layer.
The sol-gel lacquer which is applied to the pre-treatment layer is preferably a polysiloxane made from alcoholic silane solution, in particular an alkoxysilane solution, and a colloidal silicic acid solution. The polysiloxane is produced in particular by a condensation reaction between hydrolysed and cross-linked silanes, in particular alkoxysilanes, and colloidal silicic acid.
The condensation reaction between hydrolysed silanes, in particular alkoxysilanes, and between hydrolysed silanes, in particular alkoxysilanes, and colloidal silicic acid, leads to the formation of an inorganic network of polysiloxanes. At the same time, organic groups, in particular alkyl groups or simple alkyl groups, are integrated into the inorganic network by way of carbon bonds. The organic groups or alkyl groups do not however participate directly in the polymerisation or cross-linking of the siloxanes, i.e. they do not serve to form an organic polymer system but merely for functionalisation. The function lies in the fact that the organic groups, in particular the alkyl groups, are attached to the outsides of the polysiloxanes during the sol-gel process and hence form a layer which is water-repellent towards the outside, which gives the sol-gel lacquer a pronounced hydrophobic property.
The sol-gel process described, as stated, leads by targeted hydrolysis and condensation of alkoxides of silicon and silicic acid to a sol-gel lacquer from an inorganic network with integral alkyl groups. The resulting polysiloxanes should therefore rather be allocated to the inorganic polymers.
In the production of a preferred embodiment of a sol-gel lacquer as a protective coating, suitably two base solutions A and B are used.
Solution A is an alcoholic solution of one or more different alkoxysilanes, wherein the alkoxysilanes are present in non-hydrolysed form in a water-free medium. As a suitable solvent an alcohol is used such as for example methyl, ethyl, propyl or butyl alcohol and preferably isopropyl alcohol.
The alkoxysilanes are described by the general formula X n Si(OR) 4-n , in which “R” is a simple alkyl, preferably from the group comprising methyl, ethyl, propyl and butyl. “X” is suitably also an alkyl, preferably from the group comprising methyl, ethyl, propyl and butyl. Suitable alkoxysilanes are for example tetramethoxysilane (TMOS) and preferably tetraethoxysilane (TEOS) and methyltrimethoxysilane (MTMOS) and further alkoxysilanes.
In a particularly preferred embodiment, solution A is prepared from tetraethoxysilane (TEOS) and/or methyltrimethoxysilane (MTMOS) with a methyl, ethyl or propyl alcohol, and in particular with an isopropyl alcohol as solvent. Solution A can e.g. comprise 25-35 w. %, in particular 30 w. % TEOS and 15-25 w. %, in particular 20 w. % MTMOS, both dissolved in 40-60 w. %, in particular 50 w. % isopropyl alcohol.
Solution B contains colloidal silicic acid dissolved in water. In a suitable embodiment solution B is set by means of acid, preferably by means of nitric acid (HNO 3 ) to a pH value between 2.0-4, preferably between 2.5-3.0 and in particular to 2.7.
The silicic acid used is suitably silicic acid which is stabilised in an acid environment, wherein the pH value of the silicic acid is advantageously 2-4. The silicic acid is advantageously as low-alkali as possible. The alkali content (e.g. Na 2 O) of the silicic acid is preferably below 0.04 w. %.
Solution B contains for example 70-80 w. %, in particular 75 w. %, water as solvent and 20-30 w. %, in particular 25 w %, colloidal silicic acid. Solution B is preferably set by nitric acid (HNO 3 ) to a pH value between 2.0-3.5, preferably between 2.5-3.0 and in particular to 2.7. A preferred silicic acid solution is sold for example by the company Nissan Chemical Industries Ltd. under the product name “SNOWTEX® O”.
The merging and mixing of the two base solutions A and B leads, in the presence of nitric acid, to a hydrolysis reaction between the water contained in solution B and the alkoxysilanes contained in solution A.
Hydrolysis reaction: Si(OR) n +nH 2 O→Si(OH) n +nR(OH)
At the same time a condensation reaction occurs in which under water elimination from two Si—OH groups in each case, a siloxane bond (Si—O—Si) is formed. Progressive polymerisation leads to a network of polyoxysilanes on which are attached alkyl groups. The new mixed solution is present in a gel-like state. The two solutions A and B are preferably mixed in a weight ratio of 7:3 parts.
The sol-gel lacquer is suitably applied to the surface of the aluminium strip in gel form and then dried or hardened.
The continuous coating to produce the first protective layer takes place in a coil coating process. A typical coil coating process is a roll application process with two or three rolls.
The drying process comprises expelling the water and alcohols remaining in the sol-gel lacquer, whereby the sol-gel lacquer hardens and a weather-resistant and corrosion-resistant protective coating is produced on the strip surface.
The strip which is coated with the sol-gel lacquer is suitably dried or hardened by means of radiation, such as UV radiation, electron radiation, laser radiation, or by means of thermal radiation such as IR radiation, or by means of convection heating or a combination of the said drying or hardening methods.
The temperature measured on the strip surface for drying or hardening of the sol-gel lacquer is suitably more than 60° C., preferably more than 150° C. and in particular more than 200° C. The increased temperature is furthermore suitably less than 400° C., preferably less than 350° C. and in particular less than 300° C. The temperature particularly preferably lies between 250° C. and 300° C. The temperatures given are so-called “peak metal temperatures” (PMT).
The increased temperature can for example act on the strip for between 5 seconds and 2 minutes. The sol-gel lacquer is dried or hardened for a period of preferably less than 90 seconds, in particular less than 60 seconds, and preferably more than 10 seconds, in particular more than 30 seconds. On use of IR radiation, the drying times lie rather in the lower range of the given durations.
Convection heating can suitably take place by exposure to warmed gases such as air, nitrogen, noble gases or mixtures thereof. The sol-gel lacquer coating is dried in a belt oven.
The strip with the first protective coating is suitably processed further by roll forming, the metal parts are cut off and where applicable subjected to a further forming step. In a variant of the process, first metal parts are cut or punched from the strip with the first protective coating and then the cut metal parts are formed.
The formed metal parts are then lacquered with a sol-gel lacquer of polysiloxane to generate the second protective coating and transferred to an oven to dry and harden the second protective coating. Preferably the second protective coating is also dried or hardened in a belt oven.
The lacquer can be applied in any method. Spray lacquering is preferred.
The drying and hardening of the second protective coating preferably take place under the same process conditions as the drying and hardening of the first protective coating described above.
The formed parts which are produced with the method according to the invention, thanks to the hard protective coating with pronounced adhesion, have a good protective effect against weather influences, corrosion and mechanical abrasion, and are characterised by good UV resistance.
The formed parts which are produced according to the invention, thanks to the sol-gel protective coating of polysiloxanes, have a high surface hardness. The sol-gel protective coating suitably has a hardness, measured on the “Pencil method of Wolf Wilbum” to DIN 55350 Part 18, of greater than “f”, preferably greater than “h”, in particular greater than “2h” and advantageously greater than “3h”, where greater means harder.
The sol-gel layer is characterised also by a pronounced adhesion to the formed metal parts.
With reference to an example, the preparation and production of a particularly preferred embodiment of a sol-gel lacquer is described below. Solution A and solution B are prepared for this.
Solution A contains:
50 w. % isopropyl alcohol 30 w. % tetraethoxysilane (TEOS) 20 w. % methyltrimethoxysilane (MTMOS)
Solution B contains:
75 w. %
water
25 w. %
colloidal silicic acid
The pH value of solution B is set to approx. 2.7 by the addition of an acid, in particular nitric acid (HNO 3 ).
The production of the sol-gel lacquer and the coating of the aluminium strip in a preferred embodiment take place as follows:
A base solution A as described above is mixed in a proportion of 70 w. % of the mixed solution, under agitation, with a solution B in a proportion of 30 w. % of the mixed solution. Solutions A and B are transferred under continuous agitation to a mixed solution, wherein due to reaction heat is released.
The mixed solution is agitated for a particular time, for example 1 h to 10 h, preferably 4 to 8 h, in particular for around 6 h. The mixture is then-filtered. The filter serves to retain larger particles, e.g. particles of colloidal 1 silicic acid. The pore diameter or mesh width of the filter depends on the desired layer thickness, as particles of larger diameter than the targeted layer thickness reduce the surface quality of the protective coating. The filtration can for example take place by means of a polypropylene filter with a porosity of 1 μm.
The mixed solution is suitably set to a pH value of 2-4, preferably 2-3.5, in particular 2.5-3, and particularly preferably 2.7. The pH value is adjusted by means of acid, preferably nitric acid.
After conclusion of the agitation process, the sol-gel lacquer can be applied to the strip surface by means of one of the above-mentioned methods and then, as described initially, dried or hardened.
In an advantageous embodiment of the production method, the sol-gel lacquer, after production and before application to the strip surface, is left to rest for a few minutes to several hours, preferably between 1 and 24 h, in particular between 12 and 22 h and particularly preferably for around 17 h.
The element analysis of the hardened sol-gel lacquer by means of XPS (X-ray Photoelectron Spectroscopy) shows e.g. the elements oxygen, silicon and around 5-20 at. % (atomic percentage) carbon. | A method for producing weather- and corrosion-resistant shaped sheets consisting of aluminum or an aluminum alloy with a decorative finish in a coil coating process that comprises the following sequential steps: an aluminum strip or aluminum alloy strip is provided; optional continuous degreasing of the strip; optional electrochemical, chemical or mechanical burnishing of the optionally degreased strip; the optionally degreased and/or burnished strip is continuously pre-treated to create a pre-treated layer that is suitable for use as an adhesive base for a paint layer; the optionally degreased strip is continuously pre-treated to create a strip surface that is suitable for use as an adhesive base for a paint layer; the pre-treated strip is continuously painted with a sol-gel paint consisting of a polysiloxane to create a first protect protective layer; the first protective layer is continuously dried and cured in a continuous furnace; the sheets are produced by shaping the strip that comprises the first protective layer and cutting the sheets that are optionally to be further shaped, or by cutting the sheets out of the strip that comprises the first protective layer and shaping the cut sheets; the shaped sheets are painted with a sol-gel paint consisting of a polysiloxane to create a second protective layer and the second protective layer is dried and cured in a furnace. The shaped parts that are produced by the method are characterized by excellent weather- corrosion- and abrasion resistance. | 1 |
The invention described herein was made with Government support under grants no. AI-28731 and no. AI-26055 awarded by the National Institutes of Health. The Government has certain rights in this invention.
REFERENCE TO CO-PENDING APPLICATION
This application is a continuation-in-part of U.S. Ser. No. 08/402,730 filed on Mar. 13, 1995, which is a continuation of U.S. Ser. No. 08/092,248 filed on Jul. 15, 1993 (now abandoned), which is a continuation of U.S. Ser. No. 07/736,089 filed on Jul. 26, 1991 (now abandoned), which is a continuation-in-part of U.S. Ser. No. 07/659,760 filed on Feb. 22, 1991 (now U.S. Pat. No. 5,210,085) which is a continuation-in-part of U.S. Ser. No. 07/473,318 filed on Feb. 1, 1990 (now U.S. Pat. No. 5,204,466), the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to the use of and methods and compositions for preparing antiviral nucleoside analogues, particularly FTC (2'-deoxy-5-fluoro-3'-thiacytidine) and prodrug analogues of FTC. More particularly, the invention relates to the β-isomers of these compounds and their selective synthesis and use as antiviral agents.
In 1981, documentation began on the disease that became known as Acquired Immune Deficiency Syndrome (AIDS), as well as its forerunner AIDS Related Complex (ARC). Since that time, the World Health Organization (WHO) has confirmed that 300,000 people have been reported to have developed AIDS. Of these, over 150,000 are in the United States.
In 1983, the cause of the disease AIDS was established as a virus named the human immunodeficiency virus type 1 (HIV-1). As of December, 1990, the WHO estimates that the number of people who are infected with the virus is between 8 and 10 million worldwide and of that number, between 1,000,000 and 1,400,000 are in the U.S. Usually, a person infected with the virus will eventually develop AIDS; in all known cases of AIDS the final outcome has always been death.
The disease AIDS is the end result of HIV infection. The virion replication cycle begins with the virion attaching itself to the host human T-4 lymphocyte immune cell through the bonding of a receptor on the surface of the virion's protective coat (gp 120) with a glycoprotein on the lymphocyte cell (CD4). Once attached, the virion fuses with the cell membrane, penetrates into the host cell, and uncoats its RNA. The virion enzyme, reverse transcriptase, directs the process of transcribing the RNA into single stranded DNA. The viral RNA is degraded and a second DNA strand is created. The now double-stranded DNA is integrated into the T-cell genome.
The host cell uses its own RNA polymerase to transcribe the integrated DNA into viral RNA and the viral RNA directs the production of glycoproteins, structural proteins and vital enzymes for the new virion, which assemble with the viral RNA intact. Once all the components are assembled, the virus buds out of the cell. Thus, the number of HIV-1 virions grows while the number of T-4 lymphocytes declines.
There are at least three critical points in the virion's replication cycle which have been identified as targets for antiviral drugs: (1) the initial attachment of the virion to the T-4 lymphocyte (CD4 glycoprotein), (2) the transcription of vital RNA to vital DNA, and (3) the assemblage of the new virions during replication.
It is the inhibition of the virus at the second critical point, the viral RNA to viral DNA transcription process, that has provided the bulk of the therapies used in treating AIDS. This transcription must occur for the virion to replicate because the virion's genes are encoded in RNA. By introducing drugs that block the enzyme, reverse transcriptase, from transcribing vital RNA to vital DNA successfully, HIV-1 replication can be stopped.
After phosphorylation, nucleoside analogues, such as 3'-azido-3'-deoxythymidine (AZT), 2',3'-dideoxycytidine (DDC), 2',3'-didehydro-3'-deoxythymidine (D4T), 2',3'-dideoxyinosine (DDI), and various 2'-fluoro-derivatives of these nucleosides are relatively effective in halting HIV replication by inhibiting reverse transcription. Another promising anti-AIDS drug is 2'-deoxy-3'-thiacytidine (BCH-189), which contains an oxathiolane ring instead of the sugar moiety in the nucleoside. This invention provides the new antiviral nucleosides, 2'-deoxy-5-fluoro-3'-thiacytidine (FTC) and various prodrug analogues of FTC, which are unexpectedly potent and nontoxic.
AZT is a successful anti-HIV drug because it prevents the nucleotide chain-linking reaction that elongates viral DNA inside the host T-4 lymphocyte cells or other immune system cells such as macrophages. When AZT enters the cell, cellular kinases activate AZT by phosphorylation to AZT triphosphate. AZT triphosphate then competes with natural thymidine nucleotides for the receptor site of HIV reverse transcriptase enzyme. The natural nucleotide possesses two reactive ends, the 5'-triphosphate end which reacts with the growing nucleotide polymer and the 3'-OH group for linking to the next nucleotide. The AZT molecule only contains the first of these. Once associated with the HIV enzyme active site, the AZT azide group terminates viral DNA formation because the azide cannot make the 3',5'-phoaphodiester bond with the ribose moiety of the following nucleoside.
AZT's clinical benefits include increased longevity, reduced frequency and severity of opportunistic infections, and increased peripheral CD4 lymphocyte count. Immunosorbent assays for viral p24, an antigen used to track HIV-1 activity, show a significant decrease with use of AZT. However, AZT's benefits must be weighed against the adverse reactions of bone marrow suppression (neutropenia), nausea, myalgia, insomnia, severe headaches, anemia, and seizures. Furthermore, these adverse side effects occur immediately after treatment begins whereas a minimum of six weeks of therapy is necessary to realize AZT's benefits.
Several other nucleotides inhibit HIV reverse transcription as does AZT triphosphate. Initial tests on 3'-deoxy-3'-fluorothymidine show that its antiviral activity is comparable to that of AZT. DDC and D4T have been tested in vitro against AZT in a delayed drug administration study; both were found to be potent inhibitors of HIV replication with activities comparable (D4T) or superior (DDC) to AZT. Both DDC and D4T are in clinical trials. Although DDC is converted to its 5'-triphosphate less efficiently than its natural analogue, 2'-deoxycytidine, the phosphorylated derivative is resistent to both deaminases and phosphorylases. If dosage and side-effect issues can be resolved, these drugs show potential for becoming effective anti-AIDS drugs.
Currently, DDI is used alone or in conjunction with AZT to treat AIDS. However, DDI's side effects include sporadic pancreatitis and peripheral neuropathy. Owing to its toxicity, reduced doses are necessary and this may limit its usefulness as an antiviral therapeutic treatment. In addition, the drug is susceptible to cleavage under acidic conditions.
Recent cell culture tests on BCH-189 have shown that it possesses anti-HIV activity similar to AZT and DDC, but without as much cellular toxicity. However, BCH-189, like DDC, is toxic at a concentration of ≦10 μM in intact CEM cells as measured by cell growth and by determining the extent of mitochondrial DNA synthesis, thus suggesting that one of the side effects of BCH-189 might be clinical peripheral neuropathy. Furthermore, although BCH-189 is less toxic to bone-marrow cells than AZT, another side effect of BCH-189, like AZT, might be anemia. Thus, there is a need for superior therapeutic agents such as FTC and FTC prodrug analogues that are provided herein. These agents combine high antiviral activity with minimum toxicity for use as inhibitors of replication and infectivity of HIV in vivo.
The commonly-used chemical approaches for synthesizing nucleosides or nucleoside analogues can be classified into two broad categories: (1) those which modify intact nucleosides by altering the carbohydrate, the base, or both and (2) those which modify carbohydrates and incorporate the base, or its synthetic precursor, at a suitable stage in the synthesis. Because FTC substitutes a sulfur for a carbon atom in the carbohydrate ring, only the second approach is applicable. The most important factor in this latter strategy involves delivering the base from the β-face of the carbohydrate ring in the glycosylation reaction because only the β-isomers exhibit useful biological activity.
It is well known in the art that the stereoselective introduction of bases to the anomeric centers of carbohydrates can be controlled by capitalizing oh the neighboring group participation of a 2-substituent on the carbohydrate ring Chem. Ber. 114:1234 (1981)!. However, FTC and its analogues do not possess an exocyclic 2-substituent and, therefore, cannot utilize this procedure unless additional steps to introduce a functional group that is both directing and disposable are incorporated into the synthesis. These added steps would lower the overall efficiency of the synthesis.
It is also well known in the art that "considerable amounts of the undesired α-nucleosides are always formed during the synthesis of 2'-deoxyribosides" Chem. Ber. 114:1234, 1244 (1981)!. Furthermore,. this reference teaches that the use of simple Friedel-Crafts catalysts like SnCl 4 in nucleoside syntheses produces undesirable emulsions upon the workup of the reaction mixture, generates complex mixtures of the α and β-isomers, and leads to stable σ-complexes between the SnCl 4 and the more basic silyated heterocycles such as silyated cytosine. These complexes lead to longer reaction times, lower yields, and production of the undesired unnatural N-3-nucleosides. Thus, the prior art teaches the use of trimethysilyl trillate or trimethylsilyl perchlorate as a catalyst during the coupling of pyrimidine bases with a Carbohydrate ring to achieve the highest yields of the biologically active β-isomers. However, the use of these catalysts to synthesize FTC or FTC analogues exhibit little preference for the desired β-isomer; these reactions typically result in mixtures containing nearly equal amounts of both isomers. Thus, there exists a need for an efficient synthetic route to FTC and FTC prodrug analogues.
SUMMARY OF THE INVENTION
The present invention relates to the discovery of a surprisingly efficient synthetic route to 2'-deoxy-5-fluoro-3'-thiacytidine (FTC) and various FTC prodrug analogues from inexpensive precursors with the option of introducing functionality as needed. This synthetic route allows the stereoselective preparation of the biologically active β isomer of these compounds. This invention further relates to the discovery that FTC and FTC prodrug analogues possess surprisingly superior HIV inhibition and cell toxicity effects compared to BCH-189 and other analogues of BCH-189, including other 5-halo derivatives of BCH-189, or other 5-fluoro substituted nucleoside analogues such as 2'-deoxy-5-fluoro-3'-oxacytidine (FDOC). Thus, this invention provides for the therapeutic use of these compounds and pharmaceutical formulations containing these compounds as antiviral agents.
As used herein, the term "FTC prodrug analogue" refers to a 5'-oxyacyl or H substituted and/or 4-N alkyl, substituted alkyl, cycloalkyl or acyl substituted 2'-deoxy-5-fluoro-3'-thiacytidine that metabolizes to the same active component or components as FTC. The term "BCH-189 analogues" is meant to refer to nucleosides that are formed from pyrimidine bases substituted at the 5 position that are coupled to substituted 1,3-oxathiolanes.
The synthesis of the present invention includes ozonizing either an allyl ether or ester having the formula CH 2 ═CH--CH 2 --OR or a diether or diester of 2-butene-1,3-diol having the formula ROCH 2 --CH═CH--CH 2 OR, in which R is a protecting group, such as an alkyl, silyl, or acyl group, to form a glycoaldehyde having the formula OHC--CH 2 --OR; adding thioglycolic acid to the glycoaldehyde to form a lactone of the formula 2-(R-oxy)-methyl-5-oxo-1,3-oxathiolane; reducing the lactone to various compounds containing a leaving group at the 5 position of the oxathiolane ring; coupling these compounds with a silyated pyrimidine base fluoro-substituted at the 5 position of the base in the presence of SnCl 4 to form the β-isomer of a 2'-deoxy-5-fluoro-5'-(R-oxy)-3'-thia-nucleiside analogue; and replacing the R protecting group with a hydrogen or acyl to form FTC or a prodrug analogue of FTC.
Accordingly, one of the objectives of this invention is to provide the antiviral nucleoside β-2'-deoxy-5-fluoro-3'-thiacytidine (FTC), prodrug analoques of FTC that are 5'-oxyacyl substituted and pharmaceutically acceptable formulations containing these compounds. Furthermore, it is an object of this invention to provide an efficient and direct method for preparing the β-isomer of FTC and prodrug analogues of FTC in high yields. In addition, this invention provides for the use of these compounds, or pharmaceutically acceptable formulations containing these compounds, as effective and nontoxic antiviral agents.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates one embodiment of a synthesis of FTC and FTC prodrug analogues according to the present invention;
FIG. 2 illustrates one embodiment of the synthesis of BCH-189 according to the present invention;
FIG. 3 illustrates one embodiment of the synthesis of 5-methylcytidine and thymidine derivatives of BCH-189 according to the present invention;
FIG. 4 illustrates one embodiment of the synthesis of BCH-189 and BCH-189 analogues according to the present invention;
FIG. 5 illustrates one embodiment of the synthesis of FDOC, DOC and DOT according to the present invention;
FIG. 6 illustrates the effect of delayed treatment on the anti-HIV-1 activity of AZT, FTC and other nucleoside analogues in PBM cells;
FIG. 7 illustrates the effect of FTC, BCH-189, DDC and AZT on colony formation of granulocyte-macrophage precursor cells; and
FIG. 8 illustrates the effect of FTC, AZT and BCH-189 on AZT-resistant and AZT-sensitive HIV-1 in human PBM cellS.
DETAILED DESCRIPTION OF THE INVENTION
A. Synthesis of FTC or FTC Prodrug Analogues
FTC is a compound of the formula: ##STR1##
FDOC is a compound of the formula: ##STR2##
Because only the β-isomers of these nucleoside analogues generally exhibit useful biological activity, the synthesis for β-FTC is provided for by the instant invention, using a stereoselective base coupling reaction that is operative through "in situ" complexation of a suitable cyclic precursor and Lewis acid. The crucial step in the stereoselectivity of the FTC synthesis is the coupling of a 2-(R-oxy)-methyl-5-carboxy-1,3-oxathiolane with a silylated pyrimidine base at ambient temperature using the Lewis acid, SnCl 4 . Deprotection of the silyl group gives the free nucleoside β-FTC, or its analogues. The initial NMR stereochemical assignments have been reconfirmed by X-ray structures, both confirming the β selectivity. Correspondingly, the crucial step in the stereoselectivity of the FDOC synthesis is the coupling of a 2-(R-oxy)-methyl-4-carboxy-1,3-dioxolane with a silylated pyrimidine base at ambient temperature using the Lewis acid, TiCl 4 .
Other data regarding these coupling reactions also indicate a metal dependent selectivity. Use of TiCl 4 rather than SnCl 4 in the FTC synthesis, or SnCl 4 rather than TiCl 4 in the FDOC synthesis, results in a loss in stereoselectivity caused by a Lewis acid-heteroatom mismatch. Furthermore, reactions employing trimethysilyl triflate in both syntheses result in non-stereoselective reactions as well.
All of the above results can be rationalized through a heteroatom-Lewis acid interaction. Upon exposure of the carboxylate to the Lewis acid and silylated base, an intermediate oxonium ion is formed. In the presence of a complexing Lewis acid, an intermediate could be formed in which the metal would complex to the heteroatom in the ring; one of it's ligands, such as chloride or acetate, would be associated with a carbon bearing a partial positive charge. The result of this complexation would be blockage of the α-face opposite to the bulky (t-butyldiphenyl)hydroxymethyl substituent and β attack of the silylated base. Use of trimethysilyl trillate or a non-interacting Lewis acid would generate an oxonium ion that has no facial bias.
A process of the present invention for preparing FTC and FTC prodrug analogues is set forth in FIG. 1. An allyl ether or ester 1 is ozonized to give an aldehyde 2, which reacts with thioglycolic acid to give a lactone 3. The lactone 3 is treated with a reducing agent, followed by a carboxylic anhydride, to produce the carboxylate 4. This carboxylate is coupled with a silylated 5-fluoro substituted pyrimidine base in the presence of a Lewis acid that can catalyze stereoselective coupling, such as SnCl 4 , to yield the β-isomer of the substituted nucleoside 5 in essentially a 100:0 ratio of β:α isomers. The substituted nucleoside 5 is deprotected to produce FTC 6 or modified at the 5'-position to form a FTC prodrug analogue.
The process for preparing FDOC is set forth in FIG. 5. Glycolic acid reacts with glycoaldehyde 9 to form the lactone 28, which is reduced to form the carboxylate 29. 29 is coupled with a silylated 5-fluoro substituted pyrimidine base in the presence of a Lewis acid that can catalyze stereoselective coupling, such as TiCl 4 , TiCl 3 (OiPr) or TiCl 2 (OiPr) 2 , to yield the β-isomer of the substituted nucleoside 36. The substituted nucleoside 36 is deprotected to produce FDOC 37.
The protecting group R in 1 can be selected to provide protection for the corresponding alcohol until the final step in the synthesis is carried out (deprotection of 5 to form 6). Any group that functions in this manner may be used. For instance, alkyl, silyl, and acyl protecting groups or groups that possess substantially the same properties as these groups can be used.
An alkyl protecting group, as used herein, means triphenylmethyl or an alkyl group that possesses substantially the same protecting properties as triphenylmethyl. A silyl protecting group, as used herein, means a trialkylsilyl group having the formula: ##STR3## wherein R 1 , R 2 , and R 3 may be lower-alkyl, e.g., methyl, ethyl, butyl, and alkyl possessing 5 carbon atoms or less; or phenyl. Furthermore, R 1 may be identical to R 2 ; R 1 , R 2 , and R 3 may all be identical. Examples of silyl protecting groups include, but are not limited to, trimethylsilyl and t-butyldiphenylsilyl.
An acyl group, as used herein to describe an acyl protecting group (as in 1) or to describe a carboxylate (as in 4), is a group having the formula: ##STR4## wherein R' is a lower alkyl, e.g., methyl, ethyl, butyl, and alkyl possessing 5 carbon atoms or less; substituted lower alkyl wherein the alkyl bears one, two, or more simple substituents, including, but not limited to, alkyl, amino, carboxyl, pavoloyl, hydroxy, phenyl, lower-alkoxy, e.g., methoxy and ethoxy; phenyl; substituted phenyl wherein the phenyl bears one, two, or more simple substituents, including, but not limited to, lower alkyl, halo, e.g., chloro and bromo, sulfato, sulfonyloxy, carboxyl, carbo-lower-alkoxy, e.g., carbomethoxy and carbethoxy, amino, mono- and di-lower alkylamino, e.g., methylamino, amido, hydroxy, lower alkoxy, e.g., methoxy and ethoxy, lower-alkanoyloxy, e.g., acetoxy.
A 5-fluoro substituted silyated pyrimidine base, as used herein, means a compound having the formula: ##STR5## wherein X is either a trialkylsilyloxy or a trialkylsilylamino group and Z is a trialkylsilyl group. A trialkylsilyl group, as used herein, means a group having the formula: ##STR6## wherein R 1 , R 2 , and R 3 may be lower-alkyl, e.g., methyl, ethyl, butyl, and alkyl possessing 5 carbon atoms or less, or phenyl. Furthermore, R 1 may be identical to R 2 ; R 1 , R 2 , and R 3 may all be identical. Examples of trialkylsilyl groups include, but are not limited to, trimethylsilyl and t-butyldiphenylsilyl.
As used herein, a leaving group means a functional group that forms an incipient carbocation when it leaves.
Illustrative examples of the synthesis of FTC or FTC prodrug analogues, BCH-189 or BCH-189 analogues and FDOC according to the present invention are given in FIGS. 1-5 and Examples 1-6.
EXAMPLE 1--SYNTHESIS OF BCH-189
FIG. 2 shows the synthesis of BCH-189 starting with allyl alcohol 7. A NaH oil suspension (4.5 g, 60%, 110 mmol) was washed with THF twice (100 ml×2) and the resulting solid suspended in THF (300 ml). The suspension was cooled to 0° C., allyl alcohol 7 (6.8 ml, 100 mmol) was added dropwise, and the mixture was stirred for 30 minutes at 0° C. t-Butyl-diphenylsilyl chloride (25.8 ml, 100.8 mmol) was added dropwise at 0° C. and the reaction mixture was stirred for 1 hour at 0° C. The solution was quenched with water (100 ml), and extracted with diethyl ether (200 ml×2). The combined extracts were washed with water, dried over MgSO 4 , filtered, concentrated, and the residue distilled under vacuum (90°-100° C. at 0.5-0.6 mm Hg) to give a colorless liquid 8 (28 g., 94 mmol, 94%). ( 1 H NMR: (CDCl 3 , 300 MHz) 7.70-7.35 (10H, m, aromatic-H); 5.93 (1H, m, H 2 ); 5.37 (1H, dt, H 1 ) J=1.4 and 14.4 Hz; 5.07 (1H, dt, H1) J=1.4 and 8.7 Hz; 4.21 (2H, m, H 3 ); 1.07 (9H, s, t-Bu))
The silyl allyl ether 8 (15.5 g, 52.3 mmol) was dissolved in CH 2 Cl 2 (400 ml), and ozonized at -78° C. Upon completion of ozonolysis, DMS (15 ml, 204 mmol, 3.9 eq) was added at -78° C. and the mixture was warmed to room temperature and stirred overnight. The solution was washed with water (100 ml×2), dried over MgSO 4 , filtered, concentrated, and distilled under vacuum (100°-110° C. at 0.5-0.6 mm Hg) to give a colorless liquid 9 (15.0 g, 50.3 mmol, 96%). (1H NMR: (CDCl 3 , 300 MHz) 9.74 (1H, s, H--CO); 7.70-7.35 (10H, m, aromatic-H); 4.21 (2H, s, --CH 2 ); 1.22 (9H, s, t-Bu))
Silylated glycoaldehyde 9 (15.0 g, 50.3 mmol) was dissolved in toluene (200 ml) and thioglycolic acid (3.50 ml, 50.3 mmol) was added all at once. The solution was refluxed for 2 hours while the resulting water was removed with a Dean-Stark trap. The solution was cooled to room temperature and washed with saturated NaHCO 3 solution and the aqueous washings were extracted with diethyl ether (200 ml×2). The combined extracts were washed with water (100 ml×2), dried over MgSO 4 , filtered, and concentrated to give a colorless oil 10 (16.5 g, 44.3 mmol, 88%), which gradually solidified under vacuum. Recrystallization from hexane afforded a white solid 10 (15.8 g, 84%). ( 1 H NMR: 7.72-7.38 (10H, m, aromatic-H); 5.53 (1H, t, H 2 ) J=2.7 Hz; 3.93 (1H, dd, --CH 2 O) J=9.3 Hz; 3.81 (1H, d, 1H 4 ) J=13.8 Hz; 3.79 (1H, dd, --CH 2 O); 3.58 (1H, d, 1H 4 ); 1.02 (9H, s, t-Bu))
2-(t-Butyl-diphenylsilyloxy)-methyl-5-oxo-1,2-oxathiolane 10 (5.0 g, 13.42 mmol) was dissolved in toluene (150 ml) and the solution was cooled to -78° C. Dibal-H solution (14 ml, 1.0M in hexanes, 14 mmol) was added dropwise, while the inside temperature was kept below -70° C. all the time. After the completion of the addition, the mixture was stirred for 30 minutes at -78° C. Acetic anhydride (5 ml, 53 mmol) was added and the mixture was warmed to room temperature and stirred overnight. Water (5 ml) was added to the mixture and the resulting mixture was stirred for 1 hour at room temperature. The mixture was diluted with diethyl ether (300 ml), MgSO 4 (40 g) was added, and the mixture was stirred vigorously for 1 hour at room temperature. The mixture was filtered, concentrated, and the residue flash chromatographed with 20% EtOAc in hexanes to give a colorless liquid 11 (3.60 g, 8.64 mmol, 64%), which was a 6:1 mixture of anomers. ( 1 H NMR of the major isomer: 7.70-7.35 (10H, m, aromatic-H); 6.63 (1H, d, H 5 ) J=4.4 Hz; 5.47 (1H, t, H 2 ); 4.20-3.60 (2H, m, --CH 2 O); 3.27 (1H, dd, 1H 4 ) J=4.4 and 11.4 Hz; 3.09 (1H, d, 1H 4 ) J=11.4 Hz; 2.02 (3H, s, CH 3 CO); 1.05 (9H, s, t-Bu); 1 H NMR of the minor isomer: 7.70-7.35 (10H, m, aromatic-H); 6.55 (1H, d, H 5 ) J=3.9 Hz; 5.45 (1H, t, H 2 ); 4.20-3.60 (2H, m, --CH 2 O); 3.25 (1H, dd, 1H 4 ) J=3.9 and 11.4 Hz; 3.11 (1H, d, 1H 4 ) J=11.4 Hz; 2.04 (3H, s, CH 3 CO); 1.04 (9H, s, t-Bu))
Alternatively, 50 g (0.134 mol, 1.0 eq) of 2-(t-Butyl-diphenylsilyloxy)-methyl-5-oxo-1,2-oxathiolane 10 in 500 ml of anhydrous tetrahydrofuran was transferred into a flame-dried, argon-charged 3,000 ml three-necked round-bottomed flask, equipped with an addition funnel and thermometer. The clear solution was cooled to -10 ° C. (ice/acetone bath) and treated with 147 ml (0.147 mol, 1.1 equiv) of a 1M solution of lithium tri-t-butoxy aluminum hydride in THF (prepared solution of the solid obtained from Aldrich). The reaction was qualitatively monitored for the disappearance of the lactone (R f =0.38) and the appearance of a second UV-active component at R f =0.09 (SiO 2 , eluting with 90% hexanes in ethyl acetate). In addition, the reaction was quantitatively monitored by GC. The lactol formed was allowed to react at room temperature with 126 ml (1.34 mol, 10.0 equiv) of acetic anhydride (freshly distilled from calcium hydride). The reaction was monitored by the appearance of UV-active component at R f =0.34 (SiO 2 , eluting with 90% hexanes in ethyl acetate) and GC until no lactol was detected. The reaction was quenched with saturated sodium bicarbonate solution and stirred overnight. Anhydrous magnesium sulfate was added and the resulting mixture filtered, concentrated and placed under vacuum to give 49.3 g of crude material 11 as a light red oil.
2-(t-Butyl-diphenylsilyloxy)-methyl-5-acetoxy-1,3-oxathiolane 11 (0.28 g, 0.67 mmol) was dissolved in 1,2-dichloroethane (20 ml), and silylated cytosine 12 (0.20 g, 0.78 mmol) was added at once at room temperature. The mixture was stirred for 10 minutes and to it was added SnCl 4 solution (0.80 ml, 1.0M solution in CH 2 Cl 2 , 0.80 mmol) dropwise at room temperature. Additional cytosine 12 (0.10 g, 0.39 mmol) and SnCl 4 solution (0.60 ml) were added in a same manner 1 hour later. After completion of the reaction in 2 hours, the solution was concentrated, and the residue was triturated with triethylamine (2 ml) and subjected to flash chromatography (first with neat EtOAc and then 20% ethanol in EtOAc) to give a tan solid 13 (100% β configuration) (0.25 g, 0.54 mmol, 80%). ( 1 H NMR (DMSO-d 6 ): 7.75 (1H, d, H 6 ) J=7.5 Hz; 7.65-7.35 (10H, m, aromatic-H); 7.21 and 7.14 (2H, broad, --NH 2 ); 6.19 (1H, t, H 5' ); 5.57 (1H, d, H 5 ); 5.25 (1H, t, H 2' ); 3.97 (1H, dd, --CH 2 O) J=3.9 and 11.1 Hz; 3.87 (1H, dd, --CH 2 O); 3.41 (1H, dd, 1H 4' ) J=4.5 and 11.7 Hz; 3.03 (1H, dd, 1H 4' ) J=?; 0.97 (9H, s, t-Bu))
Silyether 13 (0.23 g, 0.49 mmol) was dissolved in THF (30 ml), and to it was added n-Bu 4 NF solution (0.50 ml, 1.0M solution in THF, 0.50 mmol) dropwise at room temperature. The mixture was stirred for 1 hour and concentrated under vacuum. The residue was taken up with ethanol/triethylamine (2 ml/1 ml), and subjected to flash chromatography (first with EtOAc, then 20% ethanol in EtOAc) to afford a white solid 14 in 100% anomeric purity (BCH-189; 0.11 g, 0.48 mmol, 98%), which was further recrystallized from ethanol/CHCl 3 /Hexanes mixture. ( 1 H NMR (DMSO-d 6 ): 7.91 (1H, d, H 6 ) J=7.6 Hz; 7.76 and 7.45 (2H, broad, --NH 2 ); 6.19 (1H, t, H 5' ); 5.80 (1H, d, H 5 ) J=7.6 Hz; 5.34 (1H, broad, --OH); 5.17 (1H, t, H 2' ); 3.74 (2H, m, --CH 2 O); 3.42 (1H, dd, 1H 4' ) J=5.6 and 11.5 Hz; 3.09 (1H, dd, 1H 4' ) J=4.5 and 11.5 Hz)
EXAMPLE 2--SYNTHESIS OF BCH-189 FROM A URACIL DERIVATIVE
BCH-189 and its analogues can also be synthesized by coupling a silylated uracil derivative with 11. Silylated uracil derivative 15 (1.80 g, 7.02 mmol) was coupled with 11 (1.72 g, 4.13 mmol) in 1,2-dichloroethane (50 ml) in the presence of SnCl 4 (5.0 ml) as described above in the preparation of the cytosine derivative 13. The reaction was complete after 5 hours. Flash chromatography, first with 40% EtOAc in hexane and then EtOAc, afforded a white foam 16 (1.60 g, 3.43 mmol, 83%). ( 1 H NMR: 9.39 (1H, broad, --NH) 7.90 (1H, d, H 6 ) J=7.9 Hz; 7.75-7.35 (10H, m, aromatic-H); 6.33 (1H, dd, H 5' ); 5.51 (1H, d, H 5 ) J=7.9 Hz; 5.23 (1H, t, H 2' ); 4.11 (1H, dd, --CH 2 O) J=3.2 and 11.7 Hz; 3.93 (1H, dd, --CH 2 O); 3.48 (1H, dd, 1H 4' ) J=5.4 and 12.2 Hz; 3.13 (1H, dd, 1H 4' ) J=3.2 and 12.2 Hz)
The uracil derivative 16 can be converted to the cytosine derivative 13. The uracil derivative 16 (0.20 g, 0.43 mmol) was dissolved in a mixture of pyridine/dichloroethane (2 ml/10 ml), and the solution cooled to 0° C. Triflic anhydride (72 μl, 0.43 mmol) was added dropwise at 0° C. and the mixture was warmed to room temperature and stirred for 1 hour. Additional triflic anhydride (0.50 μl, 0.30 mmol) was added and the mixture stirred for 1 hour. TLC showed no mobility with EtOAc. The reaction mixture was then decannulated into a NH 3 -saturated methanol solution (30 ml) and the mixture was stirred for 12 hours at room temperature. The solution was concentrated, and the residue subjected to flash chromatography to give a tanned foam13 (0.18 g, 0.39 mmol, 91%), which was identical with the compound obtained from the cytosine coupling reaction.
EXAMPLE 3--SYNTHESIS OF 5-METHYLCYTIDINE AND THYMIDINE BCH-189 DERIVATIVES
FIG. 3 illustrates the synthesis of 5-methylcytidine and thymidine derivatives of BCH-189. The acetate 11 (0.93 g, 2.23 mmol) in 1,2-dichloroethane (50 ml), was reacted with the silylated thymine derivative 17 (1.0 g, 3.70 mmol), and SnCl 4 solution (4.0 ml) in a manner similar to that described for the preparation of cytosine derivative 13. ( 1 H NMR: 8.10 (1H, broad, NH); 7.75-7.30 (11H, m, 10 Aromatic H's and 1H 6 ); 6.32 (1H, t, H 1' ) J=5.4 Hz; 5.25 (1H, t, H 4' ) J=4.2 Hz; 4.01 (1H, dd, 1H 5' ) J=3.9 and 11.4 Hz; 3.93 (1H, dd, 1H 5' ) J=4.5 and 11.4 Hz; 3.41 (1H, dd, 1H 2' ) J=5.4 and 11.7 Hz; 3.04 (1H, dd, 1H 2' ) J=5.7 and 11.7 Hz; 1.75 (3H, s, CH 3 ); 1.07 (9H, s, t-Bu)).
The thymine derivative 18 (0.20 g, 0.42 mmol) was dissolved in a mixture of pyridine/dichloroethane (2 ml/10 ml), and the solution cooled to 0° C. To it was added triflic anhydride (100 μl, 0.60 mmol) dropwise at 0° C., and the mixture was allowed, with continuous stirring, to warm to room temperature. After reaching room temperature, it was stirred for 1 hour. TLC showed no mobility with EtOAc. The reaction mixture was then decannulated into the NH 3 -saturated methanol solution (20 ml), and the mixture stirred for 12 hours at room temperature. The solution was concentrated, and the residue was subjected to flash chromatography to give a tanned foam 19 (0.18 g, 0.38 mmol, 90%). ( 1 H NMR: 7.70-7.30 (12H, m, 10 Aromatic H's, 1NH and H 6 ); 6.60 (1H, broad, 1NH); 6.34 (1H, t, H 1' ) J=4.5 Hz; 5.25 (1H, t, H 4' ) J=3.6 Hz; 4.08 (1H, dd, 1H 5' ) J=3.6 and 11.4 Hz; 3.96 (1H, dd, 1H 5' ) J=3.6 and 11.4 Hz; 3.52 (1H, dd, 1H 2' ) J=5.4 and 12.3 Hz; 3.09 (1H, dd, 1H 2' ) J=3.9 and 12.3 Hz; 1.72 (3H, s, CH 3 ); 1.07 (9H, s, t-Bu))
Silylether 19 (0.18 g, 0.38 mmol) was dissolved in THF (20 ml), and an n-Bu 4 NF solution (0.50 ml, 1.0M solution in THF, 0.50 mmol) was added, dropwise, at room temperature. The mixture was stirred for 1 hour and concentrated under vacuum. The residue was taken up with ethanol/triethylamine (2 ml/1 ml), and subjected to flash chromatography (first with EtOAc, then 20% ethanol in EtOAc) to afford a white solid20 (0.09 g, 0.37 mmol, 97%), which was further recrystallized from ethanol/CHCl 3 /Hexanes mixture to afford 82 mg of pure compound (89%). ( 1 H NMR: (in d 6 -DMSO): 7.70 (1H, s, H 6 ); 7.48 and 7.10 (2H, broad, NH 2 ); 6.19 (1H, t, H 1' ) J=6.5 Hz; 5.31 (1H, t, OH); 5.16 (1H, t, 1H 4' ) J=5.4 Hz; 3.72 (2H, m, 2H 5' ) 3.36 (1H, dd, 1H 2' ) J=6.5 and 14.0 Hz; 3.05 (1H, dd, 1H 2' ) J=6.5 and 14.0 Hz; 1.85 (3H, s, CH 3 ))
Silylether 18 (0.70 g, 1.46 mmol) was dissolved in THF (50 ml), and an n-Bu 4 NF solution (2 ml, 1.0M solution in THF, 2 mmol) was added, dropwise, at room temperature. The mixture was stirred for 1 hour and concentrated under vacuum. The residue was taken up with ethanol/triethylamine (2 ml/1 ml), and subjected to flash chromatography to afford a white solid 21 (0.33 g, 1.35 mmol, 92%). ( 1 HNMR: (in d 6 -Acetone): 9.98 (1H, broad, NH); 7.76 (1H, d, H 6 ) J=1.2 Hz; 6.25 (1H, t, H 4' ) J=5.7 Hz; 5.24 (1H, t, H 1' ) J=4.2 Hz; 4.39 (1H, t, OH) J=5.7 Hz; 3.85 (1H, dd, 2H 5' ) J=4.2 and 5.7 Hz; 3.41 (1H, dd, 1H 2' ) J=5.7 and 12.0 Hz; 3.19 (1H, dd, 1H 2' ) J=5.4 and 12.0 Hz; 1.80 (3H, s, CH 3 ))
EXAMPLE 4--SYNTHESIS OF FTC
Acetate 11 (1.70 g, 4.08 mmol) was dissolved in dichloromethane (100 ml). Silylated 5-fluorocytosine (1.22 g, 4.5 mmol) was mixed with tin (IV) chloride solution (8.6 ml, 1.0M in dichloromethane, 8.6 mmol) in dichloromethane (20 ml). The pre-mixed solution was decannulated in the acetate solution over 20 minutes. The mixture was stirred for 3 hours at room temperature, then pyridine (3 ml) was added to the mixture in one portion. The mixture was concentrated under vacuum, and the residue taken up with ethanol (10 ml) and subjected to flash chromatography to give a tan solid (1.80 g, 3.71 mmol, 91%), which was further recrystallized from ethanol to give a total of 1.75 g of a crystalline compound (5'-O-t-Butyldiphenysilyl-3'-thia-2',3'-dideoxy-5-fluorocytidine, 100% β configuration). ( 1 H NMR: (DMSO-d 6 ) 7.96 (1H, d, H 6 , J=6.8 Hz), 7.87 & 7.61 (2H, broad, NH 2 ), 7.64 & 7.43 (10H, m, Aromatic H's), 6.19 (1H, t, H 1' , J=5.4 Hz), 5.28 (1H, t, H 4' , J=4.0 Hz), 4.01 (H, dd, 1H 5' , J=3.6 & 11.5 Hz), 3.90 (1H, dd, 1H 5' , J=4.3 & 11.5 Hz), 3.45 (1H, dd, 1H 2' , J=5.4 & 11.5 Hz), 3.16 (1H, dd, 1H 2' , J=5.4 & 11.5 Hz); mp 214°-215° C.; Anal. Calc. for C 24 H 28 O 3 N 3 FSSi: C, 59.36; H, 5.81; N, 5.81; N, 8.65; S, 6.60. Found: C, 59.44; H, 8.60; S, 6.64.
The silylether (5'-O-t-Butyldiphenysilyl-3'-thia-2',3'-dideoxy-5-fluorocytidine, 100% β configuration) (1.12 g, 2.31 mmol) was dissolved in THF (80 ml), and to it was added n-Bu 4 NF solution (2.50 ml, 1.0M solution in THF, 2.50 mmol) dropwise at room temperature. The mixture was stirred for 0.5 hours and concentrated under vacuum. The residue was taken up with EtOH/pyridine (3 ml/1 ml), and subjected to flash chromatography to afford a white solid (0.75 g), which was further recrystallized from EtOH to give a total of 0.56 g of the crystalline compound 2'-Deoxy-5-fluoro-3'-thiacytidine (FTC; 100% β isomer; 2.26 mmol; 98%). ( 1 H NMR: (DMSO-d 6 ) 8.18 (1H, d, H 6 , J=8.4 Hz), 7.81 & 7.57 (2H, broad, NH 2 ), 6.12 (1H, dd, H 1' , J=5.7 & 4.2 Hz), 5.40 (1H, t, OH, J=5.7 Hz), 5.17 (1H, t, H 4' , J=3.6 Hz), 3.74 (2H, m, 2H 5' ), 3.41 (1H, dd, 1H 2' , J=5.7 & 11.7 Hz), 3.11 (1H, dd, 1H 2' , J=4.2 & 11.7 Hz); 13 C NMR: (DMSO-d 6 ) 157.85 (d, J=13.4 Hz), 153.28, 136.12 (d, J=241 Hz), 126.01 (d, J=32.6 Hz), 86.90, 86.84, 62.48, 37.07; mp 195°-196° C.; Anal. Calc. for C 8 H 10 O 3 N 3 SF: C, 38.86; H, 4.08; N, 17.00; S, 12.97. Found: C, 38.97; H, 4.07; N, 16.93; S, 12.89.)
EXPERIMENT 5--SYNTHESIS OF 5-HALO DERIVATIVES OF β-BCH-189
The coupling of the acetate 11 with various bases was done as shown in FIG. 4. This coupling could be done, in general, in two ways to obtain the cytidine analogues, either by direct coupling of the acetate with a corresponding bis-silylated cytosines in the presence of tin(IV) chloride or by ammonolysis of the triflate derived from the corresponding uridine analogues. The typical experimental procedure is outlined below.
The acetate 25 (0.28 g, 0.67 mmol) was dissolved in 1,2-dichloroethane (20 ml), and to it the silylated cytosine (0.20 g, 0.78 mmol) was added in one portion at room temperature. The mixture was stirred for 10 minutes and to it a SnCl 4 solution (1.34 ml, 1.0M solution in CH 2 Cl 2 , 1.34 mmol) was added, dropwise, at room temperature. Upon completion, the solution was concentrated, the residue was triturated with Et 3 N (2 ml) and subjected to flash chromatography to give a tan solid 26 (0.25 g, 0.54 mmol, 80%).
Silylether 26 (0.23 g, 0.49 mmol) was dissolved in THF (30 ml), and an n-Bu 4 NF solution (0.50 ml, 1.0M solution in THF, 0.50 mmol) was added, dropwise, at room temperature. The mixture was stirred for 1 hour and concentrated under vacuum. The residue was taken up with EtOH/Et 3 N (2 ml/1 ml), and subjected to flash chromatography to afford a white solid 27 (100% β isomer; 0.11 g, 0.48 mmol, 98%), which was further recrystallized from EtOH/CHCl 3 /Hexanes mixture.
The procedure for coupling a silylated uracil with acetate 25 is as follows: The acetate 25 (1.72 g, 4.13 mmol), in 1,2-dichloroethane (50 ml), was reacted with the silylated uracil derivative (1.80 g, 7.02 mmol) and SnCl 4 solution (5.0 ml) for 5 hours to complete the reaction. Flash chromatography with 40% EtOAc in hexane and then EtOAc afforded a white foam 26 (1.60 g, 3.43 mmol, 83%).
The uracil derivative 26 (0.20 g, 0.43 mmol) was dissolved in a mixture of pyridine/dichloroethane (2 ml/10 ml), and the solution cooled to 0° C. To the solution was added Tf 2 O (72 μl, 0.43 mmol) dropwise at 0° C. and the mixture was allowed, with continuous stirring, to warm to room temperature. After reaching room temperature, it was stirred for 1 hour. Additional Tf 2 O (0.50 μl, 0.30 mmol) was added and the mixture was stirred for 1 hour. TLC showed no mobility with EtOAc. The reaction mixture was then decannulated into the NH 3 -saturated methanol solution (30 ml), and the mixture stirred for 12 hours at room temperature. The solution was concentrated and the residue was subjected to flash chromatography to give a tanned foam 27 (100% β isomer; 0.18 g, 0.39 mmol, 91%), which was identical with the compound obtained from the cytosine coupling reaction.
The compounds synthesized include:
2'-Deoxy-5-methyl-3'-thiacytidine:
1 H NMR (DMSO-d 6 ) 7.70 (1H, s, H 6 ), 7.48 and 7.10 (2H, broad, NH 2 ), 6.19 (1H, t, H 1' , J=5.4 Hz), 5.31 (1H, t, OH, J=4.5 Hz), 5.16 (1H, t, H 4' , J=4.5 Hz), 3.72 (2H, m, 2H 5' ), 3.36 (1H, dd, 1H 2' , J=5.4 & 11.7 Hz), 3.05 (1H, dd, 1H 2' , J=5.4 & 11.7 Hz), 1.85 (3H, d, CH 3 , J allylic =0.6 Hz); mp 183°-185° C.
2'-Deoxy-5-fluoro-3'-thiacytidine:
1 H NMR (DMSO-d 6 ) 8.18 (1H, d, H 6 , J=8.4 Hz), 7.81 & 7.57 (2H, broad, NH 2 ), 6.12 (1H, dd, H 1' , J=5.7 & 4.2 Hz), 5.40 (1H, t, OH, J=5.7 Hz), 5.17 (1H, t, H 4' , J=3.6 Hz), 3.74 (2H, m, 2H 5' ), 3.41 (1H, dd, 1H 2' , J=5.7 & 11.7 Hz), 3.11 (1H, dd, 1H 2' , J=4.2 & 11.7 Hz); mp 195°-196° C.; Anal. Calc. for C 8 H 10 O 3 N 3 SF: C, 38.86; H, 4.08; N, 17.00; S, 12.97. Found: C, 38.97; H, 4.07; N, 16.93; S, 12.89.
2'-Deoxy-5-chloro-3'-thiacytidine:
1 H NMR (DMSO-d 6 ) 8.30 (1H, s, H 6 ), 7.89 & 7.26 (2H, broad, NH 2 ), 6.13 (1H, t, H 1' , J=4.5 Hz), 5.45 (1H, t, OH, J=5.7 Hz), 5.19 (1H, t, H 4' , J=3.6 Hz), 3.76 (2H, m, 2H 5' ), 3.44 (1H, dd, 1H 2' , J=5.4 & 12.0 Hz), 3.16 (1H, dd, H 2' , J=3.9 & 12.0 Hz); mp 212°-212.5° C.; Anal. Calc. for C 8 H 10 O 3 N 3 SCl: C, 36.44; H, 3.82; N, 15.93; S, 12.16; Cl, 13.44. Found: C, 36.53; H, 3.86; N, 15.90; S, 12.08; Cl, 13.50.
2'-Deoxy-5-bromo-3'-thiacytidine:
1 H NMR (DMSO-d 6 ) 8.37 (1H, s, H 6 ), 7.90 & 7.05 (2H, broad, NH 2 ), 6.14 (1H, t, H 1' , J=4.5 Hz), 5.46 (1H, t, OH, J=5.4 Hz), 5.19 (1H, t, H 4' , J=3.6 Hz), 3.76 (2H, m, 2H 5' ), 3.41 (1H, dd, 1H 2' , J=5.4 & 12.0 Hz), 3.16 (1H, dd, 1H 2' , J=3.6 & 12.0 Hz); mp 197°-198° C.; Anal. Calc. for C 8 H 10 O 3 N 3 SBr: C, 331.18; H, 3.27; N, 13.64; S, 10.40; Br, 25.93. Found: C, 31.29; H, 3.29; N, 13.54; S, 10.49; Br, 25.98.
2'-Deoxy-5-iodo-3'-thiacytidine:
1 H NMR (DMSO-d 6 ) 8.36 (1H, s, H 6 ), 7.87 & 6.66 (2H, broad, NH 2 ), 6.13 (1H, t, H 1' , J=4.5 Hz), 5.44 (1H, t, OH, J=5.7 Hz), 5.18 (1H, t, H 4' , J=3.6 Hz), 3.73 (2H, m, 2H 5' ), 3.42 (1H, dd, 1H 2' , J=5.7 & 12.0 Hz), 3.14 (1H, dd, 1H 2' , J=3.6 & 12.0 Hz); mp 188°-189° C.
2'-Deoxy-5-fluoro-3'-thiauridine:
1 H NMR (DMSO -d 6 ) 11.89 (1H, broad, NH), 8.33 (1H, d, H 6 , J=7.5 Hz), 6.15 (1H, t, H 1' , J=3.9 Hz), 5.44 (1H, t, OH, J=5.7 Hz), 5.19 (1H, t, H 4' , J=3.6 Hz), 3.75 (2H, m, 2H 5' ), 3.43 (1H, dd, 1H 2' , J=5.7 & 12.0 Hz), 3.25 (1H, dd, 1H 2' , J=4.2 & 12.0 Hz); mp 158°-159° C.; Anal. Calc. for C 8 H 9 O 4 N 2 SF: C 38.71; H, 3.65; N, 11.29; S, 12.92. Found: C, 38.79; H, 3.68; N, 11.23; S, 12.82.
2'-Deoxy-5-chloro-3'-thiauridine:
1 H NMR (DMSO-d 6 ) 11.95 (1H, broad, NH), 8.11 (1H, s, H 6 ), 6.18 (1H, t, H 1' , J=4.8 Hz), 5.38 (1H, t, OH, J=3.6 Hz), 4.47 (1H, dd, 1H 5' , J=4.5 & 12.3 Hz), 4.37 (1H, dd, 1H 5' , J=3.0 & 12.3 Hz), 3.49 (1H, dd, 1H 2' , J=5.4 & 12.0 Hz), 3.38 (1H, dd, 1H 2' , J=4.2 & 12.0 Hz).
2'-Deoxy-5-iodo-3'-thiauridine:
1 H NMR (DMSO-d 6 ) 11.73 (1H, broad, NH), 8.48 (1H, s, H 6 ), 6.15 (1H, dd, H 1' , J=4.0 & 5.0 Hz), 5.46 (1H, t, OH, J=5.4 Hz), 5.19 (1H, t, H 4' , J=3.6 Hz), 3.76 (2H, m, 2H 5' ), 3.44 (1H, dd, 1H 2' , J=5.4 & 12.0 Hz), 3.30 (1H, dd, 1H 2' , J=4.7 & 12.0 Hz); mp 177°-179° C.
EXAMPLE 5--SYNTHESIS OF DOC, DOT, and FDOC
FIG. 5 shows the synthesis of 2'-deoxy-3'-oxacytidine (DOC), 2'-deoxy-3'-oxathymidine (DOT), and 2'-deoxy-5-fluoro-3'-oxacytidine (FDOC) according to the present invention. The silyated glycoaldehyde 9 was prepared as in Example 1. (4.0 g, 13.40 mmol) of 9 was dissolved in 1,2-dichloroethane (50 ml) and to it was added glycolic acid (1.10 g, 14.46 mmol) in one portion and p-toluenesulfonic acid (0.1 g). The mixture was refluxed for 1 hour. The volume of the solution was then reduced to about half by distilling off the solvent with a Dean-Stark trap. Another 50 ml of dichloroethane was added and the solution refluxed for 30 minutes again. The solution was cooled to room temperature and concentrated under vacuum. The residue was dissolved in ether (200 ml) and the solution washed with NaHCO 3 solution (50 ml) and water (50 ml). The combined extracts were dried over MgSO 4 , filtered, and concentrated to give a colorless oil which gradually solidified under vacuum. Recrystallization from hexane afforded a was white solid 28 (2-(t-Butyl-diphenylsilyloxy)-methyl-4-oxo-1,3-dioxolane) (4.2 g, 11.78 mmol, 88%). ( 1 H NMR: (CDCl 3 , 300 MHz) 7.66 & 7.42 (10H, m, aromatic-H), 5.72 (1H, broad, H 2 ), 4.46 (1H, d, 1H 5 , J=14.4 Hz), 4.28 (1H, d, 1H 5 , J=14.4 Hz), 3.81 (2H, d, 2CH 2 O, J=1.8 Hz), 1.04 (9H, s, t-Bu); mp 94°-95° C.; MS (FAB) 357 (M+H), 299, 241, 197, 163, 135, 91; Anal. Calc'd for C 20 H 24 O 4 Si: C, 67.38; H, 6.79; Found: C, 67.32; H, 6.77.)
4-Acetoxy-2-(t-Butyldiphenylsilyloxymethyl)-1,3-dioxolane 29 was prepared using either of the following procedures A or B.
Procedure A: (DIBAL-H) The lactone 28 (1.0 g, 2.81 mmol) was dissolved in toluene (100 ml), and the solution cooled to -78° C. Dibal-H solution (3.0 ml, 1.0M in hexanes, 3 mmol) was added dropwise, while the inside temperature was kept below -70° C. throughout the addition. After the addition was completed, the mixture was stirred for 0.5 hours at -78° C. To it was added Ac 2 O (5 ml, 53 mmol) and the mixture, with continuous stirring, was allowed to reach room temperature overnight. Water (5 ml) was added to it and the mixture was stirred for 1 h, MgSO 4 (40 g) was then added, and the mixture was stirred vigorously for 1 hour at room temperature. The mixture was filtered, concentrated, and the residue flash chromatographed with 20% EtOAc in hexanes to give a colorless liquid 29 (0.70 g) which was a mixture of the desired acetates and the aldehyde 9 derived from the ring opening reaction.
Procedure B: (LiAlH(OtBu) 3 ) Lactone 28 (1.426 g, 4 mmol) was dissolved in 20 ml of THF, cooled to 0° C., and to this was added 5 ml (5 mmol, 1.25 eq) of a LiAlH(OtBu) 3 solution (1M in THF; Aldrich) over a 40 minute period. After addition was completed, the mixture was stirred for 6 hours at 0° C. After this time, 3.8 ml (40 mmol, 10 eq) of dry acetic anhydride was added, and the mixture was warmed to room temperature. The reaction was then stirred for another 40 hours and then was quenched by adding 50 ml of ether and 50 ml of saturated NaHCO 3 solution. The layers were separated after 2 hours of stirring, and the organic layer was washed successively with saturated NaHCO 3 and NaCl solutions. The aqueous layers were combined and then re-extracted with 75 ml of ether (3 times). The organic layers were combined, dried over MgSO 4 , filtered, and the solvent was removed. Column chromatography (Hexanes/EtOAc, 6/1) gave 1.09 g, which was 69% (753 mg, 47% yield) of the desired acetates 29 (3.6:1 ratio at the glycosidic center) by 1 H NMR analysis (the rest of the mixture was composed of the aldehyde 9 and the lactone 28, which were difficult to separate).
( 1 H NMR: (CDCl 3 , 300 MHz) 1.02 (s, 9H, major isomer), 1.04 (s, 9H, minor isomer), 1.96 (s, 3H, minor), 2.12 (s, 3H, major), 3.7 (m, 2H), 4.07 (m, 2H), 5.24 (t, 1H, minor, J=4.2 Hz), 5.37 (t, 1H, major, J=3 Hz), 6.3 (t, 1H, minor, J=3.9 Hz), 6.37 (dd, 1H, major, J=1.5 Hz, J=4.5 Hz), 7.39 (m, 6H), 7.67 (m, 4H). IR (neat): cm -1 3090, 2980, 2880, 1760, 1475, 1435, 1375, 1240, 1120, 1000. MS (FAB. Li 30 ): 407(M+Li), 312, 282, 241, 197, 162, 125. Anal. Calc. for C 22 H 28 O 5 Si: C, 65.97%, H, 7.05%; Found: C, 66.60%, H, 7.27%.)
The crude acetate 29 (0.25 g, 0.62 mmol, quantity assumed with 0.50 g of the previous mixture) was dissolved in methylene chloride (50 ml), and to it the silylated cytosine 30 (X═H) (0.10 g, 0.63 mmol) was added in one portion. The mixture was stirred for 10 minutes, and to it a TiCl 4 solution (1.30 ml, 1.0M solution in CH 2 Cl 2 , 1.30 mmol) was added, dropwise, at room temperature. It took 2 hours to complete the reaction. Upon completion, the solution was concentrated, the residue was triturated with pyridine (2 ml) and subjected to flash chromatography (first with neat EtOAc then 20% EtOH in EtOAc) to give a tan solid, which was further recrystallized to give a white crystalline solid 32 (0.25 g, 0.55 mmol, 89%). ( 1 H NMR (CDCl 3 , 300 MHz) 7.97 (1H, d, H 6 , J=7.8 Hz), 7.67 & 7.40 (10H, m, aromatic-H), 6.24 (1H, d, H 1' ), 5.62 (1H, d, H 5 , J=7.6 Hz), 5.03 (1H, t, H 4' ), 4.20 (1H, dd, 1H 2' , J=1.2 and 9.0 Hz), 4.15 (1H, dd, 1H 2' , J=4.8 & 9.0 Hz), 3.96 (1H, dd, 1H 5' , J=2.1 and 8.7 Hz), 3.93 (1H, dd, 1H 5' , J=2.1 and 8.7 Hz), 1.08 (9H, s, t-Bu).)
Silylether 32 (0.12 g, 0.27 mmol) was dissolved in THF (20 ml), and an n-Bu 4 NF solution (0.30 ml, 1.0M solution in THF, 0.30 mmol) was added, dropwise, at room temperature. The mixture was stirred for 1 hour and concentrated under vacuum. The residue was taken up with EtOH/pyridine (2 ml/1 ml), and subjected to flash chromatography (first with EtOAc, then 20% EtOH in EtOAc) to afford a white solid, which was further recrystallized from EtOH to give a white crystalline solid 33 (DOC) (55 mg, 0.26 mmol, 96%). ( 1 H NMR: (DMSO-d 6 , 300 MHz) 7.79 (1H, d, H 6 , J=7.5 Hz), 7.18 and 7.11 (2H, broad, NH 2 ), 6.16 (1H, dd, H 1' , J=3.0 & 4.2 Hz), 5.70 (1H, d, H 5 , J=7.5 Hz), 5.16 (1H, t, OH, J=6.0 Hz), 4.91 (1H, t, H 4' , J=2.7 Hz), 4.05 (2H, m, H 2' ), 3.62 (2H, m, 2H 5' ); mp 183°-184° C.)
The coupling reaction of acetate 29 with silylated thymine 31 showed a titanium species dependent selectivity in accordance with the following observations (ratios were determined by 1 H NMR of the crude reaction mixtures):
______________________________________Titanium Species β:α Ratio______________________________________TiCl.sub.4 7:1TiCl.sub.3 (OiPr) 10:1TiCl.sub.2 (OiPr).sub.2 >98:2______________________________________
In the coupling reaction using TiCl 3 (OiPr), the impure acetate 29 from the procedure B reduction above (assumed 69% of the mixture, 185.4 mg, 0.4653 mmol) was dissolved in 8 ml of dry dichloromethane along with 144 mg (1.15 eq) of silylated thymine 31, and this mixture was stirred under argon at room temperature. Next 0.57 ml (1.15 eq) of a freshly prepared solution of TiCl 3 (OiPr) in dichloromethane (1M solution prepared from 2 eq of TiCl 4 and 1 eq of TiCl(OiPr) 3 ) was added dropwise over a 25 minute period. After 2.5 hours, 0.07 ml (0.15 eq) of a TiCl 4 /dichloromethane solution (1M, Aldrich) was added and the reaction was stirred for an additional hour. Then 3 ml of ethanol and 5 ml of NaHCO 3 solution were added, stirred for 10 minutes, followed by extraction with additional NaHCO 3 solution. The aqueous layer was separated, washed twice with 100 ml of dichloromethane, and the organic layers were combined and dried over MgSO 4 . Filtration, solvent removal, column chromatography (1/2: Hexanes/EtOAc), and then recrystallization (1/1: Hexanes/Et 2 O) gave 160 mg (74%) of compound 34 as a white powder. ( 1 H NMR: (CDCl 3 , 300 MHz) 1.06 (s, 9H), 1.68 (s, 3H), 3.91 (t, 2H, J=3.3 Hz), 4.14 (d, 2H, J=3.9 Hz), 5.06 (t, 1H, J=3.3 Hz), 6.34 (t, 1H, J=3.9 Hz), 7.4 (m, 6H), 7.7 (m, 4H), 8.62 (bs, 1H). MS (FAB, Li + ): 473 (M+Li), 409, 307, 241, 197, 154, 127. Anal. Calc. for C 25 H 30 O 5 N 2 Si: C, 64.35%; H, 6.48%; N, 6.00%; Found: C, 64.42%; H, 6.52%; N, 5.97%.)
In the coupling reaction using TiCl 2 (OiPr) 2 , impure acetate from the procedure B reduction (assumed 50% of the mixture, 444 mg, 1.11 mmol) was dissolved in 18 ml of dry dichloromethane along with 654.1 mg of silylated thymine 31 and stirred at room temperature under argon. Next, 1.3 ml of a 2M TiCl 2 (OiPr) 2 /CH 2 Cl 2 solution was added over a 20 minute period. After 14 h, 1 ml of a 1M TiCl 4 /CH 2 Cl 2 solution was added and the reaction was stirred for an additional 3 hours. Then 4 ml of concentrated NH 4 OH was added, along with 10 ml of dichloromethane. Ten minutes of stirring followed by filtration over 1 inch of silica gel with EtOAc, solvent removal and then column chromatography of the resulting oil gave 164.9 mg (32%) of compound 34.
The silyl ether 34 (60.9 mg, 0.131 mmol) was dissolved in 2 ml of THF and 0.14 ml of a Bu 4 NF/THF solution (1M, Aldrich) was added. After stirring for 24 hours, the solvent was removed envaccuo and column chromatography (5/1: EtOAc/EtOH) of the resulting oil gave 22.6 mg (76%) of the desired nucleoside 35 (DOT) as a white powder. ( 1 H NMR: (HOD (4.8 ppm), 300 MHz) 1.83 (s, 3H), 3.82 (m, 2H), 4.18 (dd, 1H, J=10.5 Hz, J=6 Hz), 5.06 (s, 1H), 6.33 (d, 1H, J=5.7 Hz), 7.72 (s, 1H).)
The impure acetate 29 from the procedure B reduction above (assumed 80% by 1 H NMR analysis, 117.6 mg, 0.294 mmol) and 120.8 mg (1.5 eq) of silylated fluorocytosine 30 (X=F) were dissolved in 10 ml of dry dichloromethane. Then 0.59 ml (2 eq) of a TiCl 4 /dichloromethane solution was added dropwise over 1 hour. After stirring for 30 additional minutes, 5 ml of dichloromethane and 1 ml of concentrated NH 4 OH were added, the solvent was removed envaccuo, and column chromatography (EtOAc/EtOH: 1/1) gave 35 mg (25%) of compound 36 as a white solid. ( 1 H NMR: (CDCl 3 , 300 MHz) 1.06 (s, 9H), 3.62 (dq, 2H, J=2.7 Hz, J=12.3 Hz), 3.9 (m, 2H), 5.01 (t, 1H, J=2.4 Hz), 6.2 (m, 1H), 7.41 (m, 6H), 7.7 (m, 4H), 7.92 (d, 1H, J=6 Hz).)
The silyl ether 36 (116.8 mg, 0.249 mmol) was dissolved in 3 ml of dry THF, and 0.3 ml of a Bu 4 NF/THF solution (1M, Aldrich) was added. After 3 hours of stirring, the solvent was removed envaccuo and column chromatography (EtOAc/EtOH: 4/1) gave 48.1 mg (84%) of the nucleoside 37 (FDOC) as a white powder. ( 1 H NMR: (DMSO-d 6 , 300 MHz) 3.63 (m, 2H), 4.01 (dd, 1H, J=5.1 Hz, J=9.6 Hz), 4.08 (d, 1H, J=9.6 Hz), 4.87 (s, 1H), 5.26 (t, 1H, J=6 Hz), 6.07 (m, 1H), 7.49 (bs, 1H), 7.73 (bs, 1H), 8.12 (d, 1H, J=7.2 Hz).)
B. Therapeutic Use of FTC and FTC Prodrug Analogues
As shown below, the compounds of this invention either possess antiretroviral activity, such as anti-HIV-1, anti-HIV-2 and anti-simian immunodeficiency virus (anti-SIV) activity, themselves and/or are metabolizable to species that possess antiretroviral activity. Thus, these compounds, pharmaceutically acceptable derivatives of these compounds or pharmaceutically acceptable formulations containing these compounds or their derivatives are useful in the prevention and treatment of vital infections in a host such as a human, preferably HIV infections and other AIDS-related conditions such as AIDS-related complex (ARC), persistent generalized lymphadenopathy (PGL), AIDS-related neurological conditions, anti-HIV antibody positive and HIV-positive conditions, Kaposi's sarcoma, thrombocytopenia purpurea and opportunistic infections. In addition, these compounds or formulations can be used prophylactically to prevent or retard the progression of clinical illness in individuals who are anti-HIV antibody or HIV-antigen positive or who have been exposed to HIV.
As used herein, a "pharmaceutically acceptable derivative" means any pharmaceutically acceptable salt, ester, or salt of such ester, of FTC or a prodrug analogue of FTC which, upon administration to the recipient, is capable of providing, directly or indirectly, FTC or an antivitally active metabolite or residue of FTC, including, but not limited to, the mono-, di- and triphosphate esters of FTC or a prodrug analogue of FTC.
Thus, humans can be treated by administering to the patient a pharmaceutically effective amount of FTC or FTC prodrug analogues in the presence of a pharmaceutically acceptable carrier or diluent such as a liposomal suspension. A preferred carrier for oral administration is water, especially sterilized water. If administered intravenously, the preferred carriers are physiological saline or phosphate buffered saline. The compounds according to the present invention are included in the pharmaceutically acceptable carrier in an amount sufficient to exert a therapeutically useful inhibitory effect on HIV in vivo without exhibiting adverse toxic effects on the patient treated. Pharmaceutically compatible binding agents and/or adjuvant materials may also be included as part of the composition. The active materials can also be mixed with other active materials that do not impair the desired action and/or supplement the desired action.
It will be appreciated by those skilled in the art that the effective amount of a compound or formulation containing the compound required to treat an individual will vary depending on a number of factors, including whether FTC or a prodrug analogue of FTC is administered, the route of administration, the nature of the condition being treated and the age and condition of the patient. In general, however, an effective dose will range from about 1-50 mg per kg body weight of the patient per day, preferably 1-20 mg/kg/day. Preferably, a dose will produce peak blood levels of the active compound that range from about 1-10 μM, most preferably about 5 μM. The desired dose may be given in a single dose or as divided doses administered at appropriate intervals, such as two, three, four or more sub-doses per day.
Thus, FTC and FTC prodrug analogues or formulations containing these compounds or their pharmaceutically acceptable derivatives can be conveniently administered by any convenient route of administration, such as parenteral, including intramuscular, subcutaneous and intravenous; oral; rectal; nasal; vaginal or by inhalation. The compound can be administered in unit dosage form, such as formulations containing 0.1 to 50 mg, preferably, 1 to 10 mg of active ingredient per unit dosage form.
A preferred mode of administration of the compounds of this invention is oral. Oral compositions will generally include an inert diluent or an edible carrier. They may be enclosed in gelatin capsules or compressed into tablets. For the purpose of oral therapeutic administration, the compounds of this invention may be incorporated with excipients and used in the form of tablets, troches, capsules, elixirs, suspensions, syrups, wafers, chewing gums and the like.
Methodology for Testing Antiviral Activity
Antiviral compositions can be screened in vitro for inhibition of HIV by various experimental techniques. One such technique involves measuring the inhibition of viral replication in human peripheral blood mononuclear (PBM) cells. The amount of virus produced is determined by measuring the quantity of virus-coded reverse transcriptase (RT), an enzyme found in retroviruses, that is present in the cell culture medium.
PBM cells from healthy HIV-1 and hepatitis B virus seronegative donors were isolated by Ficoll-Hypaque discontinuous gradient centrifugation at 1,000×g for 30 minutes, washed twice in PBS and pelleted at 300×g for 10 minutes. Before infection, the cells were stimulated by phytohemagglutinin (PHA) at a concentration of 6 μg/ml for three days in RPMI 1640 medium supplemented with 15% heat-inactivated fetal calf serum, 1.5 mM n-glutamine, penicillin (100 U/ml), streptomycin (100 μg/ml), and sodium bicarbonate buffer. Most of the antiviral assays described below were performed with cells from at least two different donors.
HIV-1 (strain LAV-1) was obtained from the Centers for Disease Control, Atlanta, and propagated in PHA-stimulated human PBM cells using RPMI 1640 medium as above without PHA and supplemented with 7% interleukin-2 (Advanced Biotechnologies, Silver Spring, Md.), 7 μg/ml DEAE-dextran (Pharmacia, Uppsala, Sweden), and 370 U/ml anti-human leukocyte (alpha) interferon (ICN, Lisle, Ill.). Virus was obtained from the cell free culture supernatant and stored in aliquots at -70° C. until used.
Uninfected PHA-stimulated human PBM cells were uniformly distributed among 25 cm 3 flasks to give a 5 ml suspension containing about 2×10 6 cells/ml. Suitable dilutions of HIV were added to infect the cultures so that the mean reverse transcriptass (RT) activity of the inocula was 50,000 dpm/ml, which was equivalent to about 100 TCID 50 , determined as described in AIDS Res. Human Retro, 3:71-85 (1987). The drugs, at twice their final concentrations in 5 ml of RPMI 1640 medium, supplemented as described above, were added to the cultures. Uninfected and treated PBM cells were grown in parallel as controls. The cultures were maintained in a humidified 5% CO 2 -95% air incubators at 37° C. for five days after infection, at which point all cultures were sampled for supernatant RT activity. Previous studies indicate that the maximum. RT levels are obtained at that time.
The RT assay was performed by a modification of the Spira et al., J. Clin. Microbiol. 25, 97-99 (1987) method in 96-well microtiter plates. The radioactive cocktail (180 μl), which contained 50 mM Tris-HCl pH 7.8, 9 mM MgCl 2 , 5 mM dithiothreitol 4.7 μg/ml (rA) n ·(dT) 12-18 , 140 μM dATP and 0.22 μM 3 H!TTP (specific activity 78.0 Ci/mmol, equivalent to 17,300 cpm/pmol; NEN Research Products, Boston, Mass.), was added to each well. The sample (20 μl) was added to the reaction mixture and incubated at 37° C. for two hours. The reaction was terminated by the addition of 100 μl cold 10% trichloroacetic acid (TCA) containing 0.45 mM sodium pyrophosrhate. The acid insoluble nucleic acid which precipitated was collected on glass filters using a Skatron semi-automatic harvester (setting 9). The filters were washed with 5% TCA and 70% ethanol, dried, and placed in scintillation vials. Four ml of scintillation fluid (Econofluor, NEN Research Products, Boston Mass.) was added and the amount of radioactivity in each sample determined using a Packard Tri-Carb liquid scintillation analyzer (model 2,000CA). The results were expressed in dpm/ml of original clarified supernatant. The antiviral activity, expressed as the micromolar concentration of compound that inhibits replication of the virus by 50% (EC 50 ), was calculated by determining the percent inhibition by the median effect method described in Chou and Talalay, Adv. Enz. Regul., 22:27-55 (1984).
Methodology for Testing Toxicity and Inhibition of Cell Proliferation
The compounds were evaluated for their potential toxic effects on uninfected PHA-stimulated human PBM cells and also in CEM (T-lymphoblastoid cell line obtained from ATCC, Rockville, Md.) and Vero (African Green Monkey kidney) cells. PBM cells were obtained from whole blood of healthy HIV and hepatitis-B seronegative volunteers and collected by a single-step Ficoll-Hypaque discontinuous gradient centrifugation. The CEM cells were maintained in RPMI 1640 medium supplemented with 20% heat-inactivated fetal calf serum, penicillin (100 U/ml), and streptomycin (100 μg/ml). Flasks were seeded so that the final cell concentration was 3×10 5 cells/ml. The PBM and CEM cells were cultured with and without drug for 6 days at which time aliquots were counted for cell proliferation and viability using the trypan blue-exclusion method (Sommadossi et al, Antimicrob. Agents Chemother., 32:997-1001 (1988. Only the effects on cell growth are reported because these correlated well with cell viability. The toxicity of the compounds in Vero cells was assessed after 3 days of treatment with a hemacytometer as described in Schinazi etal, Antimicrob. Agents Chemother., 22:499-507 (1982). The toxicity, expressed as the micromolar concentration of compound that inhibits the growth of normal cells by 50% (IC 50 ), was determined, similarly to EC 50 , by the method of Chou and Talalay.
In Vitro Assay is Predictive of In Vivo Activity
Using the antiviral activity PBM assay described above, a number of compounds have been tested for activity against HIV. While many of the compounds have been found to have little or no activity against the virus under the test conditions, a number of the compounds have exhibited significant activity. For instance, DDI, DDC, D4T, AzddU (3'-Azido-2',3'-dideoxyuridine) and AZT were found to significantly inhibit HIV replication in vitro, and to have low cytotoxicity in PBM cells under the test conditions used. FTC also exhibits significant activity against HIV replication in the PBM cell line assay.
At least four of the compounds found active in the PBM cell line assay (DDI, DDC, DDA, and AzddU) are undergoing clinical testing in the U.S. Food and Drug Administration (FDA). All four compounds have been found to inhibit HIV in vivo. A fifth compound, AZT, is already approved by the FDA for treatment of HIV in humans. Based on the correlation of the results of the in vitro PBM assay with in vitro activity, it is clear that the activity of a compound against HIV in the PBM cell line in vitro is fairly predictive of its general activity in vivo in humans.
EXAMPLE 7--ANTIVIRAL AND CYTOTOXICITY ASSAYS OF FTC AND 3'-THZANUCLEOSlDE ANALOGUES OF FTC IN HUMAN PERIPHERAL BLOOD MONONUCLEAR (PBM) CELLS
Table 1 below lists the results of anti-HIV-1 activity and toxicity assays in human PBM Cells as described above for various 3'-thianucleoside analogues related to BCH-189. It appears that only the cytidine analogues are active in PBM cells, especially then the 5-position is substituted with H or F; FTC was more potent an inhibitor than any of the other tested compounds. Surprisingly, the 5-methyl derivative was inactive when tested up to 100 μM. These compounds were not cytotoxic to human PBM cells when tested up to 100 μM. Cells from at least two different donors were used in performing these antiviral assays. The margin of inter-assay variability error in EC 50 values determined from a concentration-response curve can vary by as much as a factor of 10. However, using the above procedure and AZT as a positive control, a variance of 0.0008 to 0.006 μM with a mean value of 0.002 μM was determined.
TABLE 1______________________________________Anti-HIV Activity and Toxicity of VariousAnalogues of 2'-deoxy-3'-thiacytidinein Human PBM CellsAntiviral Drug EC.sub.50, μM IC.sub.50, μM______________________________________2',3'-Dideoxy-3'-thiauridine >100 >1002'-Deoxy-5-methyl-3'-thiauridine 64.4 >1002'-Deoxy-5-fluoro-3'-thiauridine >100 >1002'-Deoxy-5-chloro-3'-thiauridine >60.8 >1002'-Deoxy-5-bromo-3'-thiauridine NA NA2'-Deoxy-5-iodo-3'-thiauridine >100 >1002'-Deoxy-3'-thiacytidine (BCH-189) 0.05 >1002'-Deoxy-5-methyl-3'-thiacytidine 10 >1002'-Deoxy-5-fluoro-3'-thiacytidine (FTC) 0.011 >1002'-Deoxy-5-chloro-3'-thiacytidine 37.8 >1002'-Deoxy-5-bromo-3'-thiacytidine 7.4 >1002'-Deoxy-5-iodo-3'-thiacytidine 0.72 >100______________________________________
Furthermore, as shown in FIG. 6, FTC was highly effective in PBM cells even when the drug was added 3 days after virus infection. FIG. 6 shows a comparison of the effect of delaying treatment for up to three days on the anti-HIV-1 activity for FTC, BCH-189, AZT and AzddU. These results were determined by measuring the RT activity associated with virion produced in the presence and absence of drug to quantitate virus yield as described above. The control for this experiment had 232,154 dpm/ml of RT activity.
It is possible that BCH-189 analogues can be deaminated intracellularly to the inactive uracil analogue. Close to 6% of BCH-189 can be deaminated by Cyd/dCyd deaminase in a cell free system. However, the presence of fluorine in FTC would increase the lipophilicity of the drug, which should also increase its penetration into the CNS. In addition, FTC should be markedly less susceptible to deamination. Deamination of either BCH-189 or FTC would lead to the corresponding uracil analogues, which would cause them to lose their potent activity.
EXAMPLE 8--ANTIVIRAL AND CYTOTOXICITY ASSAYS OF FTC AND AZT IN HUMAN CEM CELLS
FTC was evaluated in vitro versus HIV-1, strain HTLV-III B in CEM cells, a T-cell line, using AZT as the positive control. FTC was initially dissolved in sterile water at a concentration of 4 mM, and dilutions were prepared in RPMI-1640 medium containing 10% fetal bovine serum. The compound was tested at nine concentrations, ranging from 100 μM to 0.01 μM in half-log 10 dilutions.
The assay was done in 96-well tissue culture plates using the CEM human T-lymphocyte cell line. CEM cells were treated with polybrene at a concentration of 2 μg/ml, and 1×10 4 cells were dispensed into each well. A 50 μl volume of each test article dilution, prepared as a 4×concentration, was added to 5 wells of cells, and the cells were incubated at 37° C. for 1 hour. A frozen culture of HIV-1, strain HTLV-III B , was diluted in culture medium and 2×10 3 TCID 50 of virus were added to 3 of the wells for each test article concentration. This resulted in a multiplicity of infection of 0.2 for the HIV-1 infected samples. Normal culture medium was added to the remaining 2 wells of each test concentration to allow evaluation of cytotoxicity. Each assay plate contained 2 wells of untreated, uninfected, cell control samples and 3 wells of untreated, infected, virus control samples. The total volume in each well was 200 μl.
Assay plates were incubated at 37° C. in a humidified, 5% CO 2 atmosphere and observed microscopically for toxicity and/or cytopathogenic effect. On the 8th day post-infection, the cells in each well were resuspended and a 50 μl sample of each cell suspension was transferred to a new 96-well plate. A 100 μl volume of fresh RPMI-1640 medium and a 30 μl volume of a 5 mg/ml solution of 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT) was added to each 50 μl cell suspension, and the cells were incubated at 37° C. for 4 hours. During this incubation, MTT is metabolically reduced by living cells, resulting in the production of a colored formazan product. A 50 μl volume of a solution of 20% sodium dodecyl sulfate in 0.02N hydrochloric acid was added to each sample, and the samples were incubated overnight. The absorbance at 590 nm was determined for each sample using a Molecular Devices V max microplate reader. This assay detects drug-induced suppression of vital CPE, as well as drug cytotoxicity, by measuring the generation of MTT-formazan by surviving cells.
No cytotoxicity was noted for FTC from 0.01 to 100 μM and the EC 50 was estimated to be 0.09 μM, giving a therapeutic index (IC 50 /EC 50 ) in these cells of about 1000. In contrast, the EC 50 for AZT in CEM cells was 0.01 μM and no cytotoxicity was noted up to 5 μM, the maximum concentration tested.
EXAMPLE 9--EFFECT OF FTC, BCH-189, AZT AND DDC ON COLONY FORMATION OF GRANULOCYTE-MACROPHAGE PRECURSOR CELLS
Because the limiting, toxicity of compounds like AZT is bone-marrow toxicity, it was important to determine if FTC was also toxic to these cells. The results of a bone-marrow toxicity assay may predict if anemia will occur in humans following treatment with a particular drug because these cell culture models are good prognosticators of what may happen in humans. Thus, FTC, BCH-189, DDC and AZT were tested for their effects on colony formation of granulocyte-macrophage precursor cells.
Human bone marrow cells were collected by aspiration from the posterior iliac crest of normal healthy volunteers, treated with heparin and the mononuclear population separated by Ficoll-Hypaque gradient centrifugation. Cells were washed twice in Hanks balanced salt solution, counted with a hemacytometer, and their viability was >98% as assessed by trypan blue exclusion. The culture assays were performed using a bilayer soft-agar or methyl cellulose method. McCoy 5A nutrient medium supplemented with 15% dialyzed fetal bovine serum (heat inactivated at 56° C. for 30 minutes, Gibco Laboratories, Grand Island, N.Y.) was used in all experiments. This medium was devoid of thymidine and uridine. Human recombinant GM-CSF (50 units/ml, Genzyme, Boston, Mass.) was used as colony-stimulating factors. After 14 days of incubation at 37° C. in a humidified atmosphere of 5% CO 2 in air, colonies (≧50 cells) were counted using an inverted microscope.
As shown in FIG. 7, studies with human bone marrow cells indicate that FTC has an IC 50 greater than 50 μM, whereas in the same assay BCH-189, DDC, and AZT are clearly more toxic. The IC 50 for AZT is close to 1 μM.
Because both BCH-189, AZT and FTC do not seem to affect the proliferation of uninfected human PBM cells as shown above, it is important to calculate the therapeutic index of the drugs in terms of IC 50 (toxicity) in human bone-marrow cells to EC 50 (antiviral) against HIV in human PBM cells. The IC 50 in human bone-marrow cells for BCH-189 is about 10 μM, whereas for FTC it is about 60 μM. Hence the therapeutic index for BCH-189 is 10/0.05=200, while the index for FTC is 60/0.011=5,455. By these experiments, FTC is clearly a less toxic yet effective anti-HIV-1 agent compared to BCH-189.
EXAMPLE 10--ANTIVIRAL AND CYTOTOXICITY ASSAYS OF FTC IN MT-2 CELLS
Antiviral and cytotoxicity studies of FTC in human lymphocyte MT-2 cells were conducted. MT-2 cells (3×10 5 /ml) were incubated with serial 10-fold dilutions of an HIV (IIIb) vital supernatant (stock), centrifuged, resuspended in fresh media, and plated into microculture wells (6×10 4 cell/well/0.2 ml). Because the assay can be performed with 0.2 ml of culture supernatant in a microtiter plate, HIV inoculation of target cell cultures can be monitored conveniently and endpoint titrations of infectious HIV can be performed. No manipulation of the culture is required during the seven day evaluation. The necessary multiple replicate numbers of cultures to generate statistically significant data were included in the TCID 50 assay. Since the MT-2 cell line is highly susceptible to virus infection and syncytia formation, it is easily observed and allows for a very sensitive assay system.
Quantitation of HIV infectivity was determined for serial 10-fold dilutions of the virus stock. Calculation of the highest dilution of virus which gave evidence of syncytia in 50% of the cultures, the endpoint determination, yielded a measure of the infectious particles in the stock. A TCID 50 titer is defined as the reciprocal of the dilution of HIV that when inoculated into the microcultuzes containing MT-2 cells resulted in syncytia in 50% of the cultures by the seventh day. The results of the HIV TCID 50 assay, as described in Table 2, correlates with the results using the reverse transcriptase results, immunofluorescent, cytoplasmic staining assay, p24 antigen capture assay, and cell cytopathic effects, thereby validating our assay system.
The MT-2 syncytium-forming assay has been applied for use in discovering antiviral drugs with potent anti-HIV activity. MT-2 cells are incubated in growth medium (DMEM, 20% heat inactivated fetal calf serum and 0.25 mg/ml L-glutamine with 1% penicillin and streptomycin) at 37° C. in a 5% CO 2 atmosphere. The MT-2 cell concentration that allows for the development of readily quantifiable syncytium formation in a microtiter plate is 3×10 5 /ml (6×10 4 cell/0.2 ml).
HIV (IIIb) was obtained from the culture supernatant of H9 cells infected by multiple isolates of HIV concentrated to 10,000× by sucrose gradient centrifugation. A representative virus (IIIb) stock contained a total virus particle count of approximately 10 8 /ml to 10 9 /ml by electron microscopy. The TCID 50 was calculated as follows: Serial 10-fold dilutions of the H9 virus stock were performed and 1.0 ml used (in quadruplicate) to infect MT-2 cells. Endpoints were calculated by the method of Reed Muench from the highest dilution with detectable syncytium formation within seven days. The most recent virus stock, HIV (IIIb), that was evaluated contained an infectious vital titer of 6.23 log 10 TCID 50 /ml. The input dose of virus was adjusted to yield greater than 40 syncytia at the seventh day of culture. HIV stocks were aliquoted and stored at -85° C. until used. A frozen stock was thawed and an infectivity study was performed, in quadruplicate, to determine if >40 syncytia are formed at day seven. At the same time, the virus stock was subjected to antiviral inhibition with the use of AZT or DDA. These maneuvers, with the proper controls, ensure for reproducible input doses of virus for these studies.
TABLE 2______________________________________EFFECT OF BCH-189 AND FTC AGAINST HIV-1(strain IIIb) IN MT-2 CELLS Mean # of Conc. SyncytiaCompound (μM) (per well) % Inhib EC.sub.50, μM______________________________________Cells (no 0 0.00virus/nodrugVirus (no 62 0.00drug)DDA (pos. 1 14 77.42 ≈0.45control 10 0.5 99.19BCH-189 0.1 61 1.61 0.88 1 20.5 66.94 10 1 93.39 100 0 100.0FTC 0.1 63 -1.61 0.89 1 23 62.90 10 0.5 99.19 100 0 100.00______________________________________
The MT-2 cells for the studies were expanded and treated with DEAE-dextran (25 μg/ml) for 20 minutes followed by three washings with PBS. Cell counts were performed and an appropriate number of cells that ultimately yielded a final cell concentration of 3×10 5 cells/ml (6×10 4 cells/0.2 ml) per well was chosen. The cells were infected in bulk (not in-well infection) at a multiplicity of infection of 10 -3 and allowed to mix with the viral supernatant for one hour at 37° C. The cells were subsequently resuspended in the wells containing the HT-2 madia with drugs. The cultures were not manipulated until day seven when syncytium counts and cell viability studies were performed. The experimental controls for each experiment consisted of the following: 1) AZT or DDA; 2) uninfected MT-2 cells with drug; 3) infected MT-2 cells without drug, and 4) uninfected MT-2 cells without HIV or drugs.
The raw data was analyzed by the method of Chou and Talalay. The MT-2 cell lines were discarded at three month intervals with a new stock regrown to avoid the possibility of variations or contamination (mycoplasma) with long term growth. The original MT-2 cell frozen stock has been tested and is free of mycoplasma. EC 50 and IC 50 values were obtained by analysis of the data using the median-effect equation of Chou and Talalay. It is apparent from Table 2 that in this cell culture system, both BCH-189 and FTC are equally potent.
EXAMPLE 11--INHIBITION OF MITOCHONDRIAL DNA SYNTHESIS BY FTC IN CEM CELLS
In addition to bone-marrow toxicity, peripheral neuropathy has been observed with certain nucleoside antiviral drugs. There appears to be a good correlation between inhibition by nucleosides of mitochondrial DNA synthesis and clinical peripheral neuropathy. Therefore, studies were performed which indicated that FTC did not affect mitochondrial DNA synthesis in intact CEM cells when tested up to 100 μM. This result was determined by measuring the amount of mitochondrial DNA present in these lymphocytes after exposure using a mitochondrial DNA hybridization probe. However, BCH-189 and DDC are toxic in this system at a concentration ≦10 μM.
EXAMPLE 12--EFFECT OF FTC, BCH-189 AND AZT ON AZT-RESISTANT AND AZT-SENSITIVE HIV-1 IN HUMAN PBM CELLS
We have also evaluated FTC and BCH-189 against AZT-resistant and sensitive HIV-1, as shown in FIG. 8 and Table 3. The paired AZT-resistant and sensitive viruses strain 9F (G910-6) and 10 (H112-2), respectively, were obtained through the NIH AIDS Research and Reference Program. All the viruses were propagated in PHA-stimulated human PBM cells using RPMI 1640 medium as described previously and supplemented with 7% interleukin-2 (Advanced Biotechnologies, Silver Spring, Md.), 7 μg/ml DEAE-dextran (Pharmacia, Uppsala, Sweden), and 370 U/ml anti-human leucocyte (alpha) interferon (ICN, Lisle, Ill.). Virus was obtained from cell-free culture supernatant and stored in aliquots at -70° C. until use. The antiviral assay in PBM cells was performed as described above.
TABLE 3______________________________________ EC.sub.50, μMCompound Strain 9F* Strain 10 Fold Increase______________________________________AZT 0.298 0.00069 432BCH-189 0.244 0.040 6.1FTC 0.107 0.014 7.6______________________________________ *AZT resistant HIV
At the same multiplicity of infection, a 7-fold increased resistance was noted at the EC 50 level when the sensitivity of the pretherapy isolate was compared to the post-therapy AZT-resistant virus in PBM cells for FTC. This increase was not as great as that noted for AZT.
EXAMPLE 13--INHIBITORY EFFECT OF FTC AGAINST SIV 251
FTC was tested for its inhibitory effect against SIV 251 in the human cell line AA-2 and C-8166, using AZT as a positive control. All tests were conducted in duplicate according to a standard protocol in 96 well tissue culture plates. Briefly, cells were exposed to the virus for 1 hour at 37° C. The cells were washed and the appropriate dilution of antiretroviral agent diluted in PBS was added with complete RPMI-1640 medium. After a 7-day incubation period at 37° C. and 5% CO 2 , 95% air environment, cells were examined microscopically for cytopathic effects (syncytial cells) and cytotoxicity. The cells were counted and the percent of viable cells determined using the trypan blue exclusion method. Vital antigen expression in cell pellets was determined by an immunofluorescence (IF) assay. The percent of IF inhibition was based on the ratio of fluorescing cells in infected/treated cultures to fluorescing cells in infected control cultures.
FTC antiviral activity was observed versus SIV but less than that noted with AZT. As shown in Table 4, FTC was evaluated over a concentration range of 0 to 46 μM, and AZT was tested as the positive control.
TABLE 4______________________________________Concentration % IF Inhibition Cell No. × 10.sup.5(μM) AA-2 C-8166 AA-2 C-8166______________________________________FTC 0 0 0 6.0 3.9 0.23 0 11 6.5 5.6 0.46 17 5 6.5 6.0 2.3 22 32 6.3 5.9 4.6 36 47 7.3 6.1 23 61 63 6.2 7.4 46 70 79 9.9 9.9AZT 0.0005 0 5 7.4 6.6 0.005 30 16 7.4 8 0.05 83 79 7.5 8 0.5 100 100______________________________________
EXAMPLE 14--THYMIDYLATE SYNTHASE ASSAY OF FTC AND BCH-189
BCH-189 and FTC were also evaluated in an intact L1210 cellular thymidylate synthase (TS) assay. No evidence for any inhibition of TS by up to 1 mM of either compound as measured by the release of tritium from 5- 3 H-dUrd was noted. Using 5- 3 H-dCyd, inhibition of tritium release was observed at >10 -4 M. At 1 mM, BCH-189 and FTC gave 63.2% and 74.7% inhibition of tritium release, respectively. Since the 5- 3 H-dCyd concentration is 1 μM, it appears that the observed effects may be due to competitive inhibition of the phosphorylation of labeled dCyd by the analogue at high concentrations. The lack of TS inhibition by FTC is probably due to either of 2 alternatives: (1) its 5'-phosphate is not a substrate for dCMP deaminase; (2) if it is a substrate, the resulting 5-fluoro-3'-thia-dUMP cannot bind to TS or, if so, only very weakly.
EXAMPLE 15--ANTIVIRAL ACTIVITY OF VARIOUS PRODRUGS OF FTC IN HUMAN PBM CELLS
FTC may be modified at the 2-hydroxymethyl group of the oxathiolane ring by substituting the hydroxy group with an oxyacyl group to produce 5'-oxyacyl or 5'-H substituted prodrug analogues of FTC. Furthermore, the 4-N position of FTC may be substituted with an alkyl, substituted alkyl, cycloalkyl or acyl group. These modifications at the 4-N and 5'-O positions affect the bioavailability and rate of metabolism of the active species, thus providing control over the delivery of the active species.
Preferred FTC prodrug analogues include compounds of the formula: ##STR7## in which Y 1 and Y 2 are selected from H; lower straight or branched chain alkyl; substituted alkyl, preferrably diisopropylaminomethylene or alkoxyaminomethylene; cycloalkyl, preferrably cyclopropyl; or acyl, wherein the term "acyl" corresponds to an acyl protecting group as given above and in which the 5'-R substituent is H or oxyacyl. As used herein, the term "oxyacyl" means a group of the formula ##STR8## in which R' is selected from hydrogen, lower straight or branched chain alkyl (e.g., methyl, ethyl, n-propyl, t-butyl, n-butyl), alkoxyalkyl (e.g., methoxymethyl), aralkyl (e.g., benzyl), aryloxyalkyl (e.g., phenoxymethyl), aryl (e.g., phenyl), substituted aryl (e.g., halogen, lower alkyl or lower alkoxy substituted phenyl); substituted dihydro pyridinyl (e.g., N-methyldihydropyridinyl); sulphonate esters such as alkyl- or aralkylsulphonyl (e.g., methanesulphonyl); sulfate esters; amino acid esters (e.g., L-valyl or L-isoleucyl) and mono-, di- or tri-phosphate esters. Pharmaceutically accepted formulations of these compounds include liposome formulations.
TABLE 5______________________________________NY.sub.1 Y.sub.2 5-position 5'-position EC.sub.50, μM______________________________________NHAc H CH.sub.2 OH 0.089NH.sub.2 H n-C.sub.3 H.sub.7 C(O)OCH.sub.2 0.037NH.sub.2 H CH.sub.3 C(O)OCH.sub.2 0.089NHAc H n-C.sub.3 H.sub.7 C(O)OCH.sub.2 0.11NHAc F n-C.sub.3 H.sub.7 C(O)OCH.sub.2 0.00576NHAc F CH.sub.2 OH 0.0028NH.sub.2 F n-C.sub.3 H.sub.7 C(O)OCH.sub.2 0.00174______________________________________
Using the method of determining anti-HIV-1 activity as described in Example 6 above, various prodrugs of FTC and BCH-189 were assayed in human PBM cells infected with HIV-1, as shown in Table 5. Relative to the BCH-189 prodrug analogues listed in Table 5, the FTC prodrug analogues showed superior anti-HIV activity.
EXAMPLE 16--ANTIVIRAL AND CYTOTOXICITY ASSAYS OF NUCLEOSIDES SIMILAR TO PTC
Table 6 below lists the results of anti-HIV-1 activity in human PBM cells and toxicity assays in human PBM cells, Vero (African Green Monkey kidney) cells, and CEM cells as described above for FTC, BCH-189, 2'-deoxy-3'-oxacytidine (DOC), 2'-deoxy-3'-oxathymidine (DOT), 2'-deoxy-5-fluoro-3'-oxacytidine (FDOC) and 2'-deoxy-5-fluoro-3'-oxauridine (FDOU) to show the effect of fluoro substitution at the 5-position and S→O substitution at the 3'-position in nucleosides that are similar to FTC.
Comparison of the data for FTC, FDOC and FDOU shows that 5-fluoro substitution leads to unpredictable results in these systems. For instance, fluoro substitution of BCH-189 at the 5-position to give FTC results in a compound that possesses better anti-HIV activity and is less toxic in CEM cells; both are nontoxic in PBM and Veto cells. However, fluoro substitution of DOC at the 5-position to give FDOC results in a compound that possesses inferior anti-HIV activity and is more toxic in Vero cells; both are nontoxic in PBM and toxic in CEM cells. FDOU is nontoxic in all three types of cells but does not possess anti-HIV activity.
Similarly, comparison of the data for FTC, BCH-189 versus DOC, DOT, FDOC and FDOU shows that 3'-substitution of an S for an O gives rise to unpredictable anti-HIV activity and toxicity behavior. For instance, substitution of BCH-189 to give DOC and FTC to give FDOC results in compounds that are toxic in the rapidly dividing Vero cells and CEM cells, thus most likely rendering them not viable as anti-HIV drugs because of associated side effects. However, the presence of the oxygen at the 3'-position in DOT does not render this compound toxic in Vero cells. Thus, discovery of the superior anti-HIV and toxicity properties of FTC was surprising and unexpected.
TABLE 6______________________________________Anti-HIV Activity and Toxicity of VariousNucleosides that are similar to FTCANTI-HIVACTIVITY CYTOTOXICITYAntiviral EC.sub.50, μM IC.sub.50, μM IC.sub.50, μM IC.sub.50, μMDrug (PBM) (PBM) (Vero) (CEM)______________________________________FTC 0.011 >100 >100 >100BCH-189 0.06 >100 >100 52.6DOC 0.0047 >200 0.17 <1DOT 0.09 >100 >100FDOC 0.0063 >200 <0.1 <1FDOU >10 >200 >100 >100______________________________________
EXAMPLE 17--EFFECT OF FTC AND BCH-189 ON MITOGENIC STIMULATION
Peripheral blood mononuclear cells (PBM cells) were obtained by leukophoresis from a normal human donor and were further purified by density gradient centrifugation using Histopaque (Sigma; St. Louis, Mo.). Cells were washed twice in phosphate buffered saline, resuspended in complete media (RPMI supplemented with 10% fetal bovine serum, 2 μM L-glutamine, penicillin, and streptomycin), and adjusted to 2×10 6 cells/ml. Mitogens were added to separate aliquots of cell suspension to yield a final concentration of 1% phytohemagglutinin (PHA, a T-helper cell mitogen), 0.8 mg/ml concanavalin A (con A, a T-cytotoxic/suppressor cell mitogen), and 0.1% pokeweed mitogen (PWM, a B cell mitogen), respectively.
A cell suspension (100 μl) was dispensed into wells of 96-well flat-bottomed plates, followed by addition of 100 μl of drug diluted in complete media. Control wells received 100 μl of complete media. Cells were incubated at 37° C. in 5% CO 2 for 54 hr, at which time 2 μCi 3 H-deoxyguanosine (Moravek Biochemicals, Brea, Calif.; diluted in 20 μl complete media) was added per well. After an additional 18 hour incubation, cells were harvested on filter paper using a Skatron cell harvester with 5% TCA and 70% ETOH. Filters were placed in scintillation vials with 4 ml Ecolite, and dpm were counted using a Beckman LS3801 beta counter.
At concentrations of 0.1, 1.0, and 10 μM, both BCH-189 and FTC increased the proliferation of PBM cells exposed to PHA, whereas they caused significant reduction in proliferation at 100 μM concentrations. Con A- and PWM-stimulated cells were suppressed by both drugs. In the absence of mitogen, BCH-189 has a mildly stimulatory effect, whereas FTC had a mildly inhibitory effect.
Modifications and variations of the present invention will be obvious to those skilled in the art from the foregoing detailed description of the invention. Such modifications and variations are intended to come within the scope of the appended claims. The references cited above are hereby incorporated by reference to more fully describe the invention. | The present invention relates to a method of preparing the antiviral compounds 2'-deoxy-5-fluoro-3'thiacytidine (FTC) and various prodrug analogues of FTC from inexpensive precursors with the option of introducing functionality as needed; methods of using these compounds, particularly in the prevention and treatment of AIDS; and the compounds themselves. This synthetic route allows the stereoselective preparation of the biologically active isomer of these compounds and related compounds. | 0 |
RELATED APPLICATIONS
The present application is a 35 U.S.C. §371 national phase application of PCT International Application No. PCT/CN2012/0076187, filed May 29, 2012, which claims priority from Chinese Patent Application No. 201110393323.8, filed Dec. 1, 2011, the disclosures of which are hereby incorporated herein by reference in their entireties. PCT International Application No. PCT/CN2012/0076187 is published as PCT Publication No. WO 2013/078843 A1.
TECHNICAL FIELD
The present invention relates to the field of cooling apparatus, and more particularly to a closed circulating water cooling apparatus and a method thereof in which cooling water flowing through an air cooler is re-cooled by a plate heat exchanger.
DESCRIPTION OF THE RELATED ART
Nowadays, many power stations and power transmission stations such as converter stations are established in dry and water-shortage regions of North China, where due to high environment temperature and significant evaporation in summer, water resources are becoming more precious than ever. However, traditional water cooling methods for cooling apparatus of power stations and power transmission stations such as converter stations may exhaust scarce water resources in those regions. Thus, air coolers are usually adopted for cooling apparatus used in these power stations. Because, converter stations are always located in geographical positions having relatively lower environment temperature, the application of air coolers may meet the cooling requirement of converters, a kind of processing device used in power stations, and satisfied cooling effects may be achieved.
However, some regions have such high temperature that air coolers are unable to cool the fluid to environment temperature, causing application limitation of air coolers in such dry regions. For example, in some places in Northwest China, the highest extreme environment temperature may come up to 44° C., while the highest inlet temperature that is allowed for converter valves as core equipment of DC transmission projects is only 40° C. In this situation, pure water used for those converts cannot be cooled by air coolers. On the contrary, cooling water may be heated. Thus, air coolers are not suitable in this situation.
Also, because power generation and power transmission facilities generally enter maximum operating conditions in the hottest days in summer when environment temperature reaches its highest extreme value, in which case air coolers usually may not provide enough cooling capability. As a result, converter stations have to operate with reduced payloads, as well as lowered power levels, which may cause economic loss, and has an adverse effect on the development of national economy.
SUMMARY OF THE INVENTION
In view of this, a technical problem to be solved in this invention is to provide a cooling apparatus and improve the cooling capability thereof.
A closed circulating water cooling apparatus comprises an internal cooling apparatus, a plate heat exchanger 6 and an auxiliary cooling apparatus; wherein the internal cooling apparatus comprises an internal cooling circulation pump 2 and an air cooler 3 ; the auxiliary cooling apparatus comprises an external cooling circulation pump 7 and an underground water pipe 8 ; heat is exchanged between internal cooling water flowing through the internal cooling apparatus of the plate heat exchanger 6 and external cooling water flowing through the auxiliary cooling apparatus of the plate heat exchanger 6 .
According to an apparatus embodiment of this invention, the internal cooling apparatus further comprises a first loop valve 4 and a second loop valve 5 ; wherein when the first loop valve 4 is opened and the second loop valve 5 is closed, a first loop with internal cooling water circulating therein is formed by the air cooler 3 and a device to be cooled 1 ; when the first loop valve 4 is closed and the second loop valve 5 is opened, a second loop with internal cooling water circulating therein is formed by the device to be cooled 1 , the air cooler 3 and the plate heat exchanger 6 ; a circulation loop for external cooling water is formed by the plate heat exchanger 6 and the underground water pipe 8 .
According to an apparatus embodiment of this invention, when the environment temperature is higher than 17° C., the first loop valve 4 is closed and the second loop valve 5 is opened, in which case the internal cooling water passes through the air cooler 3 and is cooled and then flows into the plate heat exchanger 7 to be cooled again, which then is used to cool the device to be cooled 1 ; when the temperature of the internal cooling water in the internal cooling apparatus is lower than a cooling water threshold, the first loop valve 4 is closed and the second loop valve 5 is opened, in which case the internal cooling water passes through the plate heat exchanger 7 and is heated by the external cooling water and then is used to cool the device to be cooled 1 .
According to an apparatus embodiment of this invention, the internal cooling apparatus further comprises a water temperature sensor and/or an environment temperature sensor, and a control unit which is used to control the opening and closing of the first loop valve 4 and the second loop valve 5 according to a water temperature of the internal cooling water that is measured by the water temperature sensor and/or an environment temperature that is measured by the environment temperature sensor.
According to an apparatus embodiment of this invention, the underground water pipe 8 is buried at a depth of 30 to 50 m under the ground.
According to an apparatus embodiment of this invention, the internal cooling circulation pump 2 and the external cooling circulation pump 6 are in a master-slave redundant configuration.
According to an apparatus embodiment of this invention, the device to be cooled 1 is a converter valve provided in a DC power transmission device.
The cooling apparatus of this invention adopts a plate heat exchanger in connection with an underground water pipe to re-cool internal cooling water passing through an air cooler, so as to improve cooling capability of the cooling apparatus. A problem of unable to cool the fluid to environment temperature or below environment temperature by the air cooler may be solved. Further, because no water is lost during the operation of the apparatus, a purpose of water saving may be achieved. Also, at lower environment temperature in winter, taking advantage of the fact that water in the underground water pipe has a relatively higher temperature, the internal cooling water may be heated to achieve the reduction in energy consumption efficiently.
A technical problem to be solved in this invention is to provide a cooling method to improve cooling capability of a cooling apparatus.
A closed circulating water cooling method comprises cooling a device to be cooled 1 by internal cooling water flowing in an internal cooling apparatus, the internal cooling water passing through a plate heat exchanger 6 and exchanging heat with external cooling water flowing through an auxiliary cooling apparatus of the plate heat exchanger 6 , wherein the internal cooling apparatus comprises an internal cooling circulation pump 2 and an air cooler 3 ; the auxiliary cooling apparatus comprises an external cooling circulation pump 7 and a underground water pipe 8 .
According to a method embodiment of this invention, a first loop is formed by the air cooler 3 and the device to be cooled 1 when a first loop valve 4 is opened and a second loop valve 5 is closed, wherein the internal cooling water circulates in the first loop; a second loop is formed by the device to be cooled 1 , the air cooler 3 and the plate heat exchanger 6 when the first loop valve 4 is closed and the second loop valve 5 is opened, wherein the internal cooling water circulates in the second loop; a circulation loop for external cooling circulation water is formed by the plate heat exchanger 6 and the underground water pipe 8 , wherein the external cooling circulation water circulates in the circulation loop for external cooling circulation water.
According to a method embodiment of this invention, when the environment temperature is higher than 17° C., the first loop valve 4 is closed and the second loop valve 5 is opened, in which case the internal cooling water passes through the air cooler 3 and is cooled and then flows into the plate heat exchanger 7 to be cooled again, which then is used to cool the device to be cooled 1 ; when the temperature of the internal cooling water in the internal cooling apparatus is lower than a cooling water threshold, the first loop valve 4 is closed and the second loop valve 5 is opened, in which case the internal cooling water passes through the plate heat exchanger 7 and is heated by the external cooling water and then is used to cool the device to be cooled 1 .
According to a method embodiment of this invention, the internal cooling apparatus is further provided with a water temperature sensor and/or an environment temperature sensor; wherein a control unit provided in the internal cooling apparatus controls the opening and closing of the first loop valve 4 and the second loop valve 5 according to a water temperature of the internal cooling water that is measured by the water temperature sensor and/or an environment temperature that is measured by the environment temperature sensor.
According to a method embodiment of this invention, the underground water pipe 8 is buried at a depth of 30 to 50 m under the ground.
According to a method embodiment of this invention, the internal cooling circulation pump 2 and the external cooling circulation pump 6 are in a master-slave redundant configuration.
According to a method embodiment of this invention, the device to be cooled 1 is a converter valve provided in a DC power transmission device.
The cooling method of this invention adopts a plate heat exchanger in connection with an underground water pipe to re-cool internal cooling water passing through an air cooler, so as to improve cooling capability of the cooling apparatus. A problem of unable to cool the fluid to environment temperature or below environment temperature by the air cooler may be solved. Further, because no water is lost during the operation of the apparatus, a purpose of water saving may be achieved. Also, at lower environment temperature in winter, taking advantage of the fact that water in the underground water pipe has a relatively higher temperature, the internal cooling water may be heated to achieve the reduction in energy consumption efficiently.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which constitute a part of the specification, provide a further understanding of this invention. Exemplary embodiments of this invention and their illustrations are given for the purpose of illustrating the present invention, which are not limits of the present invention, in the figures:
FIG. 1 is a schematic diagram of an embodiment of the cooling apparatus according to this invention;
FIG. 2 is a schematic diagram of an operating state of an embodiment of the cooling apparatus according to this invention;
FIG. 3 is a schematic diagram of another operating state of an embodiment of the cooling apparatus according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The cooling apparatus and method of this invention adopts an underground water pipe in connection with a plate heat exchanger to re-cool internal cooling water passing through an air cooler, so as to improve cooling capability of the cooling apparatus.
A description of the technical solution of this invention will be given in terms of many aspects below with reference to the drawings and embodiments.
FIG. 1 is a schematic diagram of an embodiment of the cooling apparatus according to this invention. As shown in FIG. 1 , the internal cooling apparatus comprises: an internal cooling circulation pump 2 , an air cooler 3 , a first loop valve 4 , a second loop valve 5 ; the auxiliary cooling apparatus comprises an external cooling circulation pump 7 and an underground water pipe 8 ; wherein a loop is formed by the air cooler 3 and the device to be cooled 1 when the first loop valve 4 is opened and the second loop valve 5 is closed; the internal cooling water is powered by the internal cooling circulation pump 2 to circulate in the loop; wherein the internal cooling water is cooled when passing through the air cooler 3 , and then is used to cool the device to be cooled 1 .
When the first loop valve 4 is closed and the second loop valve 5 is opened, a loop is formed by the device to be cooled 1 , the air cooler 3 and the plate heat exchanger 6 . The internal cooling water is powered by the internal cooling circulation pump 2 to circulate in the loop, wherein the internal cooling water is cooled when passing through the air cooler 3 and then flows into the plate heat exchanger 6 to be cooled again, which is then used to cool the device to be cooled 1 .
External cooling circulation water is powered by the external cooling circulation pump 7 to circulate in a loop formed by the plate heat exchanger 6 and the underground water pipe 8 , wherein the external cooling circulation water is cooled by the underground water pipe 8 . Wherein, the underground water pipe 8 is a water pipe which is buried deeply underground. External cooling water in the underground water pipe is cooled taking advantage of the fact that the temperature is relatively low and constant under the earth's surface.
According to an embodiment of this invention, there may be one second loop valve provided at the outlet or inlet of the plate heat exchanger 6 . There may also be two second loop valves provided at the outlet and inlet of the plate heat exchanger 6 , respectively.
According to an embodiment of this invention, the device to be cooled 1 is a converter valve provided in a DC power transmission device, and the internal cooling water is pure water.
According to an embodiment of this invention, the internal cooling water is heated at the converter valve and then is driven by the internal cooling circulation pump 2 to pass through the plate heat exchanger 6 , where the internal cooling water is cooled. The cooled internal cooling water is driven by the internal cooling circulation pump 2 and is transported to the converter valve again, and moves in cycles in this manner.
In the case of a relatively higher environment temperature, the first loop valve 4 is closed and the second loop valve 5 is opened. Internal cooling water having some heat dissipated at the air cooler is further cooled by the plate heat exchanger 6 to a temperature range allowable for the industry device. Heat is dissipated from the plate heat exchanger 6 by means of the underground water pipe 8 . The air cooler 3 may operate or may not operate. The auxiliary cooling system is started to cool by means of the underground water pipe 8 , so that the design load of the internal air cooler is reduced and the footprint of the cooling apparatus may be reduced.
According to an embodiment of this invention, the cooling apparatus of this invention may realize a function of antifreezing and fluid heating in winter by means of the underground water pipe 8 . For example, in a converter station of a DC power transmission project, in order to guarantee the safe operation of converter valves, which are a kind of a process device, there is a requirement that the fluid temperature must be higher than a certain value. Taking a converter valve adopted in a DC power transmission project as an example, it is required that the lowest valve inlet temperature must be higher than or equal to 10° C. In the event of a relatively low environment temperature and a lighter load of the converter valve, it is necessary to heat the internal cooling water by an additional heat source.
According to an embodiment of this invention, at a lower environment temperature in winter, when the temperature of the internal cooling water in the internal cooling apparatus is lower than a cooling water temperature threshold, the first loop valve 4 is closed and the second loop valve 5 is opened, in which case the internal cooling water is heated by the external cooling water when passing through the plate heat exchanger 7 and then is used to cool the device to be cooled 1 . With the fact that the temperature of water in the underground water pipe 8 is relatively high, through closing the first loop valve 4 and opening the second loop valve 5 , the internal cooling water is heated by the plate heat exchanger 6 to a temperature range that is allowable for the process device.
According to an embodiment of this invention, the first loop valve 4 and the second loop valve 5 may be automatic or manual valves.
The internal cooling apparatus further comprises a control unit, which is not shown in FIG. 1 , when the temperature of the internal cooling water is higher than a threshold or the environment temperature is higher than a threshold or heating the internal cooling water by external circulating water in winter, the control unit closes the first loop valve 4 and opens the second loop valves 5 . The internal cooling apparatus is provided with a water temperature sensor and/or an environment temperature sensor for measuring water temperature of the internal cooling water and the environment temperature.
According to an embodiment of this invention, the internal cooling circulation pump 2 and the external cooling circulation pump 8 may be in a master-slave redundant configuration to improve the operation safety and reliability of the cooling apparatus.
According to an embodiment of this invention, heat is dissipated from the plate heat exchanger 6 to the ground by means of the underground water pipe 8 which is buried underground generally at a depth of 30 to 50 m.
Because the temperature at the layer at a depth of 5 to 10 m under the earth's surface does not vary with the atmospheric temperature, which is always maintained at 15 to 17° C., according to an embodiment of this invention, when the environment temperature exceeds above 17° C., the first loop valve 4 is closed and the second loop valve 5 is opened, so that the internal cooling water is cooled when passing through the air cooler 3 (or the air cooler 3 may not operate at all) and flows into the plate heat exchanger 7 to be cooled again and then is used to cool the device to be cooled 1 .
According to an embodiment of this invention, a converter valve cooling system in practice, with the same equivalent cooling capacity (4900 kW, for example), if the designed environment temperature of the air cooler is 38° C., the number of channels that are required for the air cooler is 8 (there are three 11 kW fan motors in each channel) and the size of each channel is 9*3.1 m, the air cooler has a footprint of about 10*25 m; if the designed environment temperature of the air cooler is 17° C., only 4 channels of the same type are required for the air cooler (with a 10% margin or above), and the footprint turns into 9*13 m. In addition to the reduction of the number of channels that are required by the air cooler from 8 to 4, the number of fan motors is changed to 12 from 24, cutting down the footprint by half accordingly. The corresponding plate heat exchanger has the same designed cooling capacity as the air cooler, in which case the plate heat exchanger has a shape size of only 0.9*0.8*1.4 m and a footprint that is negligible.
FIG. 2 is a schematic diagram of an operating state of an embodiment of the cooling apparatus according to this invention. As shown in FIG. 2 , the internal cooling apparatus comprises: an internal cooling circulation pump 2 , an air cooler 3 , wherein a loop is formed by the device to be cooled 1 and the air cooler 3 ; the internal cooling water is powered by the internal cooling circulation pump 2 to circulate in the loop; wherein the internal cooling water is cooled when passing through the air cooler 3 and then is used to cool the device to be cooled 1 . The internal cooling water moves in cycles in this manner.
FIG. 3 is a schematic diagram of another operating state of an embodiment of the cooling apparatus according to this invention. As shown in FIG. 3 , the internal cooling apparatus comprises an internal cooling circulation pump 2 , an air cooler 3 ; the auxiliary cooling apparatus comprises: an external cooling circulation pump 7 and a underground water pipe 8 ; wherein external cooling circulation water is powered by the external cooling circulation pump 7 to circulate in a loop formed by the plate heat exchanger 6 and the underground water pipe 8 , wherein the underground water pipe 8 is used to cool the external cooling circulation water.
A loop is formed by the device to be cooled 1 , the air cooler 3 and the plate heat exchanger 6 ; internal cooling water is powered by the internal cooling circulation pump 2 to circulate in the loop; wherein after being cooled by the air cooler 3 , the internal cooling water enters the plate heat exchanger 6 to be further cooled and then is used to cool the device to be cooled 1 ; heat is exchanged between the internal cooling water flowing through the plate heat exchanger 6 and the external cooling water flowing through the plate heat exchanger 6 , and the internal cooling water moves in cycles in this manner.
It can be seen from the content described above, all of the water closely circulates within the interior of the apparatus without any loss or waste of water, showing a characteristic of zero-water-loss.
The cooling apparatus of this invention may solve the problem that the air cooler is unable to cool the fluid to the environment temperature or below the environment temperature. When the environment temperature is higher than or equal to a maximum inlet water temperature that is allowable for a process device, cooling water may not be cooled by the air cooler at a time. On the contrary, cooling water may be heated. The cooling apparatus of this invention still has enough cooling capability to satisfy the operation requirement of the process device. There is not any water loss during the operation of the cooling apparatus, so that a purpose of water saving may be achieved, and the shortcoming of heavy water consumption caused by cooling towers may be solved. In addition, at low environment temperature in winter, taking advantage of the fact that water in the underground water pipe has a relatively higher temperature, outdoor heat exchanger antifreezing and fluid heating may be realized, which may reduce energy consumption efficiently.
At last it should be noticed that the above embodiments are given for the purpose of illustrating the technical solution of this invention, and are not limitation thereof. Although this invention has been described in detail according to preferable embodiments, those skilled in the art may understand that modifications and substitutions may be made to some technical features of those specific embodiments without departing from the spirit of this invention, which therefore should be encompassed in the scope to be protected by this invention. | A closed circulating water cooling apparatus includes an internal cooling apparatus, a plate heat exchanger, and an auxiliary cooling apparatus. The internal cooling apparatus comprises an internal cooling circulator pump and an air cooler. The auxiliary cooling apparatus comprises an external cooling circulator pump and an underground water pipe. Internal cooling water flowing through the plate heat exchanger from the internal cooling apparatus exchanges heat with external cooling water flowing through the plate heat exchanger from the auxiliary cooling apparatus. Utilization of the closed circulating water cooling apparatus and method allows for increased cooling capacity, when the environmental temperature is greater than the maximum inflow water temperature permitted by a piece of technical equipment, for the cooling apparatus to still provide sufficient cooling capacity, and for the equipment to obviate any water loss during operation. | 7 |
BACKGROUND OF THE INVENTION
This invention generally relates to an improved valve apparatus and a method of operating thereof which has a spring retainer member suitable for accommodating a spring member therein for operably coupling thereabove a pipe coupling body. Inside the pipe coupling body is a ball headed member operably coupled to the spring retainer member suitable for blocking or allowing medium passage through the pipe coupling body.
Conventional valve devices often utilize a so-called flap valve which has an operably connected flap member inside a pipe member suitable for being operated outside the pipe member. Here, the flap member is operably coupled on at least one end to the inner surface of the valve device, the free end suitable for being moved. The flap member is suitable for being operably held at an upstanding position when passage of medium through the valve device is intended to be blocked. When passage of the medium through the valve device is required, the free end of the flap member is moved upwards for opening the passageway inside the valve device. Similarly, a so-called "butterfly" valve is readily available for use. In the so-called "butterfly" valve, a flap member is held inside the valve member, preferably at the middle portion thereof, in order to permit the ends of the flap member to be free and unobstructed. The middle portion of the flap member of the "butterfly" valve device can be manipulated from the exterior portion of the device for allowing the flap member to be in an upstanding position for stopping flow of medium through the valve device and flipped open for allowing flow therethrough.
These types of valve devices are, however, often ineffective, both in blocking off or in allowing the medium to pass through the valve devices. Here, unnecessary blockage of medium occur by the free end of the flap member of the flap valve device or the middle portion of the flap member in the "butterfly" valve device when in operation. Moreover, in both instances, leaks can occur therebetween the edges and the internal surface of the valve device when blockage of medium is required. Also, the flap members in both instances tend to jam inside the valve member due to various operational parameters, such as thermal expansions generated by the variegated medium temperatures passing therethrough, corrosion, bad fittings, or the like.
Thus, there is a dire need to provide an efficient and improved valve apparatus and a method of operation thereof in order to avoid the above-discussed problems. More particularly, a need is felt to provide an improved valve which can completely block off passing medium when desired, as well as allow the rapid, complete and efficient passage therethrough when required. Moreover, the improved valve should be suitable for being operated with efficiency and quickness.
It is therefore an object of the present invention to provide an improved valve apparatus and a method of operation thereof.
It is another object of the present invention to provide an improved valve apparatus and a method of operation thereof which is suitable for efficiently and completely blocking off medium passing through the improved valve; and rapidly, efficiently and unimpedingly allowing passage thereof when desired.
It is yet another object of the present invention to provide an improved valve apparatus and a method of operation thereof which is suitable for being spring loaded to provide a quick "on-off" feature for passage of medium therethrough.
It is a further object of the present invention to provide an improved valve apparatus and a method of operation thereof having a ball headed member therein with an aperture passing therethrough for blocking off and allowing a passage of medium therethrough.
It is yet a further object of the present invention to provide an improved valve apparatus and a method of operation thereof which can be easily and economically produced, yet sturdy in construction and highly efficient in operation.
It is yet a further object of the present invention to provide an improved valve apparatus and a method of operation thereof which is constructed with simplicity, embodying simple removable parts, and therefore capable of being retailed for a low price, long-lasting in use, and convenient to handle and operate.
SUMMARY OF THE INVENTION
The aforementioned and other objects of the present invention are accomplished by providing an improved valve apparatus and a method of operation thereof having a spring retainer member suitable for accommodating a spring member therein for being operably coupled thereabove a pipe coupling body are disclosed. The improved valve of the present invention further has a ball headed member with an aperture passing therethrough operably coupled to the spring retainer member for a quick "on-off" passage of medium passing therethrough. To further provide efficient operation of the ball headed member, a plurality of washers, including a washer having a plurality protruding spring members therefrom, are provided proximate the ball headed member. The improved valve apparatus and method of operation thereof can efficiently and completely block off passage of medium therethrough and can rapidly, efficiently and unimpedingly permit passage therethrough of said medium, when desired.
These and other features of the invention will be understood upon reading of the following description along with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of an improved valve of the present invention showing a plurality of internal and external parts thereof.
FIG. 2 is a cross-sectional view of the improved valve of the present invention when fully assembled.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2 of a spring retainer member with a spring member therein.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 2 of a pipe coupling body with a plurality of internal parts housed therein.
FIG. 5 is an exploded view showing the manner in which a first alternative inside washer having a plurality of integral spring means and an adjacent washer seal backup member are assembled proximate a ball headed member.
FIG. 6 is a cross-sectional view of a fully assembled improved valve of the present invention with the first alternative inside washer and the adjacent washer seal backup member in use.
FIG. 7 is a top elevational view of the first alternative inside washer.
FIG. 8 is a top elevational view of a washer seal backup member.
FIG. 9 is a perspective view of a second alternative inside washer having a plurality of integral spring means extending therefrom.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, an exploded view of an improved valve, generally referred to by reference number 1, is shown having a pipe coupling body 3 with a spring retainer member 5 to be operably mounted thereabove. On a first end 7 of the pipe coupling body 3 are internal threads 8. On an opposing second end 10 of the pipe coupling body 3 are internal threads 11 (see FIG. 2, infra). On the first end 7 is a first aperture 9 passing therethrough while on the second end 10 is a second aperture 13 passing therethrough (see also FIG. 2, infra). Therealong an intermediate portion 12 of the pipe coupling body 3 is a groove 14. Passing therethrough a side 16 of the pipe coupling body 3 is an aperture 17 while on the intermediate portion 12 is a notch 19. The pipe coupling body 3 is preferably made out of sturdy, durable and long-lasting material, such as metal (e.g., brass, stainless steel or the like), plastic (e.g., PVC or the like), or the like. Thereabove the pipe coupling body 3 is the spring retainer member 5 having a space portion 15 therein for accommodating a spring member 21, preferably a coil spring. The spring member 21 has a first integral protruding end 18 suitable for being accommodated inside a notch portion 20 thereabove the space portion 15. Also, the spring member 21 has a second integral protruding end 22 suitable for being seated into the notch 19.
The spring retainer member 5 has a handle member 24 having a loop end 25 suitable for being easily gripped by a user. Preferably at the center of the spring retainer member 5 is an a central aperture 28 passing therethrough for accommodating therein a bolt 30. The bolt 30 with an integral bolt head 31 has a washer 32 therebetween the bolt head 31 and the spring retainer member 5.
Fitted inside the spring retainer member 5 is a ball headed member 33 with an upper extending member 35 having a threaded notch 37 for accommodating the external threads 38 of the bolt 30.
The ball headed member 33 has a ball portion 38 with a central aperture 40 passing therethrough. The axis of the central aperture 40 is substantially aligned with the axes of first 9 and second 13 apertures. When the ball headed 33 is fitted inside the pipe coupling body 3, the upper extending member 35 is initially passed through the aperture 13, then upwardly through the aperture 17 of the side 16 of the pipe coupling body 3. The upper extending member 35 preferably has a middle portion 36 thereof which is preferably configured to accommodate therein an O-ring member (not shown for clearly illustrating the middle portion 36) between the upper extending member 35 and the side 16 of the pipe coupling body 3 (see also FIG. 2, infra).
Proximate the first end 7 of the pipe coupling body 3 is a first set of washer members, comprising of a first 41, second 42 and third 43 washers. The first washer member 42, as shown in FIG. 1 has a plurality of integral wave configurations 47 and preferably made out of urethane or metal. The second washer member 42 is preferably a flat washer made out of non-corrosive material. The third washer member 43 is preferably made out of teflon having a groove therealong for accommodating a rubber ring 48.
Proximate the opposing second end 10 is a fourth washer member 44 and a retainer member 45 for retaining the ball headed member 33 in place. The fourth washer member 44 is preferably also made of teflon while the retainer member 45 is preferably made out of stainless steel. The retainer member 45 preferably also has a plurality of extending members 59 therefrom.
The spring retainer member 5 is preferably made out of a metallic material, such as "ZAMAC 3" or the like, preferably having a gold erudite finish. The handle member 24, including its loop end 25, are made of metal, such as spring steel or the like. The spring member 21 is preferably made out of stainless steel. The ball headed member, including its upper extending member 35 is made out of metal, such as brass or the like.
As shown in FIG. 2, the spring member 21 which is completely deflected is accommodated inside the spring member 5 when the bolt 30 is screwed into the threaded notch 37 of the upper extending member 35 of the ball headed member 33. In order for the spring retainer member 5 to move when it is rotated, therebelow is a bottom notch portion 52 which is suitable for providing a space for the second integral protruding end 22 of the spring member 21.
As also shown in FIG. 2, the first 41, second 42 third 43 washers are placed adjacent to each other proximate the first aperture 9 of the pipe coupling body 3. After the ball headed member 33 is inserted into the pipe coupling body 3, the fourth washer member 44 is fitted thereto and thereafter, the retainer member 45 is fitted wherein the edges thereof are accommodated therein an internal groove portion 55 of the pipe coupling body 3. The non-apertured side 58 (see FIG. 1, supra) of the ball headed member 33 directly covers the first 9 and second 13 apertures in order for any medium to pass therethrough when the improved valve 1 is in use.
Due to the spring retainer member 5 being bolted onto the ball headed member 33, as also illustrated in FIG. 3, the spring retainer member 5 can be moved or rotated by the use of the handle member 24, either (1) for blocking off the first 9 and second 13 apertures of the pipe coupling body 3 with the use of the non-apertured side 58 or (2) for completely aligning the aperture 40 of the ball headed member 33 with the first 9 and second 13 apertures of the pipe coupling body 3, as shown in FIG. 4.
As shown in FIG. 5, the first 41 and second 42 washer members (previously shown in FIGS. 1, 2 and 4) can be replaced with an alternative washer member 59 (see also FIG. 7, infra) and a seal backup washer member 60 (see also FIG. 8, infra), respectively. The alternative washer member 59, preferably made out of urethane or metal, has a plurality of internally protruding members 63 (see also FIG. 6, infra). The seal backup washer member 60 has a generally hexagonal-configured (although not limited thereto) aperture 65 passing therethrough. As further shown in FIG. 6, the plurality of internally protruding members 63 are initially impinged inwardly by the adjacent seal backup washer member 60 when first assembled, then an elongated driver member end (not shown) is inserted into the first aperture 9. The elongated driver member end, preferably has a hexagonal (although not limited thereto) end which can be fitted into the hexagonal-configured aperture 65 to thereafter twist off the alternative washer member 60 to permit the plurality of internally protruding members 63 to be generally "popped out" or released, thus efficiently providing a spring-induced operation at the ball portion 38 of the ball headed member when rotated during use.
In FIG. 9, another alternative washer member 70 for replacing the washer member 47 and the alternative washer member 59 is shown. Also, the another alternative washer member 70 with an aperture 73 passing therethrough is made out of urethane or metal and has a plurality of internally protruding members 75. Here, each protruding member 75 has an extending portion 76 with a protruding portion 78 therefrom for impinging with the adjacent seal backup washer member 60 (see, e.g., FIG. 6).
When in use, passage of medium initially occurs at the second aperture 13 then through the first aperture 9 of the pipe coupling body 3.
Also when in use, the initial position of the ball headed member 33 is as shown in FIG. 2, supra, and, as described above, for initially blocking off the medium passing therethrough the first 9 and second 13 apertures. When flow of medium is required to pass through the first 9 and second 13 apertures, the ball headed member 33 is rotated by the turning of the handle member 24 in order for the aperture 40 of the ball portion 38 of the ball headed member to be partially or fully aligned (see, e.g., FIG. 4, supra) with the first 9 and second 13 apertures of the pipe coupling member 3, thus allowing therethrough a controlled passage of medium therein.
While the invention has been particularly shown and described to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the spirit and scope of the invention. | An improved valve apparatus and a method of operation thereof having a spring retainer member means suitable for accommodating a spring means therein for operably coupling thereabove a pipe coupling body means are disclosed. Inside the pipe coupling body means is a ball headed member means having an aperture passing therethrough for blocking off or allowing passage of medium through the pipe coupling body means. The spring retainer member means is turned in one direction in order to allow unimpeded passage or to control the amount of flow thereof of said medium and can be rapidly and efficiently sprung back to its original position in order to completely block off the passage of said medium through the pipe coupling body means for a rapid and efficient "on-off" control thereof. | 5 |
[0001] The present invention relates generally to lights or lamps, i.e., illuminating apparatus. More particularly, the present invention relates to lights which are attachable to a person's head to free the person's hands for the work at hand.
[0002] A number of attempts have been made to provide a light attachable to a person's head. Thus, U.S. Pat. No. 3,683,168 to Tatje discloses illuminating spectacles having a light bulb with batteries on opposite sides of the bulb. Undesirably, the spectacles and their placement on a person's head are not able to suitably support the weight of the lamp components.
[0003] U.S. Pat. No. 3,912,919 to Eriksson discloses a head lamp comprising a bulb and batteries (one mounted on either side of a glow lamp holder) mounted in a casing, and a strap is extractable from the lid interior to be extended about a person's head so that the light is disposed centrally of the person's forehead. Undesirably, this lamp fixture is unstable on the person's forehead and places undue stress at the center of the person's forehead. In addition, this lamp is undesirably difficult to position for proper aim and to maintain in the adjusted position.
[0004] U.S. Pat. No. 5,853,241 to Sharrah et al discloses a flashlight having a head portion in which the light bulb is received and a pair of arms in which batteries are received and which diverge from the head portion for mounting of the head portion on the forehead of a user by means of an elastic strap. The arms are provided with resilient removable cover members to provide a resilient head mounting surface. See also U.S. Pat. No. 4,916,596 to Sharrah et al, which discloses an earlier version. This flashlight undesirably is difficult to position and to maintain the position for proper aim in view of the rigid arms.
[0005] U.S. Pat. No. 5,163,420 to Van Der Bel discloses a head light system which includes a housing mounted on the front surface of a head cap 11 . A fiber optic light conduit introduces light from a remote light source to the housing. The housing is mounted on the front surface of a head cap. The rear surface of the housing, which is the surface which is next to the forehead, is concave. The provision of a remote fiber optic light source is undesirably not suitable for the general utility purposes of the present invention.
[0006] Also see U.S. Pat. No. 5,898,472 to Oshikawa, which discloses a strap winding mechanism and reel for head wear.
[0007] The heretofore problem with mounting of traditional sources of light such as incandescent bulbs is addressed in the third paragraph of the Van Der Bel patent as follows:
[0008] Traditional sources of light, however, such as incandescent bulbs, do not lend themselves well to positioning at approximately between the surgeon's eyes. Such traditional light sources had the problem that, if they were large enough to provide sufficient light, they were too bulky and obscured the surgeon's vision. Furthermore, they were frequently heavy and they also generated a great deal of heat . . .
[0009] It is accordingly an object of the present invention to provide a traditional light source (i.e., a light bulb and batteries) which may be easily and comfortably worn on a person's head and easily positioned for proper aim to free the user's hands when working in darkened conditions.
[0010] In order to provide such a head light, in accordance with the present invention, a housing for the light bulb and batteries has at least a portion composed of elastomeric material having a rear concave surface shaped for conforming to a person's forehead to allow elastomeric conformity of the rear surface to the person's forehead.
[0011] The above and other objects, features, and advantages of the present invention will be apparent in the following detailed description of a preferred embodiment thereof when read in conjunction with the accompanying drawings wherein the same reference numerals denote the same or similar parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a perspective view from forwardly thereof of a head-mountable light in accordance with the present invention.
[0013] [0013]FIG. 2 is a perspective view thereof from forwardly thereof.
[0014] [0014]FIG. 3 is a side view thereof shown mounted to a person's head.
[0015] [0015]FIG. 4 is a front elevation view thereof.
[0016] [0016]FIG. 5 is a right side elevation view thereof, with a strap broken away.
[0017] [0017]FIG. 6 is a left side elevation view thereof, with the strap broken away.
[0018] [0018]FIG. 7 is a section view taken along lines 7 - 7 of FIG. 4, with the strap broken away.
[0019] [0019]FIG. 8 is a detail partial section view along the left side thereof.
[0020] [0020]FIG. 9 is a view similar to that of FIG. 8 illustrating removal of a housing member for replacement of a battery.
[0021] [0021]FIG. 10 is a perspective view thereof shown standing on its left side.
[0022] [0022]FIG. 11 is a partial elevational view taken along lines 11 - 11 of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to the FIGS., there is shown generally at 20 a light or lamp which emits light, illustrated at 18 , and which is mountable to the head 22 of a person, as illustrated in FIG. 3, by means of a strap 24 or other suitable attachment means which encircles the head 22 . If desired, the strap 24 may be of a retractable type or with a winding mechanism and reel, such as disclosed in the aforesaid U.S. Pat. No. 5,898,472, which is hereby incorporated herein by reference.
[0024] The light includes a housing 26 having a forward surface 28 and a rear surface 30 . The housing 26 comprises sheet material 32 composed of rigid plastic or other suitable material, preferably non-conductive to accommodate the circuitry hereinafter described, rigidly forming a forward wall 34 , a top wall 36 , a bottom wall 38 , a right side wall 40 , and a left side wall 42 . The front wall is formed by member 44 , which will be described in greater detail hereinafter. These walls define a cavity, illustrated at 46 , in which various light components, as described hereinafter, are contained or housed.
[0025] The front wall 34 has a generally rectangular (or otherwise suitably shaped) opening, illustrated at 48 , therein. The wall 34 has an inwardly offset lip or flange 50 along one edge, i.e., as shown, the edge corresponding to the right side of the opening 48 , and a generally rectangular rigid member 51 is mounted in the opening 48 so that an edge thereof rests on the lip 50 so that the forward surface of the member 51 is flush with the forward surface of the front wall 26 . The opposite edge of the member 51 has an inwardly offset lip or flange 54 which nests under the respective front wall edge, and the member 51 is suitably attached to the lip 50 such as by a pair of screws 56 . The member has a generally rectangular opening, illustrated at 53 , therein. A conventional reflector/bulb holder 58 including a suitable conventional lens 52 , composed for example of plastic, is suitably positioned in the cavity 46 in back of the opening 53 (to be generally flush with the front wall) to allow passage of light 18 through the opening 53 , the edges of the lens 52 being suitably mounted to the edges of the member 51 (inwardly of lip 54 ) by means such as, for example, an adhesive. A conventional flashlight-type bulb 60 is suitably mounted centrally of the reflector 58 such as by a threaded portion 62 which is threadedly received in reflector aperture 64 . A pair of suitable flashlight-type batteries 66 are received within the cavity 46 on opposite sides of the bulb 60 . The batteries 66 may, for example, be no. 950 size D type.
[0026] The side walls 40 and 42 extend rearwardly for a short distance beyond the cavity 46 , and a generally cylindrical 9 or otherwise suitably shaped) cut-out 71 is provided in each side wall 40 and 42 , the cut-out extending through the rear edge of the respective side wall and spaced from each of the other edges thereof to provide an opening through which the respective battery 66 can be inserted and removed, as seen in FIG. 9. Suitable springs, illustrated at 79 , are desirably attached to the inner surface of the respective door to apply pressure to the batteries 66 respectively so that the batteries are secured against shaking when in the cavity 46 . The opening 71 is closed by a door or closure plate 73 which has an inwardly offset forward lip or flange 75 to be received inwardly of the corresponding edge portion 77 of the respective wall 40 and 42 so that the outer surface of the door 73 is flush with the outer surface of the respective wall 40 and 42 , as seen in FIG. 8. A forward end portion of a rigid plate 72 is received inwardly of the respective door 73 , and the plate 72 is secured to (embedded in) member 44 as hereinafter discussed. Each door 73 is suitably attached to the respective plate 72 by a finger screw 74 received in an aperture 70 in a rear edge portion of the door 73 and threadedly received in a threaded aperture 76 in a forward edge portion of the plate 72 . The plate 72 extends rearwardly beyond the respective side wall and terminates short of the respective rearward-most surface 78 of the member 44 so that the member 44 extends rearwardly beyond the respective plate 72 . The lateral walls 80 of the member 44 are flush with respect to the doors 73 and the side walls 40 and 42 respectively whereby the plates 72 are partially embedded in the material of the member 44 to provide a secure position thereof for secure attachment of the doors 73 . Each plate 72 has an enlarged rearward end portion 82 which extends laterally outwardly from the member 44 , the enlarged portion 82 having suitable structure for receiving an end of the strap for adjustably attaching the light 20 to the person's head 22 , in accordance with principles commonly known to those of ordinary skill in the art to which the present invention pertains.
[0027] A suitable conventional on-off switch 84 is suitably mounted so that it is suitably secured to one of the plates 72 (i.e., as shown, the right plate), in accordance with principles commonly known to those of ordinary skill in the art to which the present invention pertains. One side of the switch 84 is electrically connected to the bulb 60 by line 86 . The bulb is also electrically connected to the negative terminal of one of the batteries 66 by line 88 . The positive terminal of that battery 66 is electrically connected to the negative terminal of the other battery 66 by line 90 whereby the batteries are connected in the circuit in series. Finally, the positive terminal of this other battery 66 is electrically connected to the switch 84 by line 92 thereby completing the circuit for supplying electricity to the bulb 60 for lighting by turning the switch 84 on. It should however be understood that the circuitry may be embodied otherwise. For example, the circuitry may alternatively be of a type which includes a ground to the housing sheet material 32 , which accordingly is a conductive material.
[0028] In order to accurately and easily and comfortably mount the light assembly 20 to the user's forehead so that the light 18 is aimed in the direction of sight, in accordance with the present invention, the housing member 44 is composed of an elastomeric material such as, for example, foam rubber, which has suitable softness to comfortably conform to the person's forehead. The elastomeric material is suitably molded about the rigid plates 72 as illustrated in FIG. 7 to hold the plates 72 securely in place and so that the plates provide a secure means of attachment of the member 44 . The molded elastomeric material may extend forwardly beyond the rigid plates 72 a distance of, for example, about ½ inch. The member 44 has a symmetrical concave rearward surface 94 for engaging the typical forehead of the user 22 , as illustrated in FIG. 3. For example, for a typical adult, the concave surface 94 may have a width of about 6 inches and a depth of about 2 inches. The light assembly 20 may be provided in more than one size of the concave surface 94 . The overall width of the light apparatus 20 may, for example, be about 6¾ inches, the lens width may, for example, be about 4 inches, and the overall light apparatus depth (front to back) may, for example, be about 3½ inches. The above dimensions are for exemplary purposes only and not for purposes of limitation.
[0029] In order to provide a stand, i.e., a means for setting the light assembly 20 down without damage to the lens or switch, while allowing access to the switch, feet members or legs 96 are suitably attached to the side of the housing 26 which does not contain the switch. Thus, the feet 96 are shown on the left side wall 42 . Feet 96 may be composed of hard rubber other suitable material adhesively or otherwise suitably attached to the side wall 42 . For example, 4 such feet 96 may be provided at the four corners respectively of the side wall 42 , as shown in FIG. 6.
[0030] Thus, the light assembly 20 may be easily and quickly mounted on a person's head 22 by receiving the forehead in the symmetrical concave surface 94 , which accordingly properly centers the light 20 to aim in the direction in which the user sees, and adjusting the straps 24 as necessary. The elastomeric material of the member 44 allows a snug and comfortable fit when the straps are suitably tightened as necessary.
[0031] It should be understood that, while the present invention has been described in detail herein, the invention can be embodied otherwise without departing from the principles thereof, and such other embodiments are meant to come within the scope of the present invention as defined by the appended claims. | A light apparatus attachable to the head of a person to emit light generally along the line of sight of the person. The light apparatus includes a housing cavity in which are contained a light bulb and a pair of batteries on opposite sides thereof and connected thereto. At least a portion of the housing is composed of elastomeric material having a rear concave surface shaped for conforming to a person's forehead to allow elastomeric conformity of the rear surface to the person's forehead. The light bulb and a lens are disposed for directing light forwardly of the housing and generally along the line of sight of the person. A plurality of legs on at least one side of the housing provide support for setting the light apparatus down. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to novel liquid, storage-stable, modified diphenylmethane diisocyanate compositions and to a process for the preparation of these novel liquid, storage-stable, modified diisocyanate compositions.
Polyisocyanate compositions exhibiting low viscosities and high functionalities and a process for their preparation are disclosed in U.S. Pat. No. 6,730,405. These polyisocyanate compositions may be reacted with a compound comprising a mobile hydrogen, which are also known as masking agents. Masking agents are described as having at least one functional group carrying a mobile (or reactive) hydrogen, and the functional group should have a pKa of at least 4 to less than or equal to 14.
U.S. Pat. Nos. 5,777,023 and 5,881,648 disclose diamidediurethanes and hot melt printing from hot melt inks comprising these diamidediurethanes. The diamidediurethanes are prepared by reaction of a hydroxycarboxylic acid and/or lactone with either (1) monoamine and diisocyanate, or (2) diamine and monoisocyanate. These may also be prepared by reacting a non-hydric carboxylic acid and/or anhydride with a hydroxylamine and a diisocyanate. These products are solids. Also, the products are diurethanes, end-capped with an amide group.
It has surprisingly been found that diisocyanates which are modified with a compound containing both an amide and a hydroxyl group as described herein are low viscosity liquid products which are storage-stable at room temperature. It has also been found that these modified diisocyanates exhibit lower freezing points than the corresponding unmodified diisocyanates. Advantages of these modified diisocyanates include the ability of store and use them in processes without the need to maintain a >25° C. storage temperature
SUMMARY OF THE INVENTION
This invention relates to liquid, storage-stable diisocyanates having an NCO group content of 11 to 32% by weight, and to a process for the preparation of these liquid, storage-stable diisocyanates.
These liquid, storage-stable diisocyanates comprise the reaction product of: (A) diphenylmethane diisocyanate, with (B) at least one compound which contains both an amide group and a hydroxyl and corresponds to one of two specified formulas.
The a diphenylmethane diisocyanate (A) comprises:
(1) from 0 to 6% by weight of the 2,2′-isomer, (2) from 0 to 60% by weight of the 2,4′-isomer, and (3) from 34 to 100% by weight of 4,4′-isomer,
wherein the sum of the %′s by weight of (1), (2) and (3) totals 100% by weight of (A) the diphenylmethane diisocyanate.
Component (B) comprises at least one compound selected from the group consisting of:
(1) compounds which contain both an amide group and a hydroxyl group, and correspond to the structure:
wherein:
R 1 : represents an alkyl radical containing from 1 to 20 carbon atoms, a cycloalkyl radical containing 5 to 6 carbons, or an aryl radical containing 6 carbons; and R 2 : represents an alkyl radical containing from 1 to 12 carbon atoms;
and
(2) compounds which contain both an amide group and a hydroxyl group, and correspond to the structure:
wherein:
R 3 : represents an alkyl radical containing from 1 to 16 carbon atoms, a cycloalkyl radical containing 5 to 6 carbons, or an aryl radical containing 6 carbons and R 4 : represents an alkyl radical containing from 1 to 12 carbon atoms.
The process for producing these liquid, storage-stable diisocyanates comprises reacting (A) diphenylmethane diisocyanate, with (B) at least one compound which contains both an amide group and a hydroxyl group and corresponds to formula (I) or (II) above, in the presence of at least one catalyst.
DETAILED DESCRIPTION OF THE INVENTION
As used in the present invention, the term liquid means that the modified diisocyanate or polyisocyanate product does not precipitate solids when stored at 25° C. for 3 months.
As used herein, the term “storage-stable” means that the modified diisocyanate or polyisocyanate product has up to a 1% absolute change in the % NCO group content and up to a 10% change in the viscosity when stored at 25° C. for 3 months.
The liquid, storage stable, amide-modified diisocyanates of the present invention are typically characterized by an NCO group content of at least about 11% NCO, and preferably of at least about 14% NCO. These liquid diisocyanates are also typically characterized by an NCO group content or less than or equal to about 32% NCO, and preferably less than or equal to about 30% NCO. The liquid modified diisocyanates may also have an NCO group content ranging between any combination of these upper and lower values, inclusive. For example, the liquid diisocyanates may have an NCO group content of from about 11% by weight NCO to about 32% by weight NCO and preferably from about 14% by weight NCO to about 30% by weight NCO.
In accordance with the present invention, the following components are, generally speaking, suitable.
Suitable diisocyanates to be used as component (A) herein include comprise diphenylmethane diisocyanate in which the 2,2′-isomer is present in an amount of from 0 to 6% by weight, and preferably 0 to 2% by weight; the 2,4′-isomer is present in an amount of 0 to 60% by weight, and preferably 1 to 30% by weight; and the 4,4′-isomer is present in an amount of from 34 to 100% by weight, and preferably 68 to 99% by weight. When mixtures of the 2,2′-isomer, the 2,4′-isomer and the 4,4′-isomer of diphenylmethane diisocyanate are used, the sum of the %′s by weight of the individual isomers totals 100% by weight of the diphenylmethane diisocyanate.
Component (B) comprises at least one compound selected from the group consisting of:
(1) compounds which contain both an amide group and a hydroxyl group, and correspond to the structure:
wherein:
R 1 : represents an alkyl radical containing from 1 to 20 carbon atoms, a cycloalkyl radical containing 5 to 6 carbons, or an aryl radical containing 6 carbons, and preferably an alkyl radical containing from 1 to 3 carbon atoms; and R 2 : represents an alkyl radical containing from 1 to 12 carbon atoms, and preferably from 1 to 6 carbon atoms;
and
(2) compounds which contain both an amide group and a hydroxyl group, and correspond to the structure:
wherein:
R 3 : represents an alkyl radical containing from 1 to 16 carbon atoms, a cycloalkyl radical containing 5 to 6 carbons, or an aryl radical containing 6 carbons, and preferably an alkyl radical containing from 2 to 8 carbon atoms; and R 4 : represents an alkyl radical containing from 1 to 12 carbon atoms, and preferably from 2 to 6 carbon atoms.
Some examples of compounds which contain both an amide group and a hydroxyl group which correspond to structure (I) above and are suitable to be used as component (B)(1) herein include N-(2-hydroxyethyl)acetamide, N-(2-hydroxyethyl)propanamide, N-(3-hydroxypropyl)acetamide, N-(2-hydroxyethyl)cyclohexanecarboxamide, N-(2-hydroxyethyl)benzamide, etc. Preferred compounds are N-(2-hydroxyethyl)acetamide, and N-(3-hydroxypropyl)acetamide.
Some examples of compounds which contain both an amide group and a hydroxyl group which correspond to structure (II) above and are suitable to be used as component (B)(2) herein include N-methyl-3-hydroxylpropanamide, N-(2-ethylhexyl)-6-hydroxyhexamine, N-cyclohexyl-6-hydroxyhexanamide, N-phenyl-6-hydroxyhexanamide, etc. Preferred compounds are N-methyl-3-hydroxylpropanamide, and N-(2-ethylhexyl)-6-hydroxyhexamine.
In a preferred embodiment of the invention, it is preferred to react from 0.01 equivalent of component (B) per equivalent of component (A) up to 0.5 equivalent of component (B) per equivalent of component (A) in preparing the liquid, storage stable, modified diisocyanates of the invention. It is preferred that from 0.03 to 0.20 equivalent of component (B) per equivalent of component (A) is present.
In accordance with the present invention, a suitable catalyst may be present. Some examples of such catalysts include, but are not limited to, zinc acetylacetonate, zinc 2-ethylhexanoate, and other common zinc compounds, tin octanoate, dibutyltin dilaurate, and other common tin compounds, cobalt naphthanate, lead linoresinate, titanium 2-ethylhexanoate and other titanium (IV) compounds, zirconium 2-ethylhexanoate and other common zirconium (IV) compounds, bismuth 2-ethylhexanoate and other common bismuth compounds. The catalyst is typically used in an amount of at least about 50 ppm, and preferably at least about 100 ppm, based on the weight of isocyanate compound. The catalyst is also typically used in an amount of less than or equal to 5000 ppm, and preferably of less than or equal to about 1000 ppm, based on the weight of the isocyanate compound. The catalyst may be present in an amount ranging between any combination of these upper and lower values, inclusive. For example, the catalyst may be present in an amount of from 50 ppm to 5000 ppm, and preferably from about 100 ppm to 1000 ppm, based on the isocyanate compound.
Generally, the process of preparing the liquid, storage stable di- and/or poly-isocyanates of the invention comprises reacting (A) a suitable diphenylmethane diisocyanate component, with (B) a compound selected from the group of amides, bisamides and cyclic ureas as described above in the presence of a catalyst. The reaction typically is at a temperature of at least about 50° C., and more preferably at least about 70° C. The reaction also typically is at a temperature of less than or equal to 150° C., and more preferably less than or equal to 120° C. The reaction may occur at a temperature between any combination of these upper and lower values, inclusive. For example, the reaction may occur at a temperature of from 50 to 150° C., and more preferably of from 70 to 120° C.
The modified isocyanate compositions of the present invention may be reacted with one or more isocyanate-reactive components to form, for example, polyurethanes and/or polyureas.
The following examples further illustrate details for the preparation of the compositions of this invention. The invention, which is set forth in the foregoing disclosure, is not to be limited either in spirit or scope by these examples. Those skilled in the art will readily understand that known variations of the conditions and processes of the following preparative procedures can be used to prepare these compositions. Unless otherwise noted, all temperatures are degrees Celsius and all parts and percentages are parts by weight and percentages by weight, respectively.
EXAMPLES
The following components were used in the working examples:
ISO A: 4,4′-diphenylmethane diisocyanate Amide A: N-(2-ethylhexyl)-6-hydroxyhexamide Amide B: N-(2-hydroxyethyl)acetamide
Example 1
In a suitable flask, were added 250 g of Isocyanate A and the 20 g of Amide A, followed by heating to 60° C. under nitrogen. Zinc acetylacetonate (300 ppm) was added, and the mixture heated at 90° C. for 5 hours to yield a liquid product with 26% NCO.
Example 2
In a suitable flask, were added 250 g of Isocyanate A and the 20 g of Amide B, followed by heating to 60° C. under nitrogen. Zinc acetylacetonate (300 ppm) was added, and the mixture heated at 90° C. for 3 hours to yield a liquid product with 27.7% NCO.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | This invention relates to novel liquid, storage-stable diisocyanates and to a process for the preparation of these liquid, storage-stable diisocyanates. These comprise diphenylmethane diisocyanate and at least one compound which contains both an amide group and a hydroxyl group and which corresponds to one of two specified formulas. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefits under 35 U.S.C. §119(e) of Provisional Application Serial No. 60/298,009, filed Jun. 13, 2001 and No. 60/371,069, filed on Apr. 9, 2002, the disclosures of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to process for preparing rac-bicalutamide and its intermediates. The prevent invention also relates to micronized rac-bicalutamides and their preparations thereof.
BACKGROUND OF THE INVENTION
[0003] Bicalutamide is also known as N-[4-cyano-3-trifluoromethyl-phenyl]-3-[4-fluorophenyl-sulfonyl]-2-hydroxy-2-methyl-propionamide and has the following chemical formula.
[0004] Bicalutamide is an acylanilid that has anti-androgen activity. It is known to selectively decrease the testosterone level without influencing the regulation mechanisms of the hypothalamus.
[0005] The international patent No. WO 93/19770 describes both R-(−) enantiomer and S-(+) enantiomer for bicalutamide, of which the R-(−) isomer is reported to be more active and possesses lesser side-effects (e.g., headache, gynecomistia and giddiness) when used in therapy treatment.
[0006] U.S. Pat. No. 4,636,505 describes processes for preparing acylanilides.
[0007] The international Pat. No. WO 01/00608 describes a process for racemic and optically pure N-[4-cyano-3-trifluoromethylphenyl]-3-[4-fluorophenyl-sulfonyl]-2-hydroxy-2-methyl-propionamide. The process involves multiple steps including at least reacting with thionyl choride; hydrolyzing under aqueous basic conditions; sulfonylating with sulfonyl halogenide; and oxidizing with inorganic peroxy salt, or m-chloroperbenzoic acid (MCPBA) or aqueous hydrogen peroxide. However, the synthetic pathways involve the use of substrates (such as sodium hydride) that are dangerously explosive in nature.
[0008] There is a constant need to improve the synthesis process for bicalutamide which are economical and environmental safe and feasible.
[0009] We have now found a simpler method of preparing bicalutamide and its intermediates without using dangerous oxidizing compounds such as m-chloroperbenzoic acid.
OBJECTS AND SUMMARY OF THE INVENTION
[0010] The present invention provides new synthetic pathways for preparing rac-bicalutamide and its intermediates.
[0011] According to one object, the present invention is directed to a rac-bicalutamide intermediate having a chemical formula of [X], which represents a stable organo lithium salt of 4-fluorophenyl methyl sulfone.
[0012] According to another object, the present invention is directed to a process of preparing [X], comprising the step of reacting 4-fluorophenyl methyl sulfone with butyl lithium to form the organo lithium salt of 4-fluorophenyl methyl sulfone.
[0013] According to another object, the present invention provides a novel process for preparing rac-ethyl 1-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionic acid, comprising the step of reacting the organo lithium salt of 4-fluorophenyl methyl sulfone with ethyl pyruvate.
[0014] According to another object, the present invention is directed to a rac-bicalutamide intermediate having a chemical formula of [Y], which represents a stable lithium salt of 5-amino-2-cyano-benzotrifluoride.
[0015] According to another object, the present invention provides a precess for preparing [Y], comprising the step of reacting 5-amino-2-cyano-benzotrifluoride with butyl lithium to form the lithium salt of 5-amino-cyano-benzotrifluoride.
[0016] According to another object, the present invention provides a process for preparing rac-bicalutamide, comprising the step of reacting [Y] with rac-ethyl 1-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionic acid.
[0017] According to another object, the present invention provides a process for preparing rac-ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionic acid, comprising the steps of:
[0018] 1) mixing 4-fluorophenyl methyl sulfone with butyl lithium to obtain an intermediate having a chemical structure [X];
[0019] 2) adding ethyl pyruvate; and
[0020] 3) recovering rac-ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionic acid.
[0021] Preferably, 1,4 diazabicyclo[2.2.2]octane in tetrahydrofuran is used as a stablizied agent in step 1.
[0022] According to another object, the present invention provides a process for preparign rac-bicalutamide comprising the steps of:
[0023] 1) mixing 5-amino-2-cyano-benzotrifluoride and butyl lithium to obtain a lithium salt of 5-amino-2-cyano-benzotrifloride;
[0024] 2) adding rac-ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionic acid; and
[0025] 3) recovering rac-bicalutamide.
[0026] Preferably, the step 1) is occurred in the presence of 1,4 diazabicyclo[2.2.2]octane in tetrahydrofuran.
[0027] According to one object, the present invention provides a novel process of preparing micronized forms of rac-bicalutamide.
[0028] According to another object, the present invention provides a synthesis process of preparing rac-bicalutamide with a particle size in which the mean particle size enhances the rate of dissolution and the reproducibility of dissolution. The present invention provides rac-bicalutamide in which the mean particle size imparts an improved and stable dissolution profile.
[0029] According to another object, the present invention provides rac-bicalutamide formulations containing rac-bicalutamide having relatively small particles, and corresponding large surface area.
[0030] According to another object, the present invention provides rac-bicalutamide with a particle size which enhances the rate of dissolution and the reproducibility of the rate of dissolution.
[0031] According to another object, the present invention provides rac-bicalutamide in which the mean particle size imparts an improved and stable dissolution profile.
[0032] According to another object, the present invention provides rac-bicalutamide and formulations containing rac-bicalutamide having a mean particle diameter of less than 200 μm.
[0033] According to another object, the present invention provides a process for preparing micronized rac-bicalutamide.
[0034] According to another object, the present invention provides pharmaceutical compositions comprising micronized rac-bicalutamide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1 depicts the reaction pathway of rac-bicalutamide synthesis starting from ethyl pyruvate.
[0036] [0036]FIG. 2 depicts the reaction pathway of rac-bicalutamide synthesis starting from methyl methacrylate.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Definitions
[0038] As used herein, rac-bicalutamide refers to both the R-(−) enantiomer and S-(+) enantiomer of bicalutamide. Rac-bicalutamide is the racemic and optically pure R-(−) and S-(+) isomers of N-[4-cyano-3-trifluoromethyl-phenyl]-3-[4-fluorophenyl-sulfonyl]-2-hydroxy-2-methyl-propionamide. It is to be understood that this invention encompasses the racemic form of bicalutamide and any optically-active form which possesses anti-androgenic activity. It is a matter of common general knowledge how a racemic compound may be resolved into its optically-active forms and how any anti-androgenic activity present in any of these forms may be determined. One skilled in the art will appreciate that the separation of optical isomers can be achieved by conventional resolution; such as fractional crystallization or flash-chromatography.
[0039] As used herein, the term “micronized” refers to particles having a mean particle diameter of less than about 200 μm.
[0040] As used herein, the term “μm” refers to “micrometer” which is 1×10 −6 meter.
[0041] The following abbreviations are used herein: DCM is dichloromethane. THF is tetrahydrofuran. DABCO is 1,4 dizazbicyl[2.2.2]octane. ACB is 5-amino-2-cyano-benzotrofluoride. BCL is rac-bicalutamide. 4-FPMS is 4-fluorophenyl methyl sulfone.
[0042] The present invention provides a novel process for preparing rac-bicalutamide from ethyl pyruvate and 4-fluoropheynl methyl sulfone via the formation of an intermediate with chemical formula of [X].
[0043] The present invention further provides a novel process for preparing rac-bicalutamide from 4-fluorophenyl methyl sulfone. Butyl lithium reacts with 4-fluorophenyl methyl sulfone with a base to form an organo lithium the intermediate (i.e., with chemical formula of [X]), optionally in the presence of anion stabilizer such as DABCO. The base refers to strong bases such as lithium diisopropyl amid (LDA) or its derivatives. This reaction is preferably carried out in an inert organic solvent, for example tetrahydrofuran or diethyl ether. Most preferable solvent is tetrahydrofuran. The reaction is preferably carried out at a low temperature, for example −40° C. to 10° C. Most preferable temperature is between −2° C. and 2° C.
[0044] [0044]FIG. 1 illustrates the schematic process for preparing rac-bicalutamide from ethyl pyruvate and 4-fluorophenyl methyl sulfone. The intermediate with general chemical formula of [X] reacts with ethyl pyruvate to form ethyl-[2-4-{4-fluorophenyl sulfone}]-2-hydroxy propionate. This reaction is preferably carried out in an inert organic solvent, for example tetrahydrofuran or diethyl ether. Most preferable solvent is tetrahydrofuran. The reaction is preferably carried out at a low temperature, for example −60° C. to −100° C. Most preferable temperature is −60° C.
[0045] The present invention provides a process of preparing rac-bicalutamide from 5-amino-2-cyano-benzotrifluoride. Butyl lithium reacts with 5-amino-2-cyano-benzotriflouride with a base to form an organo lithium the intermediate (i.e., with chemical formula of [Y]), optionally in the presence of anion stabilizer such as DABCO. The base refers to strong bases such as lithium diisopropyl amid (LDA) or its derivatives. This reaction is preferably carried out in an inert organic solvent, for example tetrahydrofuran or diethyl ether. Most preferable solvent is tetrahydrofuran. The reaction is preferably carried out at a low temperature, for example −40° C. to 10° C. Most preferable temperature is between −2° C. and 2° C.
[0046] The present invention provides a process of preparing rac-bicalutamide from 5-amino-2-cyano-benzotrifluoride via intermediate with chemical formula of [Y]. Intermediate with chemcial formula [Y] thus formed reacts with rac-ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionate to form rac-bicalutamide. This reaction is preferably carried out in an inert organic solvent, for example tetrahydrofuran or diethyl ether. Most preferable solvent is tetrahydrofuran. The reaction is preferably carried out at a low temperature, for example −60° C. to −100° C. Most preferable temperature is −60° C.
[0047] The detailed procedures of preparing rac-ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionic acid from ethyl pyruvate and 4-fluorophenyl methyl sulfone as well as rac-bicalutamide from rac-ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionic acid and 5-amino-2-cyano-benzotrifluoride are illustrated in FIG. 1.
[0048] The process according to our invention is described in detail by the following, but not limiting, examples.
EXAMPLE 1
Preparation of rac-Ethyl-[2-{4-Fluorophenyl Sulfone}]-2-Hydroxy Propionate
[0049] 4-Fluorophenyl methyl sulfone (4-FPMS) (5 grams, 27.8 mmol) and 1,4 diazabicyclo[2.2.2]octane (DABCO) (3.2 grams, 28.5 mmol) were dissolved in tetrahydrofuran (THF) and cooled in dry-ice acetone bath to about −2° C.
[0050] A 2.5 M solution of butyl lithium in hexanes (14.5 mL, 36.2 mmol) was added to the cold THF solution dropwise via a syringe while keeping the temperature between about −2° C. to about 2° C. After addition was completed the stirring was continued for about 1 hour while maintaining the temperature at about −2° C. Then, the temperature was lowered to about −65° C. and a solution of ethyl pyruvate (3.67 grams, 31.6 mmol) in THF (30 mL) was added dropwise.
[0051] After addition was completed, the stirring was continued for an hour at temperatures between about −65° C. and about −30° C. and then followed by an addition of 2N HCl (30 mL) dropwise to the reaction mixture at about −30° C. The reaction was allowed to warm-up to room temperature and the mixture was evaporated in vacuo on a rotary evaporator to remove THF and ethanol.
[0052] The residual material was extracted with diethyl ether (3×100 mL). The combined ether extracts were dried over Na 2 SO 4 , filtered and the filtrate was completely evaporated to give a crude oil.
[0053] The product was purified by column chromatography on silica gel via eluting with dichloromethane (DCM) to give rac-ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionate as colorless oil.
[0054] The purified product was characterized by a 1 H NMR (500 MHz, CDCl 3 ): 7.92 (m, 2H), 7.22 (m, 2H), 4.29 (m, 2H, OCH 2 ), 3.77 (d, J=15 Hz,1H, CH 2α ), 3.68 (bs, 1H, OH), 3.55 (d, J=15 Hz, 1H, CH 2β ), 1.45 (s, 3H, Me), 1.35 (t, J=7 Hz, 3H, OCH 2 CH 3 ).
[0055] The purified product was further characterized by a 13 C NMR (125.7 MHz, CDCl 3 ): 174.7 ppm (CO ester ), 166.4 (C-4′, J C-F =258 Hz), 137.5 ((c-1′), 131.7 (C-2′,6′, J C-F =9 Hz), 117.0 (C-3′,5′, J C-F =21.6 Hz), 72.9 (C quat ), 64.6 (CH 2 ), 63.6 (OCH 2 ), 27.9 (CH 3 ), 14.7 (OCH 2 CH 3 ).
[0056] The purified product was further characterized by HPLC (acetonitrile:water 1:1 with 0.01% TFA): 5.4 mins.
EXAMPLE 2
Preparation of rac-N-[4-Cyano-3-Trifluoromethyl-Phenyl]-3-[4-Fluorophenyl Sulfonyl]-2-Hydroxy-2-Methyl-Propionamide
[0057] 5-Amino-2-cyano-benzotrifluoride (ACB) (0.27 grams, 1.45 mmol) and 1,4 diazabicyclo[2.2.2]octane (DABCO) (0.32 grams, 2.85 mmol) were dissolved in tetrahydrofuran (THF) (30 mL) and cooled in dry-ice acetone bath to about −2° C.
[0058] A 2.5M solution of butyl lithium in hexanes (2 mL, 5 mmol) was added to the cold THF solution dropwise via a syringe while keeping the temperature between about −2 to about 2° C. After addition was completed, the stirring was continued for 1 hour while maintaining the temperature at about −2° C. The temperature was then lowered to about −65° C. and a solution of rac-Ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionate (0.34 grams, 1.17 mmol) in THF (20 mL) was added dropwise.
[0059] After addition was completed, the stirring was continued for an hour at temperatures between about −65° C. and about −30° C. after which 2N HCl (30 mL) was added dropwise to the reaction mixture at about −30° C. The reaction was allowed to warm-up to room temperature and the mixture was evaporated in vacuo on a rotary evaporator to remove THF and ethanol.
[0060] The residual material was extracted with diethyl ether (3×100 mL). The combined ether extracts were dried over Na 2 SO 4 , filtered and the filtrate was completely evaporated to give a crude oil.
[0061] The product was purified by column chromatography on silica gel eluting with ethyl acetate-petroleum ether to give rac-N-[4-cyano-3-trifluoromethyl-phenyl]-3-[4-fluorophenyl sulfonyl]-2-hydroxy-2-methyl-propionamide in about 40% yield, as a pale yellow solid.
[0062] The present invention further provides a novel process for preparing rac-bicalutamide from methyl methacrylate. FIG. 2 illustrates the schematic process for preparing rac-bicalutamide from methyl methacrylate.
[0063] According to FIG. 2, the starting material was methyl methacrylate, which can usually be converted into the epoxide only under harsh conditions (i.e. with peracetic acid in ethyl acetate at 75° C. [J.A.Chem., 81, 680 (1959)], or with 90% hydrogen peroxide-trifluoroacetic anhydride at 40° C. [J.Am.Chem., 77, 89 (1955)], or with MCPBA in dichloromethane at 0° C. in low yield [J.Med.Chem., 29, 2184 (1986)]. The epoxidation under these conditions can be explosive. The present invention describes this oxidation using Oxone®.
[0064] The methyl 2-methyl-oxirane-carboxylate of formula (1), which was obtained by epoxidation, was reacted with 4-fluorothiophenol [formula (2)] in the presence of sodium hydride under the conditions listed in Scheme-2. The obtained methyl 2-hydroxy-2-methyl-3-(4-fluorophenylthio)-propionate of formula (3) was hydrolyzed with potassium hydroxide in aqueous ethanol over a period of 22 hours to yield the 2-hydroxy-2-methyl-3-(4-fluorophenylthio)-propionic acid of formula (4), which was converted into the acid chloride of formula (5) with thionyl chloride in dimethyl acetamide at −15° C.
[0065] The obtained acid chloride was reacted with 4-amino-2-trifluoromethyl-benzonitrile in dimethylacetamide at −15° C. to yield the thioether derivative of formula (6). The oxidation of the thioether derivative was carried out by known method with m-chloroperbenzoic acid in dichloromethane to yield the final product, bicalutamide, of formula (7).
[0066] The process according to our invention is described in detail by the following, but not limiting, examples.
EXAMPLE 3
Preparation of Methyl 1,2-Epoxy-2-Methyl-Propionate
[0067] In a 3 L four-neck round bottom flask, Oxone® (50% KHSO 5 , 227 grams, 0.75 mol) was dissolved in water (1 L) and 10 M KOH was added to adjust the pH to ˜6 (˜53 mL). Then, methyl methacrylate (13 mL, 0.122 mol) in methanol was added (50 mL) followed by 360 mL of water.
[0068] The solution was stirred at room temperature and the pH was continuously adjusted to pH=6 with 1M KOH (˜270 mL). After 6 hr the reaction was stirred over night. Then, 2N HCl was added (100 mL, pH=3) and the entire aqueous solution was extracted with DCM (3×150 mL) for each 400 mL reaction solution. The combined DCM extracts were washed with saturated sodium sulfite solution followed by saturated sodium bicarbonate solution.
[0069] After drying and filtartion, DCM was removed by evaporation and the unreacted methyl methacrylate was distilled out. The residue contained the product as an oily material.
[0070] GC: (>97%, 1.45 min); yield: 66%; 1 H NMR (500 MHz, CDCL 3 ; □ ppm 3.72 (s,3H, Me), 3.07 (dd, J=6 Hz, J=16 Hz, 1H, H □ ), 2.73 (d, J=6 Hz, 1H, H □ ), 1.55 (s, Me); 13 C-NMR (125.7 MHz, CDCL 3 ; □ ppm): 172 (CO ester ), 54.3 (CH 2 ), 53.6 (C quat ), 53.2 (Me ester ), 18 (Me).
EXAMPLE 4
Preparation of 2-Hydroxy-2-Methyl-3-(4-Fluorophenylthio)Propionic Acid
[0071] To a solution of 4-fluorothiophenol (1 mL) in MeOH (32 mL) was added dropwise 2N NaOH aq (16 mL) under N 2 , while the temperature was kept at 25° C. during the addition period. When addition was completed, the reaction mixture was stirred at room temperature for a further 90 min.
[0072] A solution of methyl-1,2-epoxy-2-methyl propionate (1.2 gram) in MeOH (20 mL) was then added dropwise at room temperature. When addition was completed, the reaction mixture was stirred over night at ambient temperature. To the reaction mixture 2N HCl (20 mL) was added followed by ethyl acetate (60 mL). The organic phase was separated. The aqueous phase (pH˜2) was extracted with 60 mL of chloroform and then discarded. The ethyl acetate and chloroform extracts were combined.
[0073] After drying (MgSO 4 ) and filtration, the two organic solvents were evaoprated to leave an oily product which solidified upon standing at room temperature.
[0074] Purity: 75% (according to GC); Yield: 66%. GCMS: 230 m/z (13%); M.p.: 69.1-72.7° C.; 1 H NMR (500 MHz, CDCL 3 ; □ ppm 7.43 (m, 2H, H-2′,6′), 6.96 (m, 2H, H-3′,5′), 3.39 (d, J=14 Hz, 1H, H □ ), 3.17 (d, J=14 Hz, 1H, H □ ), 1.53 (s, Me); 13 C-NMR (125.7 MHz, CDCL 3 ; □ ppm ): 180.4 (CO acid ), 162.6 (d, J C-F =248 Hz, C-4′), 134.3 (d, J C-F 7.5 Hz, C-2′,6′), 130.8 (d, J C-F =3.2 Hz, C-1′), 116.5 (d, J C-F =21.6 Hz, C-3′,5′), 7.52 (C quat ), 53.3 (Me ester ), 46.4 (CH 2 ), 26.0 (Me).
Micronized Rac-Bicalutamide
[0075] The Particle Size Distribution (PSD) of rac-bicalutamide may be used to determine the available surface area for the drug dissolution. Often, it is observed that the available surface area for drug dissolution correlates to both (a) the rate of dissolution and solubility where a great surface area enhances the solubility of a drug; and (b) enhances the rate of dissolution of a drug. The rate of dissolution of a drug effects the drug's bioavailability. Thus, the PSD of rac-bicalutamide, and in particular, the meagrn particle diameter, are important parameters to characterize and predict the bioavailibility of rac-bicalutamide.
[0076] The present invention provides rac-bicalutamide formulations containing rac-bicalutamide having relative small particles and corresponding relatively large surface area.
[0077] The present invention provides rac-bicalutamide formulations containing rac-bicalutamide having a mean particle diameter of less than 200 μm, preferably the mean particle diameter is less than 100 μm, more preferably the mean particle diameter is less than 20 μm, and most preferably the mean particle size is about 10 μm.
[0078] The present invention provides rac-bicalutamide having a mean particle diameter of between about 200 μm and about 10 μm. In one embodiment of the invention, rac-bicalutamide has a mean diameter of about 4.2 μm, more preferably a mean diameter of 4.0 μm.
[0079] The present invention also provides process for preparing micronized rac-bicalutamide. By the methods of the present invention, rac-bicalutamide, which is prepared by methods known in the art, is separated by sieves to produce rac-bicalutamide wherein 50% has a mean particle diameter of below about 250 μm and about 80% has a mean particle diameter of below about 500 μm. The sieved rac-bicalutamide is then micronized by methods known in the art, e.g., in a micronizer, to yield rac-bicalutamide wherein 100% of rac-bicalutamide has a mean particle size of less than about 45 μm, preferably 99% of the rac-bicalutamide has a mean particle size of less than about 45 μm, more preferably, 93% of the rac-bicalutamide has a mean particle size of less than about 7.5 μm, more preferably the rac-bicalutamide isolated has a mean particle diameter of less than about 10 μm.
[0080] Micronized particles of rac-bicalutamide can be obtained by the use of conventional micronizing techniques after sieving to provide rac-bicalutamide wherein about 50% has a particle size of less than about 250 μm and about 80% has a particle size of less than 500 μm. By the methods of the present invention, the rac-bicalutamide where about 50% has a particle size less than 500 μm and about 80% has a particle size below about 500 μm, is micronized to the desired particle size range by methods known in the art, for example, using a ball mill, ultraonic means, fluid energy attrition mills, or using a jet mill, or other suitable means as disclosed in Pharmaceutical Dosage Forms: Tablets, Vol. 2, 2 nd Ed., Lieberman et al. Ed., Marcel Dekker, Inc. New York (1990) p.107-200, the content of which is incorporated by reference herein.
[0081] The present invention provides micronized rac-bicalutamide as pharmaceutical compositions that are particularly useful for its anti-androgen activity. Such compositions comprise micronized rac-bicalutamide with pharmaceutically acceptable carriers and/or excipients known to one of skilled in the art.
[0082] Preferably, these compositions are prepared as medicaments to be administered orally or intravenously. Suitable forms for oral administration niclude tablets, compressed or coated pills, dragees, sachets, hard or gelatin capsules, sub-lingual tablets, syrups and suspensions. While one of ordinary skill in the art will understand that dosages will vary according to the indication, age and severity of the disease of the patent etc., generally micronized rac-bicalutamide of the present invention will be administered at a daily dosage of about 2 mg to about 200 mg per day, and preferably about 5 mg to about 100 mg per day. | The present invention relates to a new process for the synthesis of racemic and optically active bicalutamide starting from ethyl pyruvate and methyl methacrylate. The present invention discloses processes of preparing bicalutamide intermediates including ethyl-[2-{4-fluorophenyl sulfone}]-2-hydroxy propionate, 1,2-epoxy-2-methyl propionate and 2-hydrox-2-methyl-3-(4-fluorophenylthio)propionic acid. The present invention further discloses micronized rac-bicalutamide and the preparation thereof. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to an electrolysis cell.
[0003] 2. Discussion of Related Art
[0004] Electrolysis cells of this kind are generally known and are disclosed, for example, by German Patent References DE 10 2009 004 031 A1 and DE 34 01 637 A1. Through electrolysis of water, oxidizing agents can be produced at suitably embodied anodes and can be used for oxidative treatment of the water or for disinfection of the water. The processes that occur at the electrodes during electrolysis of natural water, e.g. tap water, are predominately the oxidation and reduction of water:
[0000] At the anode: H 2 O→½O 2 +2H + +2e − (1)
[0000] At the cathode: 2H 2 O+2e − →H 2 +2OH − (2)
[0005] In the water, the current is transported by the dissolved ions. When a flow of current occurs, a pH gradient builds up in the electrolysis cell (pH <7 at the anode, pH >7 at the cathode). The pH gradient causes alkaline earth carbonate and/or alkaline earth hydroxide to precipitate on the alkaline cathode (“calcification”). Because of the low ion concentrations and the resulting low conductivity, the electrolysis of natural water is limited in the practicable current densities.
[0006] Through the use of a cation exchange membrane as an electrolyte (proton exchange membrane=PEM), it is possible to increase by several orders of magnitude the practicable current density of an electrolysis cell operated in water and to produce oxygen in the form of O 2 and/or O 3 at the anode. The membrane in this case is contacted over its entire area on both sides by the porous electrodes (anode and cathode). The processes occurring at high current densities at the electrodes in this arrangement are comprised of:
[0000] At the anode: H 2 O→⅓O 3 +2H + +2e −
[0000] At the cathode: 2H + +2e − →H 2 (3)
[0007] In the cation exchange membrane, the current is transported by protons (H+) in accordance with equations 1 and 3 and is not limited by the ion concentration in the water. Primarily, the conduction of current with protons, which are present in a high concentration in the membrane, produces no pH gradients. But since the membrane is in chemical equilibrium with the water, cations dissolved in the water migrate into the membrane through ion exchange with protons and accumulate there. Even if the portion of the current transported by dissolved cations in a membrane cell is far less than one percent, it can influence the behavior of the cell significantly. Cations being exchanged at the anode generate a proton surplus (=acidification), as occurs in the cell without a membrane. Thermodynamically, the discharging of protons of hydrogen is the preferred reaction at the cathode. The metal cations that have migrated into the membrane therefore accumulate in the vicinity of the cathode and after a threshold concentration in the membrane at the cathode is reached, can lead to the production of hydroxides according to reaction (2). The operation of such known cells is limited by the presence of hardness components dissolved in the water, such as Ca 2+ and Mg 2+ ions in the form of dissolved hydrogen carbonates. The hardness components precipitate onto the cathode in the form of carbonate and/or hydroxide and therefore result in coatings that increase ohmic resistance of the electrolysis cell and limit the economically practicable operating times of such cells in natural water to a few hours.
[0008] Various methods are known from the prior art that make it possible to operate such electrolysis cells in hard water (i.e. with a large quantity of dissolved hardness components) in an economical way. PCT Publication WO 2012/159 206 A1 discloses dissolving cathodically generated deposits by reversing the polarity of the cell. The electrodes used for this, however, are very expensive to manufacture and the method requires disadvantageously large electrode surfaces. The patent specification of European Patent Reference EP 1 649 080 B1 discloses a cell in which a pre-electrode made of wire mesh is situated between the cathode and the membrane. This cell, however, also disadvantageously leads to a cell voltage of greater than 20 V after 100 hundred hours of operation. Alternatively, it is known to use conventional softeners to soften a partial flow of the water that is to be treated, but this is very complex in terms of both operation and maintenance.
[0009] The known approaches to solving the problem are comparatively complex and rather inefficient. One object of this invention, therefore, is to provide an electrolysis cell that does not have the disadvantages of the prior art and in which it is possible to prevent the formation of a barrier layer on the cathode so that the electrolysis cell can be operated even with hard water, i.e. in the presence of large quantities of hardness components, and can therefore be reliably used in natural water for longer periods of time.
SUMMARY OF THE INVENTION
[0010] The above object and others are attained by an electrolysis cell described by this specification and the claims.
[0011] As proposed according to this invention, the cathode contact area is greater than the anode contact area, the membrane has a surface oriented toward the cathode that is larger than the cathode contact area, and the electrolysis cell has cathodically polarized surfaces that are in direct contact with the electrically conductive water. It is thus possible for at least a part of the current flow prevailing in the electrolysis cell, after crossing over into the membrane, to be first conveyed along the cathode contact area, entraining hardness components that are adhering to the cathode contact area, and next to the cathode, for it to cross over into the electrolytes, e.g. natural water, and from there, for it to be conveyed to the cathode or to the cathodically polarized surfaces that are in direct contact with the electrically conductive water.
[0012] This is dictated by the accumulating hardeners producing an electrical insulation that prevents charge carriers from crossing over directly into the cathode contact area. In this regard, a forced diversion along the cathode contact area into the electrically conductive water takes place and from there to the cathode or the cathodically polarized surfaces that are in direct contact with the electrically conductive water and function as auxiliary cathodes. This gives the electrolysis cell a self-cleaning function and automatically counteracts the previously inevitable accumulation of hardness components in a continuous fashion.
[0013] As part of this invention, a good function in water is achieved if the anode contact area has a length of at most 10 mm in at least one of its main axis directions.
[0014] According to one embodiment of this invention, the cathode is structured so that it has at least one contact protrusion, which is in contact with a surface of the membrane via a cathode contact subarea, with the cathode contact subareas combining to form the cathode contact area, and the surface of the membrane has at least one open region, which is in contact not with the at least one contact protrusion of the cathode, but with electrically conductive water.
[0015] The structured design of the cathode divides the ion flow generated by the electrolysis current into two partial flows so that one of the partial flows does not flow directly via the cathode contact subarea of the contact protrusion that is in contact with the membrane, but rather via the open region protruding beyond the cathode contact subarea and the conductive water, and is shunted to the cathode. This ion flow via the water or the water phase makes it possible to influence the dynamic solution equilibrium at the cathode through the removal of alkaline earth cations and makes it possible to reduce the thickness of the passivating layer, i.e. the barrier layer or coating. Primarily only loose deposits, for example of CaCO 3 , form in the regions of the cathode that are not directly in contact with the membrane, which result in a voltage increase only after longer operating times and can easily be removed mechanically if necessary.
[0016] The division of the currents is implemented by the special structured design of the cathode. Of particular importance here is the ratio of the area that the contact protrusions contact in the region of the cathode contact subareas (also called “cathode contact area” below) of the membrane to the open area or to the total area of the membrane as well as the dimensions and geometric form of the at least one contact protrusion contacting the membrane. Thus, for example, the increase rate of the cell voltage can be reduced by 40 to 100 times in water with a hardness of approximately 16 German degrees. The optimal ratio of cathode contact area to membrane area or open area depends on the concentration of the hardness components dissolved in the water. Hardness components are, for example, Ca 2+ and Mg 2+ ions in the form of dissolved hydrogen carbonates. In an advantageous fashion, this invention can be technically implemented in numerous different cell designs and is not limited to particular designs such as a circular electrode geometry. The essential thing is that the ratio of the total cathode contact area to the membrane is embodied to be greater than the ratio of the total anode contact area to the membrane.
[0017] The electrolysis cell according to this invention can be used in a particularly efficient way for in-situ production of oxidizers in natural water that contains hardness components, in particular tap water. The membrane can, for example, be a perfluorinated cation exchange membrane, which is placed by a suitable pressing device, for example, between the cathode and the anode and is contacted by them.
[0018] The membrane is embodied as plate-shaped, i.e. the membrane extends essentially along a main plane so that the length and width of the membrane are essentially greater than the thickness of the membrane. The length is the dimension of the membrane in a so-called longitudinal direction and the thickness is the dimension of the membrane in a so-called vertical direction that is perpendicular to the longitudinal direction. The width of the membrane extends perpendicular to the longitudinal direction and the vertical direction in a width direction, which, like the longitudinal direction, extends in the main plane.
[0019] In the following, the terms “down,” “up,” “lower,” and “upper” refer to positions with reference to the vertical direction. The terms “left” and “right” will be used below to refer to positions with reference to the longitudinal direction. When the term “cross-section” is used below, this means a section lying in the plane that is defined by the vertical direction and the longitudinal direction and is oriented perpendicular to the width direction. This invention is not limited, however, to the orientations mentioned. The person skilled in the art will instead recognize that inversions of the orientation mentioned as well as other modifications are possible.
[0020] The membrane has an upper surface and a lower surface. The upper surface contacts the cathode and the at least one contact protrusion in the region of the cathode contact area or the cathode contact subareas that make up the latter while the lower surface contacts the anode in the region of the anode contact area or the anode contact subareas that make up the latter. The surfaces of the membrane extend parallel to the main plane. The surfaces of the membrane are embodied as planar or flat.
[0021] Viewed in the vertical direction, the anode is situated under the membrane. With its anode contact area embodied on the surface, the anode contacts the lower surface of the membrane so that during operation of the electrolysis cell, when a correspondingly suitable supply voltage is provided, an ion flow is produced in a known way. Viewed in the vertical direction, the cathode or the contact protrusion is situated above the membrane. The cathode contact area and the cathode contact subareas of the at least one contact protrusion of the cathode are likewise embodied as planar or flat so that this cathode contact area extends parallel to the upper surface of the membrane.
[0022] Advantageous embodiments and modifications of this invention can be inferred from the remaining dependent claims and the description, taken in conjunction with the drawings.
[0023] In one exemplary embodiment, there can be a recessed or overlapping region of the surface of the cathode, which is spaced apart from the upper surface of the membrane. The recessed region is spaced apart such that no direct or immediate ion flow from the surface of the membrane into the recessed region of the surface of the cathode is possible. By contrast with the contact protrusion, there is thus no contact between the surface of the cathode and the surface of the membrane in the recessed region. This space is filled with the electrically conductive water. Consequently, ions from the membrane can only reach the recessed region of the surface of the cathode by traversing the water that is contained between the membrane and the recessed region during operation of the electrolysis cell.
[0024] According to an exemplary modification, the at least one contact protrusion or the cathode contact area is embodied as block-shaped or linear. The term “linear” is used here to mean that the contact protrusion is embodied as elongated, for example in a block shape. The contact protrusion can also be embodied as cruciform, i.e. composed of lines that cross each other.
[0025] According to another exemplary modification, the cathode contact area is circular and the at least one contact protrusion is embodied as cylindrical. It is also possible for the cathode to have a plurality of contact protrusions that are spaced apart from one another. The contact protrusions are spaced apart from one another in the longitudinal direction and/or width direction. It is thus advantageously possible to substantially reduce the formation of a coating. In particular, it is possible, for example, for the contact protrusions to be arranged in a grid-like pattern. The term “grid-like” is used here to mean that the contact protrusions are arranged, for example, in the form of a lattice.
[0026] The distance between adjacent contact protrusions can, for example, be at least 3 mm. According to another embodiment, they can be at least 6 mm. This permits a particularly efficient operation of the electrolysis cell because it is possible to extend the operating time of the electrolysis cell considerably.
[0027] The cathode contact subareas can be arranged and spaced apart in accordance with the spacing and arrangement of the contact protrusions of which they are composed.
[0028] According to another exemplary modification, the at least one contact protrusion is composed of a porous material. The at least one contact protrusion can be composed of a different material than the rest of the cathode. The cathode or the at least one contact protrusion can, for example, be composed of a porous, catholically resistant material (stainless steel, brass, graphite, etc.).
[0029] According to another exemplary embodiment, the electrolysis cell has a movable rake device for mechanically removing calcification deposits on the regions of the cathode that are spaced apart from the membrane. The term “rake device” is used here to mean a rake with tines that is inserted between the contact protrusions from above and whose tines remove the deposits on the cathode. It is thus advantageously possible to clean the electrolysis cell in a particularly simple way so that the service life of the electrolysis cell can be extended considerably.
[0030] According to another exemplary embodiment, the area of the at least one open region is greater than the area of the at least one contact region by a factor of 2 to 4. It is thus advantageously possible to efficiently reduce the increase in cell voltage.
[0031] According to another exemplary embodiment, the anode is likewise embodied as structured so that the anode has at least one lower contact protrusion, which contacts the lower surface of the membrane via an anode contact subarea, with the anode contact subareas combining to form the anode contact area, and the lower surface of the membrane has at least one lower open region, which is not in contact with the at least one lower contact protrusion of the anode.
[0032] Through this structured embodiment of the anode, it is advantageously possible to achieve a further improvement in the efficiency of the electrolysis cell. The above statements that apply to the lower contact protrusion of the anode also correspondingly apply to the contact protrusion of the cathode. Thus for the description of the structured anode, refer to the description of the structured cathode. In particular, there can also be a plurality of lower contact protrusions on the anode.
[0033] The anode or the lower contact protrusion can, for example, be composed of a porous, anodically resistant material (for example valve metal, titanium, tantalum, or niobium, with an electroactive coating composed of PbO 2 , platinum metals and their oxides, or boron-doped diamond). The lower contact protrusion and the rest of the anode can be made of a different material. In particular, the anode or the lower contact protrusion can be made of a porous, passivating material, where an electrochemically active coating is applied to the region of the surface of the lower contact protrusion, which is in direct contact with the membrane. Electrically conductive and anodically stable catalytic coatings are applied to the anode contact area.
[0034] According to another exemplary embodiment, the electrolysis cell has cathodically polarized surfaces that are in direct contact with the electrically conductive water. Such surfaces can, for example, be recessed surfaces or overlapping surfaces of the cathode that protrude beyond the contact protrusion.
[0035] The method according to this invention for operating an electrolysis cell in natural water is based on immersing the electrolysis cell, which has an anode, a cathode, and a membrane situated between the anode and cathode, which contacts the anode via an anode contact area and contacts the cathode via a cathode contact area, and in the natural water and applying an electrical voltage to the anode ( 5 ) and cathode ( 2 ), which produces a current flow from the anode ( 5 ) to the cathode ( 2 ) via the membrane ( 4 ).
[0036] In order to counteract the depositing of inevitably settling hardness components from the water on the cathode, according to a proposal of this invention, at least a part of the current flow, after crossing over into the membrane, is first conveyed along the cathode contact area, entraining hardness components adhering to the cathode contact area and next to the cathode, crosses over into the natural water, and is conveyed from there to the cathode. This guidance of the current flow and entrainment of the hardness components occurs in a forced fashion because the adhering hardness components in the region of the cathode contact area gradually form an electrical insulating layer around which the charge carriers are forcibly guided because of the potential difference prevailing in the electrolysis cell.
[0037] In this way, the electrolysis cell automatically cleans itself and there is no drop in performance due to the hardness components since they are no longer deposited in the cathode contact area.
[0038] According to another exemplary embodiment, the gases forming at the anode and cathode are dissolved directly into the water and are not separated physically. Alternatively, it is possible for the gases forming at the anode and cathode to be separated physically by the membrane and possibly assisted by a suitable flow guidance of the water.
[0039] The electrolysis cell is operated in a vessel with water, for example at a current density of 0.5 to 1.5 A/cm 2 .
[0040] Another subject of this invention involves the use of an electrolysis cell according to one of the previously described embodiments for disinfecting water, in particular spring water and/or drinking water. Otherwise, refer to the descriptions above. With the use of this electrolysis cell, it is possible to generate ozone at the anode (ozone generator). The generated ozone kills germs, for example, in the water, making it possible to achieve an efficient disinfection of the water.
[0041] Exemplary embodiments of this invention are shown in the drawings and described in greater detail in the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 schematically shows an electrolysis cell according to an exemplary embodiment of this invention;
[0043] FIG. 2 schematically shows an electrolysis cell according to another exemplary embodiment; and
[0044] FIG. 3 shows a schematic graph in which an average cell voltage increase is plotted for different membrane diameters.
DETAILED DESCRIPTION OF THE INVENTION
[0045] In the figures, parts that are the same are consistently provided with the same reference numerals and are therefore as a rule named and/or mentioned only once.
[0046] FIG. 1 schematically shows a cross-section taken through an electrolysis cell 1 according to an exemplary embodiment of this invention. The electrolysis cell 1 has a cathode 2 situated or positioned at the top in the vertical direction Z. The cathode 2 has a cathode surface 9 , which is oriented toward a membrane 4 situated or positioned under the cathode 2 . The cathode surface 9 is provided with a porous contact protrusion 3 . Viewed in the longitudinal direction X, to the left and right of the contact protrusion 3 , the cathode surface 9 has a recessed spacing region 10 . In other words, this spacing region 10 is recessed upward in comparison to the contact protrusion 3 and is in direct contact with the surrounding electrically conductive water.
[0047] The flat membrane 4 is situated or positioned under the cathode 2 . The membrane 4 is embodied in the form of a plate. The membrane 4 has an upper surface 11 , which is oriented toward the cathode 2 . The membrane 4 has a lower surface 13 which is oriented toward an anode 5 . The membrane 4 is arranged so that its surfaces 11 , 13 are oriented perpendicular to the vertical direction Z and parallel to the longitudinal direction X. On the upper surface 11 , the membrane 4 contacts and is connected to the contact protrusion 3 . This contact is composed of or comprises a cathode contact area 12 on a subarea of the membrane surface.
[0048] The porous anode 5 is situated or positioned under the membrane 4 . The entire upper surface of the anode 5 contacts the lower surface 13 of the membrane 4 , forming a lower anode contact area 14 . An anode power supply 6 is situated or positioned under the anode 5 and serves in a known way as a power supply for the anode 5 .
[0049] In the exemplary embodiment shown, the anode contact area 14 and the cathode contact area 12 are embodied as round. It is clear that the cathode contact area 12 is embodied as slightly larger than the anode contact area 14 .
[0050] If the electrolysis cell 1 is now switched into operation, then the anode power supply 6 supplies current to the anode 5 . The electrolysis cell 1 is operated, for example, in a vessel containing natural water (tap water), for example at a current density of 0.5 to 1.5 A/cm 2 , and an ion flow or current flow from the anode 5 via the anode contact area 14 into the membrane 4 is produced (see arrow 15 ). The ion flow first flows via the cathode contact area 12 directly into the contact protrusion 3 of the cathode 2 (see arrow 16 ). As operating time increases, however, hardness components gradually accumulate on the cathode contact area, which function as an insulation layer. As a result, only part of the ion flow travels from the membrane 4 via the cathode contact area 12 directly into the contact protrusion 3 of the cathode 2 (see arrow 16 ). Another part of the ion flow, however, first flows according to arrow 17 along the cathode contact area 12 until it arrives in a region next to or near the contact protrusion 3 . From there, the ion flow travels starting from the surface 11 of the membrane 4 via the water between the recessed region 10 and the membrane 4 , and into the cathode 2 , bypassing at least some regions of the contact protrusion 3 (see arrow 18 ). An excessive coating between the membrane 4 and the contact protrusion 3 can thus be advantageously prevented from forming or can be removed since any adhering hardness components on the cathode contact area 12 are entrained by the partial (ion) flow indicated by arrow 17 and are conveyed into the surrounding water.
[0051] FIG. 2 schematically shows a cross-section through an electrolysis cell 1 according to another exemplary embodiment of this invention. In this embodiment, the cathode 2 has a plurality of porous contact protrusions 3 , which are embodied in an elongated or linear form. In FIG. 2 , three contact protrusions 3 are shown, but the cathode 2 can have even more contact protrusions. Each contact protrusion 3 contacts the surface of the membrane 4 in a cathode contact subarea 12 . 1 , 12 . 2 , 12 . 3 . All of the cathode contact subareas 12 . 1 , 12 . 2 , 12 . 3 combine to form the effective cathode contact area 12 . The contact protrusions 3 are spaced apart from one another in the longitudinal direction X.
[0052] The porous anode 5 is situated or positioned under the membrane 4 . In this exemplary embodiment, the surface of the anode 5 is also embodied as structured and has lower contact protrusions 21 , which are in contact with the lower surface 13 of the membrane 4 in the anode contact subareas 14 . 1 , 14 . 2 , 14 . 3 . All of the anode contact subareas 14 . 1 , 14 . 2 , 14 . 3 combine to form the effective anode contact area 14 . The lower contact protrusions 21 are likewise embodied as elongated and are dimensioned so that the anode contact area 14 is smaller than the cathode contact area 12 . The length of the contact protrusions 21 visible in the drawing and the length of the anode contact subareas 14 . 1 , 14 . 2 , 14 . 3 constituted by them in the direction of the main axis X is at most 10 mm. The lower contact protrusions 21 are spaced apart from each other in the direction X. This leaves open regions 20 on the lower surface 13 of the membrane 4 that are not contacted by the anode 5 . In addition, the electrolysis cell 1 has a power supply 6 for the anode 5 .
[0053] If the electrolysis cell 1 is now operated in a container with water, for example at a current density of 0.5 to 1.5 A/cm 2 , then in a fashion corresponding to the one in FIG. 1 , an ion flow from the porous anode 5 via the porous lower contact protrusions 21 into the membrane 4 takes place. The ions flow from the membrane 4 partially via the cathode contact subareas 12 . 1 , 12 . 2 , 12 . 3 into the porous contact protrusions 3 of the cathode 2 . In addition, part of the ions flow between the contact protrusions 3 , through the water situated there, and toward the upper region of the contact protrusions 3 . In the upper region of the electrolysis cell 1 , a rake 7 is provided, which can be moved perpendicular to the vertical direction Z and longitudinal direction X (see double arrow 8 ) so that its tines can remove deposits between the contact protrusions 3 on the cathode 2 . Otherwise, refer to the explanations with regard to FIG. 1 .
[0054] FIG. 3 depicts a schematic graph in which the average cell voltage increase V/day (vertical axis) is plotted for different membrane diameters D (horizontal axis). FIG. 3 shows a plot of the average cell voltage increase V/day over a respective run time of 2 to 6 days. In this exemplary embodiment, which principally corresponds to the exemplary embodiment in FIG. 1 , a perfluorinated cation exchange membrane 4 cut into a circle (diameter D in mm) was contacted with a porous, circular anode 5 made of titanium, with a diameter of 5 mm, with a surface on the membrane side, i.e. in the contact region, that is coated with PbO 2 , and a porous cathode 2 made of stainless steel (with a diameter of the circular contact protrusion of 3 to 7 mm). The electrolysis cell 1 thus formed was operated in a vessel containing 250 ml water with a content of more than 73 mg/liter calcium and more than 12 mg/liter magnesium at a current density of 1 A/square centimeter. The water composition in the vessel was kept constant through a continuous addition of fresh water (200 ml/h). The cell voltage was measured as a function of the operating time. The experiment was repeated with a series of cells 1 whose design was identical except for the area of the circular membrane used. The membrane diameter in this repeated experiment was varied between 7 mm and 16 mm. The average cell voltage increase V/day turns out to depend on the diameter D of the membrane 4 used.
[0055] FIG. 3 shows that with a diameter D of 7 mm of the membrane 4 , the average cell voltage increase V/day equals 6 V. With increasing diameter D, the average cell voltage increase V/day drops to a value of less than 1 V, which is achieved between 9 and 16 mm. The increase of the diameter D of the membrane 4 , i.e. the increase of the open region or the open area 19 or 20 , consequently yields a significant drop in the average cell voltage increase V/day from 6 V to less than 1 V.
[0056] For the sake of completeness, it should be noted that the exemplary embodiments described above are only intended for illustrating this invention. In no way is the subject of this invention limited by the exemplary embodiments described.
[0057] German Patent Application DE 10 2014 110 422.6, filed 23 Jul. 2014, the priority document corresponding to this invention, to which a foreign priority benefit is claimed under Title 35, United States Code, Section 119, and its entire teachings are incorporated, by reference, into this specification. | An electrolysis cell, having an anode, a cathode, and a membrane that is situated between the anode and the cathode and contacts the anode via an anode contact area and contacts the cathode via a cathode contact area, wherein the cathode contact area is greater than the anode contact area, the membrane has a surface oriented toward the cathode that is greater than the cathode contact area, and the electrolysis cell has cathodically polarized surfaces that are in direct contact with the electrically conductive water. This invention also relates to a method for operating an electrolysis cell in natural water and a use of such an electrolysis cell for disinfecting water are also proposed. | 8 |
BACKGROUND OF THE INVENTION
Coffee makers using bowl-shaped paper filters in a filter basket in which coffee is brewed by passing boiling water through ground coffee beans placed in the filter have recently become very popular. Such devices are considered to be very efficient and easy to use, especially since the coffee grounds are easily disposed by simply lifting the filter containing the used coffee grounds from the filter basket. Thus, the used coffee grounds are easily discarded without being separately cleaned from a metal brewing basket used in the well known percolator-type coffee maker.
As convenient as drip coffee makers are to use, a disadvantage is that once the filter paper is wetted, the vertical side of the bowl-shaped filter become limp and does not retain its shape againt the vertical side of the filter basket. When this occurs, as the hot water pours into the filter basket, coffee grounds floating on top of the water level surface may spill over the limp and sagging upper edge of the filter and pass between the filter and the filter basket and into the coffee. The device of the present invention is intended to reduce or eliminate such a problem.
SUMMARY OF THE INVENTION
The present invention provides a device intended to reduce or eliminate the unintended travel of coffee grounds from within the filter, between the filter and the filter basket, and into the coffee. The device comprises an expandable ring which is placed inside the filter below the upper edge thereof and which presses against the inner filter surface urging it against the side of the filter basket. Such a device prevents the wet filter side from sagging or otherwise being displaced and prevents coffee grounds from passing around the filter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the ring device of the invention;
FIG. 2 is a fragmented perspective view illustrating the relationship of the end of the ring and ring contracting means;
FIG. 3 is a top view of another ring variation illustrating a ring expansion retaining means;
FIG. 4 illustrates ends of yet another ring embodiment for expanded ring retention; and
FIG. 5 is a perspective view of the inside of a filter basket illustrating the relationship of the filter and ring in place therein.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates the annular member or ring 10 of the invention having a pair of opposite and free ends 22 and 24 whereby the ring can be expanded or contracted. Also referring to FIGS. 6 and 7, since the purpose of the ring, as previously described, is to be placed inside a bowl-shaped filter within a filter basket of a drip coffee maker, the ring material must be rigid, but at the same time flexible enough so that the opposite ends may be moved relative to one another for expansion and contraction. Preferably, the ring will have a rest expanded condition giving it a diameter at least slightly greater than the inner diameter of the filter side against which it will be urged when placed in the filter basket. However, the maximum expanded ring diameter is not to be necessarily so limited, so long as it can be contracted sufficiently to be relatively easy to place within the filter and filter basket. Preferably, the rest expanded condition of the ring is of substantially greater diameter than the filter basket, so that when compressed, the ring will be sufficiently urged against the filter to be effective.
FIGS. 1 and 2 also illustrate examples of means for easily contracting the device comprising a pair of tabs 12 and 14, tab 12 being secured to the ring adjacent ring end 24 and having a slot or channel 25 through which the other end or portion of the ring may pass. Such a relationship is illustrated in FIGS. 1 and 2. Another tab 14 is secured to the ring so that it is near tab 12 but spaced therefrom so that when a user grasps the tabs and urges the tabs together, the ring will be compressed. Preferably, such a compressible ring will be one having memory retention so that when the tabs are released the ring will expand to its normal expanded condition. Also illustrated are guide members 16, 17, and 18 for holding or retaining a portion of ring portion adjacent free ring end 22 in planar relationship with the ring portion adjacent end 24. Without such guide or channeling means, the two free ends of the ring could be displaced in different planes which may affect the resulting operaton of the device. A stop member 27 at the ring end 22 will prevent the end from slipping past guide member 16 thereby further assisting in maintaining the ring ends substantially in a single plane. The guides shown are for the purpose of illustration only, and any number of such guides as well as other guiding means or channels having the same function may be used.
Although the ring may have an expanded memory condition sufficient to urge it rather tightly against the filter paper, it is also desirable to ensure that the expanded condition is retained, even in the presence of hot water to which the ring will be exposed during use. For example, where the ring material is made of a thermoplastic, with sufficient strength to retain it rather snugly against the filter under ambient conditions, in the presence of hot water, it may become somewhat softer whereby the material will be relaxed. In FIGS. 3 and 4, there are illustrated examples of means for retaining the ring in an expanded condition whereby it may be snugly urged against the filter and maintained in that condition without regard to any changes in the flexibility or softening of the ring material. Again, such expansion retainers are especially useful where the ring material is made of a thermoplastic, for example polycarbonate resins, polysulfones, polyphenyl oxides, polyethylene, polyvinyl chloride, polyvinyl acetate, polystyrene, acrylics, or similar plastics. Other useful plastics include polystyrene, high impact polystyrene containing butadiene copolymer, and heat resistant polystyrene which includes alpha-methylstyrene copolymer. Such materials are only examples and are not to be limiting of plastics that may be used. However, the specific resin selected must be able to withstand hot or boiling water without being distorted, warping, crystallized, or otherwise deteriorating at such temperatures. Of course, the ring may also be made of metal. In FIG. 3, a tooth 30 or similar projection may be provided along a surface adjacent ring end 22 for contacting ring end 24 to hold or maintain the ring in a desired expanded condition. Other such expansion retaining means are illustrated in FIG. 4, for example, a pluralty of notches or cavities 36 adjacent ring end 24 in which one or more teeth or ratchets 34 adjacent ring end 22 may be received. Such expansion retaining means are shown by way of example only, and a variety of other such means may be used, including clamps, protrusions and cooperating cavities of any desirable shape which may be snap-fitted or otherwise held together to hold the ring in a desirably expanded condition so that it is snugly or firmly urged against the inside vertical surface of the filter.
FIG. 5 shows the ring device of the invention in position for use within the filter and filter basket of a drip coffee maker. A bowl-shaped coffee filter 44 is placed in filter basket 40 so that the side 42 of the filter is against the vertical filter basket surface 42. Ring 10 may be placed inside the filter, preferably so that it is just below the upper filter edge. As previously explained, regarding FIGS. 1 and 2, where the ring is provided with tabs 12 and 14, or similar means for easily contracting the ring by hand, the user will simply compress the tabs toward one another thereby contracting the ring so that it can more easily be placed within the filter. Once the ring is at a desirable location, where the ring material is such that it will expand naturally once the tabs are released against the filter paper, the device is ready for use. Otherwise, where expanded retention means as previously described are incorporated, they may be secured or locked in place so that the ring is held snugly against the filter paper. The user may simply then insert the coffee grounds in the filter and the coffee made. When it is desired to remove the filter paper with the coffee grounds, the ring device is simply contracted and lifted or removed from the filter and the filter and coffee grounds discarded. It will be evident by using such a device, the filter paper is held against the inside vertical surface of the filter basket whereby the filter paper, even when wetted and otherwise becomes limp, will not separate from the filter basket side which would otherwise allow coffee grounds to float between the sides of the filter and filter basket and into the coffee. Such advantages as well as other embodiments within the purview of the invention will be evident to those skilled in the art. | A device for securing a coffee filter in a coffee maker basket comprises a contractable annular member expandable for urging the coffee filter against the inner side of the basket to prevent coffee grounds from slipping between the filter and the side of the basket and into the coffee. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional and claims priority under 35 U.S.C. §120 to U.S. Ser. No. 11/695,312, filed on Apr. 2, 2007, which is a continuation of and claims priority under 35 U.S.C. §120 to PCT/EP2005/010613, filed on Oct. 1, 2005, and designating the U.S., which claims priority under 35 U.S.C. §119 to European Patent Application No. EP20040023524.4, filed on Oct. 2, 2004. The contents of all the prior applications are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] This invention relates to a laser processing machine head, a laser processing machine head monitoring system, and a method of monitoring an optical element of a laser processing machine.
BACKGROUND
[0003] Optical elements such as lenses, e.g. meniscus lenses, are normally circularly ground on the outside diameter. The lenses used in CO 2 lasers are additionally usually decentered. The centering error for a 7.5″ lens is typically <0.1 mm after adjustment. If a lens is removed for cleaning, the position of the optical element relative to the holder is usually rotated after re-insertion due to the circular peripheral surface. The optical element must then be realigned (readjusted), since a centering from focus to nozzle better than 0.05 mm is required.
[0004] When workpieces are processed using a machine for thermal welding or cutting, in particular a laser processing machine, the cutting lenses can become contaminated. Impurities, deposits, or damage to the optics surface can result in increased absorption of the laser radiation. Consequently, the thermal loading of the optical element is increased. This ultimately results in a perceptible reduction in the laser power available in the processing region. In cases of severe contamination, in particular by spattering, the increased absorption of the laser radiation can lead to destruction of the optical element.
[0005] WO 99/59762 describes a device for checking the condition of a glass plate in a laser machining system with regard to contamination by dirt particles. The device comprises a holder for the glass plate. A temperature sensor in contact with the holder detects an increase in temperature of the holder. The increase in temperature is caused by increased absorption of radiation by the glass plate as a result of the dirt particles.
SUMMARY
[0006] Disclosed herein is a holder that simplifies insertion and alignment and reduces rotation of an optical element in a laser processing machine head, while also allowing monitoring of a status of the optical element.
[0007] In some embodiments, photocurrent from a light beam transmitted through the optical element may be assessed by a photodiode. This photodiode can subsequently be used to detect radiation intensity or radiation heat which leads to thermal loading of the optical element. The optical element may thus be monitored in a particularly advantageous manner. The reflected light beam may also be used for testing a photodiode before laser machining.
[0008] In an embodiment, a holder of an optical element includes a radiation measuring device with a light source positioned at a first position of a peripheral surface of the optical element for emitting a light beam and a sensor element positioned at a second position of the peripheral surface of the optical element for receiving the light beam reflected by a reflecting surface. An increased intensity of reflected light at the sensor element indicates an increased thermal loading of the optical element. In an embodiment, the light source is a light-emitting diode and the sensor element is a photodiode, allowing particularly simple and cost-effective monitoring of the reflected radiation.
[0009] In some embodiments, a delineated surface segment is formed on the peripheral surface of the optical element proximate a light-emitting diode. Light from the light-emitting diode can thereby be coupled more efficiently into the optical element.
[0010] In a preferred embodiment, the delineated surface segment has a ground or polished surface. The nature of the delineated surface segment is chosen to suit the intended use of the photodiode.
[0011] In some embodiments, the optical element holder includes a spring-mounted clamping body with a pressure surface for applying pressure in the radial direction to the delineated surface segment of the optical element. In particular, a contour of the pressure surface may be complementary to a contour of the delineated surface segment, allowing the optical element to be installed in the optical element holder with a mated fit.
[0012] In an embodiment, the clamping body includes a temperature sensor for measuring the temperature of the optical element. The clamping body may be in direct contact with the delineated surface segment via the pressure surface, thus allowing contact temperature measurement.
DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows a laser machining system;
[0014] FIG. 2 is a perspective view of a holder of an optical element of the laser machining head of a laser machining system;
[0015] FIG. 3 is a perspective view of the assembly of the optical element holder;
[0016] FIG. 4 is a side view of an optical element;
[0017] FIG. 5 is a plan view of an optical element including a monitoring device;
[0018] FIG. 6 is a plan view of another optical element including a monitoring device.
[0019] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0020] FIG. 1 shows the structure of a laser machining system 1 for laser cutting using a CO 2 laser 2 , a control device 3 , a laser machining head 4 (nozzle 4 a ) and a workpiece support 5 . A generated laser beam 6 is guided to the laser machining head using deflecting mirrors and is directed onto the workpiece 8 by means of a focusing lens 7 .
[0021] Before a continuous flat joint is produced, the laser beam 6 must pass through the workpiece 8 . Workpiece 8 may be, for instance, sheet metal. Workpiece 8 may be fused or oxidized at one location in a point. The plunge-cutting process may be effected rapidly (for instance, at full laser power) or slowly (via a so-called “ramp”).
[0022] During slow plunge-cutting using a ramp, the laser power may be gradually increased, reduced, and kept constant for a certain period of time until the plunge-cut hole has been formed. Both the plunge-cutting and the laser cutting are assisted by adding a gas. Oxygen, nitrogen, compressed air and/or gases specific to the application may be used as cutting gases 9 . A gas may be chosen based on materials to be cut and desired quality of the cut.
[0023] When cutting using oxygen, a maximum gas pressure of 6 bar may be used. At the point where the laser beam 6 impinges upon the workpiece 8 , the material is fused and largely oxidized. The melt formed may be blown out together with the iron oxides. Particles and gases formed may be extracted from an extraction chamber 11 by means of an extraction device 10 . During the oxidation process (an exothermic reaction), additional energy is released, facilitating the cutting process. For a given material thickness and laser power, significantly higher cutting speeds may be achieved with oxygen gas than with high pressure nitrogen. Alternatively, a thicker material may be cut with oxygen as the cutting gas than would be possible with nitrogen as the cutting gas.
[0024] The holder 12 of the optical element 7 may be a cylindrical receptacle 13 and a cylindrical retaining device 14 as shown in the embodiment depicted in FIG. 2 .
[0025] The assembly of a holder 12 is shown in FIG. 3 . The receptacle 13 may have a concentric recess at one end in which a retaining ring 15 can be inserted and the optical element 7 can rest thereon. The optical element is circular, except for a delineated, planar surface segment 16 bounded by circular portions of the peripheral surface 16 . A shoulder 17 of a clamping body 18 can be secured to the retaining device 14 and engage the delineated surface segment 16 , thereby inhibiting rotation of optical element 7 . This is shown more clearly in FIG. 4 .
[0026] In some embodiments, optical element 7 may be a lens, as shown in FIG. 5 . The optical element 7 has a reflecting surface 19 . Reflecting surface 19 may be a delineated surface segment on the peripheral surface 20 of the optical element 7 . A portion of reflecting surface 19 may be planar. The planar portion may be ground or polished. In some embodiments, reflecting surface 19 is substantially parallel to a beam axis of a laser aligned with respect to optical element 7 .
[0027] In certain embodiments, a clamping body may engage reflecting surface 19 with a pressure surface to align the optical element 7 such that rotation of the optical element with respect to the optical element holder is inhibited. In some embodiments, a light-emitting diode (LED) 22 may be coupled to the optical element holder at a first position 21 of the peripheral surface 20 of the optical element 7 . The LED 22 may emit a light beam 23 continuously or non-continuously (for instance, at specific time intervals) before or during operation of the laser. Light from the LED may enter volume 7 ′ and may be reflected at the reflecting surface 19 . After reflection, the light beam 23 impinges upon a photodiode 24 which is secured at a second position 25 of the peripheral surface 20 on the holder of the optical element 7 . The status of the photodiode 24 may be monitored. The photodiode 24 may be used to detect the radiation heat or radiation intensity absorbed by the optical element 7 as a result of the contamination of the optical element during the laser machining. As the radiation intensity increases, the photocurrent increases. The change in the radiation intensity (change in the photocurrent compared with a reference photocurrent) may thus be used to deduce the change in the optical element 7 related to decreased performance of the optical element,
[0028] The LED 22 and the photodiode 24 may be part of a radiation measuring device integrated in the holder of the optical element. In some embodiments, the temperature of the optical element 7 may be measured by a temperature sensor positioned in the clamping body of the holder of the optical element.
[0029] It is not necessary for the delineated surface segment to be a planar surface. The delineated surface segment may be a profiled or shaped surface, such as a notch. The surface of the delineated surface segment may be ground, polished, or machined in another manner.
[0030] According to the embodiment depicted in FIG. 6 , an optical element 37 has a delineated surface segment with a face 41 . The delineated surface segment may facilitate orientation and installation of the optical element 37 . In some embodiments, the delineated surface segment may facilitate efficient coupling of light from the LED 38 to the optical element. In some embodiments, a photodiode 39 is located on the optical element 37 for monitoring the process (laser) light. Photodiode 40 may be provided to monitor light from the LED 38 .
[0031] In addition to the embodiments of the delineated surface segment on the peripheral surface of an optical element described herein, other embodiments are also feasible in which the delineated surface segment is formed on the top or bottom (that is, on a broad surface) of an optical element. The delineated surface segment may include one or more angled faces. The angled faces may be arranged at any location on the outer peripheral surface of the optical element. In addition to inhibiting rotation of an optical element in a holder, a delineated surface segment may be shaped to facilitate proper insertion of the element into the holder. For instance, a delineated surface segment with an angled face may require proper insertion of the element, such that the optical element is not inadvertently inserted upside down with respect to the incident process light.
[0032] It is to be understood that while the invention has been described in conjunction with the detailed description of multiple examples, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims. | A laser processing machine head, a laser processing machine head monitoring system, and a method of monitoring an optical element of a laser processing machine feature a light-transmissive optical element and an optical element holder defining a cavity in which the optical element is retained against rotation. A light source mounted to the holder directs a beam of light into the optical element through a peripheral surface of the optical element. A light receiver is responsive to light from the light source reflected through the optical element. Monitoring a signal from the light receiver allows a status of the optical element to be assessed. | 1 |
BACKGROUND
Field
[0001] The embodiment disclosed relates to data processing system, methods, apparatus and computer program products. More particularly, the embodiment relates to a uniform architecture for processing data from optical and radio frequency sensors for combined barcode and radio frequency readers.
BACKGROUND
[0002] Optical bar code readers and Radio Frequency-Identification (RF-ID) readers identify objects and take other actions. An optical bar code reader illuminates a bar code on an object and detects light reflected from the bars and spaces of a code. The detected signal is transmitted to a processor for decoding and further processing. An RF-ID reader interrogates a tag attached to or included in an object for information stored in the tag. The information is descriptive of the object. The tag generates and transmits a signal to the RF-ID reader in response to the interrogation signal. The signal contains the stored information in the tag. The RF-ID reader processes and stores or passes the received information to an application or a network for further processing.
[0003] Optical bar code readers and RF-ID readers maybe combined and contained in a mobile phone or like device. Several manufacturers provide combined optical bar code—RF-ID readers including the Nokia N 93, Espoo, Finland; Di-400—Diagnostics Instruments, Livingston, England, and Sabre 1555 Scanner—Intermec, Everett, Wash., USA.
[0004] A combined optical bar code-RF-ID reader can be used for different bar code formats including Data Matrix, Quick Response (Q/R), Universal Product Code and in a Near Field Communication (NFC) environment which is a short-range connectivity technology that provides contact less connectivity between electronic devices. The NFC short-range wireless connectivity is promoted by the NFC Forum, Wakefield, Mass., which supports implementation and standardization of NFC technology. The NFC Forum has adopted the Java Specification Request (JSR) 257 as an application programming interface for contactless communication. The JSR 257 API provides separate data processing paths for bar code and RFID data in a combined bar code -RFID reader, as will be described in FIG. 2 , hereinafter.
SUMMARY
[0005] The example embodiments provide a method, apparatus and computer program product implemented in a uniform architecture responsive to optical and radio frequency sensors for barcode-readers and radio frequency reader combined in a portable or handheld device, e.g. a mobile phone. In one embodiment, electrical signals generated from a scanning device and representative of an object including a description thereof are received at a first terminal in the device. The electrical signals are read and digitized into a first data format including a first identifier indicating the first data format. The digitized data in the first data format including the first identifier is stored in a memory for subsequent data processing. Digitized data in a second data format is received at a second terminal of the device. The digitized data is representative of another object including a description thereof and a second identifier indicative of the second data format. The digitized data in the second data format including the second identifier is stored in the memory for further processing. The digitized data in the first or second data format is validated in a processor by comparison of the digitized data to a standardized data format corresponding to the first or second identifier for the related digitized data. The processor determines if the digitized data matches the standardized data format for the identifier and continues the processing of the digitized data if matched to the standardized data format or terminates processing if the digitized does not match the standardized data format. A common data format, e.g. the Near Field Communication Data Exchange Format (NDEF) is stored in the memory. The digitized data in the first or second data formats is parsed to match a record layout of the common data format. The processor reforms the digitized data in the first or second data format into the common data format; and transmits the digitized data of the bar-code or RF-ID readers in the common data format to storage or for use in an application or a network. The digitized data will be suitable for use in a Short Message Service (SMS) or Instant Messaging (IM) or a Vicinity Card (VC) card or other applications.
DESCRIPTION OF THE DRAWINGS
[0006] The exemplary embodiments will be described in conjunction with the appended drawing, in which:
[0007] FIG. 1 is a representation of a mobile device for processing optical and RF sensor data in a Near Field Communication (NFC) environment for automatic identification and data capture of objects and incorporating the principles of the present embodiment;
[0008] FIG. 1A is a representation of a data processing architecture for a combined bar-code and Radio Frequency- Identification (RF-ID) included in the mobile device of FIG. 1 ;
[0009] FIG. 1B is a partial listing of software in the architecture of FIG. 1A for implementing the processing of optical and RF sensor data;
[0010] FIG. 2 is a flow diagram of a current process for processing optical and RF sensor data;
[0011] FIG. 3 is a representation of a tag containing data for use in the system of FIG. 1A ;
[0012] FIG. 3A is a representation of a data format for the data stored in the tag of FIG. 3 :
[0013] FIG. 4 is a representation of a Universal Product Code (UPC) and Electronic Article Number (EAN) codes for providing electrical signals from scanning an object for automatic identification and data capture;
[0014] FIG. 4A is a representation of a Quick Response pattern of data for automatic identification and data capture;
[0015] FIG. 5 is a representation of a record layout for a common data format in the NFC environment for use in FIG. 1 , and
[0016] FIG. 6 is a flow diagram for processing optical and sensor data in the architecture of FIG. 1A and using the record layout of FIG. 5 .
DETAILED DESCRIPTION
[0017] Before describing an exemplary embodiment of a combined barcode- RF-ID reader with a uniform architecture, it is believed appropriate, as background, to describe a current architecture for a combined barcode and RF-ID reader.
[0018] Referring to FIG. 2 , a bar code data path 202 receives bar code data in block 204 . The bar code data is read in block 206 and stored in a data buffer in block 208 . The data is validated in block 210 by matching the received data to a bar code specification, e.g. UPC standard, Quick Response (Q/R), Universal Product Code (UPC) in block 212 . The validated data is tested for usability in block 214 . A “yes” directs the data to a bar code parser in block 216 . A “no” condition for the test 218 ends the process. The barcode parser 216 receives a textual, numeric or binary string and places the validated data into a data format for an application, according to the parsed bar code. The formatted data is passed to the application in block 220 .
[0019] In like manner to the bar code data processing, RFID data in a path 203 is received at block 205 , read in block 207 , and stored in block 209 . The data is validated in block 211 by matching to an RFID format 213 , including Electronic Product Code (EPC) 1 , International Standards Organization (ISO) 15693 and Electronic Article numbering (EAN) 128 . The validated data is tested in block 215 . If the data is not found useable the process ends at block 218 . If usable, a RF-ID parser receives the data as a textual, numeric, binary string and formats the data according to the JSR 257 specification for an application in block 216 . The formatted data is passed to an application in block 220 .
[0020] Currently, a combined barcode—RF-ID reader requires different parsers and different architectures for processing sensor data. The present embodiment provides a uniform architecture using a single parser and a common data format based on the Near Field Data Exchange Format (NDEF). The uniform architecture will avoid companies having to build and maintain two different architectures and skill sets. The uniform architecture will also make clear to companies building services around the bar-code and RF sensor technologies, how to implement their designs.
[0021] Now referring to FIG. 1 , a combined barcode-RF-ID reader 100 is disclosed based on a uniform data processing architecture serving all sensors with a single parser and using a common data format, e.g. the NDEF format. The combined bar-code—RFID reader is included in a mobile device 100 , e.g. a Nokia phone. The phone includes a bar-code reader sensor 102 , e.g. a camera attached to a keyboard 104 via a swivel joint 106 which enables the sensor screen to be rotated to different positions. The back of the camera serves as a lid for the phone. The keyboard includes a 5-way scroll or navigation key 108 , selection keys 110 including a menu key, edit and clear keys, call and end keys.
[0022] FIGS. 1A and 1B describe a uniform architecture including circuitry 112 and software 136 for processing optical or bar-code signals and RF signals for automatic identification and data capture of objects in a retail or other environment. In FIG. 1A , a bar-code reader 116 receives data signals from an optical sensor 102 scanning an object (not shown). The sensor 102 may be any bar code reader including a light source, a lens and a photo conductor translating optical impulses into electrical impulses. The optical sensor may be pen, laser, and charge controlled device (CCD), video based and the like.
[0023] In one embodiment, the sensor uses CCD devices as a camera to record an image of an object. Instead of having a single row of CCD devices, the camera has hundreds of rows of sensors arranged in a two dimensional array to capture image signals from the sensors representative of a bar code. A processor 118 connected to a buss bar 120 receives the camera data and stores the digitized camera data for further processing in a Read Only Memory (ROM) 122 coupled to the processor, as will be described herinafter.
[0024] Input/Output circuitry 124 is coupled to the buss bar 120 for processing signals entered by a user from the key board 104 for operating the bar code reader an associated decoder (not shown) and a RFID reader 126 .
[0025] A display circuit module 126 is coupled to the buss bar and is responsive to the processor for controlling the camera 102 in displaying and capturing bar codes on objects.
[0026] A RF-ID Reader 128 is coupled to the bus bar 120 and transmits interrogation signals via antenna 130 to tags (See FIG. 3 ) within a defined coverage area of the reader. The tags contain information which can be data descriptive of an object to which it is attached. The descriptive information includes an identifier and data for subsequent processing purposes. The tag in response to the interrogation signals generate and transmit digitized data to the RFID reader which stores the information or transmits the digitized data to an application or transmits the digitized data to a network via a wireline or wireless connection (not shown).
[0027] A random access memory (RAM) 132 is linlked to the processor 118 and stores the software implementing computer operations of capturing and identifying bar-code and tag data for objects in retail or other environment. A power supply 134 provides energy for operating the combined bar-code and RF-ID reader 100 .
[0028] FIG. 1B describes software 136 for operating the combined bar-code and RF-ID reader. A standard operating system 138 provides program instructions for managing the operations of the processor and peripherals and apportioning the ROM and RAM for storing data and programs.
[0029] Commercially available software programs for bar-code reading 140 are stored in the RAM 132 for operation of the bar code reader 116 , after identification of the bar code type by reading an identifier in the bar code data. A number of bar code type software are available including Universal Product Code (UPC), Electronic Article Numbering (EAN), Quick Response (QR),
[0030] Commercially available software programs for RF-ID systems 142 are stored in the RAM 132 for operating the RF Reader 126 , after identification of the RF-ID data format by reading an identifier in the tag data. A number of tag processing software are available, including International Standards Organization (ISO) 15593; Electronic Product Code (EPC) 1.3, NFC NDEF and UCC/EAN GTAG.
[0031] Standard communication protocols 144 are stored in the RAM 132 for short-range and cellular communication via antennas (not shown) for wireline and wireless communication with external networks.
[0032] A data processing program 146 for implementing a unified architecture is stored in the RAM 132 and will be described in conjunction with FIG. 6 .
[0033] Applications 148 for Short Messaging Service (SMS), Instant Messaging (IM), Vicinity Card (VC) and other like applications are stored in the RAM 132 for operation using identified bar codes and tags.
[0034] Turning to FIG. 3 , RFID technology utilizes electromagnetic or electrostatic coupling in the radio frequency (RF) portion of the electromagnetic spectrum, typically 125 kHz, 134.2 kHz, and 13.56 MHz. for short range communication and up to 2.45 GHz for long range (8-10 meters) communication. An RF interrogation signal is transmitted from the RFID reader 126 to a tag 300 for activating the tag in either a short range or long range mode of operation. An antenna 302 is included in the tag for capturing the interrogation signals transmitted by the reader 126 ( FIG. 1 ) when within the coverage area of the reader transceiver. The antenna 302 is coupled to a transceiver 304 in the tag 300 .
[0035] A processor 306 is coupled to the transceiver 304 for processing signals transmitted by the reader 126 and generating a response signal to the interrogation signal based on information stored in a memory 308 coupled to the processor 306 .
[0036] When a tag has been activated, information in the memory 308 is transmitted back to the RFID reader 126 ( FIG. 1 ). In the case of a passive tag, the tag may be energized by a time-varying electromagnetic RF wave generated by the RFID reader 126 . When the RF field passes through the antenna coil associated with the tag, a voltage is generated across the coil. This voltage is ultimately used to power the tag, and make possible the tag's return transmission of information to the reader, sometimes referred to as backscattering. Using this information, the RFID reader 126 can direct the mobile device 100 to perform an action identified from the received information. One advantage of RFID is that it does not require direct contact, although direct contact with an RFID tag can occur, and in some instances may be required. The frequency employed will at least partially dictate the transmission range of the reader/tag link. The required proximity of the mobile device 100 to a tag can range from a very short range (touching or near touching) to many meters, depending on the frequency employed and the power output reader transceiver.
[0037] Any type of RFID tag may be used in connection with the present embodiment. RFID tags can be either passive or active. Passive tags, as in the present instance, do not require a dedicated power source, but rather obtain operating power generated from the reader 126 transmission. Active tags require an internal battery and are often read/write tags. Further, tags may come in a variety of shapes and sizes, but are generally based on a custom designed silicon integrated circuit. Any transponder/tag may be used in connection with the present embodiment. The tag type, size, etc. depends on the particular environment and the purpose of reading the tag.
[0038] FIG. 3A describes standard information 310 stored in the tag memory tag 308 by bytes for identifying the object to which tags for various items may be attached. The information block 310 includes an identifier 312 comprising two bytes of information reserved for an identifier (ID NUMBER). The block 310 provides a content type 314 , which defines the type of content that is provided via the tag 300 . The content types may include SMS, Multi Media Messaging (MMS), and Uniform Resource Locator (URL) for use with Wireless Application Protocol (WAP) browsing, Java program download request and/or Java programs (e.g., MIDlets), UPC/EPC, smart message, and the like. Each of these and other content types can be identified via the content type field 314 .
[0039] The information block 310 may also include a content length field 316 which indicates the length of the content 318 portion of the tag information. Representative types of content that can be included as content 318 in the tag information 310 have been previously described. An optional certificate field 320 , illustrated as one octet but of any desired length, may be provided. The field 320 may be used to provide an electronic signature to guarantee authenticity of a service provider, from which the user may access the public key location and verify the signature based on Public Key Infrastructure (PKI) policies. A check sum field 322 , such as Cyclic Redundancy Check (CRC) field, may also be provided with the tag information 300 . The CRC information may be used error checking the tag information. Other and/or different information may also be provided in different tag content types, formats, fields, etc.
[0040] The RF tag data may appear in several RF formats including Joint Test Action Group (JTAG) RF-Tag Data format, Version 2; Electronic Product Code (EPC) Gen 2 and International Standards Organization (ISO) 15693.
[0041] FIG. 4 describes representative Universal Product Codes (UPC) code 39 and Electronic Article Number (EAN) code 128 formats, which may be scanned and processed by the barcode reader 116 ( FIG. 1 ). The code 39 format is shown in low density 402 , medium density 404 and high density 406 formats. Code 39 has nine bars and spaces, 3 bars are wide and 6 are narrow. Likewise, the EAN code 128 is stored in low density 401 , medium density 403 and high density 405 formats. EAN 128 has four widths applicable in combinations to all 128 ASCII characters.
[0042] Each of the sensing devices in the camera 102 ( FIG. 1 ) is vertically aligned with an object on which is located a plurality of dot matrix printed coded bars. Each of the sensing devices is positioned so as to sense one of the matrix dots which form the coded bar and output an analog signal whose signal level varies directly in accordance with the ink intensity of the sensed dot. Signals are then amplified, filtered and converted to digital signals which are then examined. If a predetermined number of dots in the bar have been sensed and of the dots sense, no more than two dots are found to be separated by more than one blank space where a dot would normally be located, a signal is generated indicating that a valid bar has been sensed. These signals are then used by a decoder (not shown) associated with the bar-code reader in decoding the bars sensed and communicating the decoded bar codes as digitized data to a processor.
[0043] FIG. 4A describes a Quick Response (QR) barcode 410 , which is a two-dimensional general-purpose matrix. The QR code carries QR symbols horizontally and vertically. The symbols are contained in module 412 shown in black The barcode is scanned 360 degrees using postion detection paterns 414 at the matrix corners.
[0044] FIG. 5 shows the NFC Data Exchange Format (NDEF) 500 which in the present instance serves as a common data format for receiving bar code and RF-ID data in various data formats, as will be described in conjunction with FIG. 6 . The NDEF 500 is described in the NDEF Technical Specification (NFCForum-TS-NDEF — 1.0), available from the NFC Forum, Wakefield, Mass. The format is a lightweight message format designed to encpsulate small payloads ranging between 0 and 255 octets.
[0045] A first octet 502 contains bit flags: MB=Message Begin; ME=Message End; CF=Chunk Flag; SR=Short Record; IL=ID Length Field Present; TNF=Type Name Format.
[0046] A Type Field 504 is an unsigned 8 -bit integer that specifices the length in octets of the ID field.
[0047] A Payload Length Field 506 is an unsigned integer that specifies the length in octets of a Payload field. If the SR flag is set, the Payload Length is a single octet if the SR flag is clear, the Payload Length is four octets.
[0048] An ID length Field 508 is an unsigned 8-bit integer that specifies the length of an ID field in octets.
[0049] A Type Field 510 is an identifier describing the type of the payload.
[0050] An ID Field 512 is an identifier in the form of a Uniform Resource Locator (URL).
[0051] A Payload Field 514 carries the payload intended for a user application.
[0052] The NFC data need not be or have a payload that describes the item to which it is attached. The NFC data can contain a phone number, a URL for web browsing, a business card, a travel card, a discount voucher, or any of the data formats defined. In such instances it is the association of the tag with an object such as an advertisement for which the phone number or the URL is provided.
[0053] Referring to FIG. 6 , a program 600 processes data from bar code and RFID readers into a common data format executable by applications stored in a communicating device, e.g a mobile device 100 (See FIG. 1 ). The program uses a single parser and is initiated by the mobile device for bar code or RF-ID data data processing beginning at a start block 601 or 602 , respectively.
[0054] Bar code data scanned by a reader in the device 100 is received at a terminal represented by a block 603 . The bar code data is read in a block 605 . The bar code data format is determined in block 607 from reading the identifier. The bar code data is compared succesively to different bar code data formats UPC, EAN, Q/R, etc in blocks 609 , 611 , and 613 , respectively, until a match occurs between a format and the bar code data. When a match occurs, the data is formatted according to the format specification and stored in a memory represented by block 615 . If none of the bar code formats apply, a user is alerted to the presence of erroneous data in block 617 and the program ends in block 619 .
[0055] In like manner, RFID data is received by an RFID reader in block 604 ; read by the reader in block 606 and the format determined in block 608 by comparing the RFID tag data to the various tag formats including standard tag data described in FIG. 3A ; ISO 15693 and EPC Gen 2 formats in blocks 610 , 612 and 614 . When a match occurs between the RFID data and the comparing format, the data is formatted and passed to the memory 615 . The user is alerted in block 616 and the program ends in block 618 if there is no match between the RFID data and the formats.
[0056] An NDEF parser is included in the program 600 and selects either formatted bar code data in block 620 or RFID data in block 621 for processing. The NDEF parser parses or deconstructs the NDEF message by transforming input text into a data structure, usually a tree, using well-known parsing routines and hands off the payload to an application.
[0057] The selected formatted data is parsed in block 622 for the common data fields NDEF fields, including bit flags; type length; payload length; ID length; Type; ID amd Payload, as described in FIG. 5 . The parsed data is installed in the common data format in block 624 and passed to an application via a reader interface 626 . The application may be stored in the mobile device 100 or in a network accessed by the mobile device using the communication protocols stored in the RAM 132 ( FIG. 1A ).
[0058] The bar code data and the RFID data included in the common data format may contain an indentifier and related content. The identifier identifies and initiatees an application on the Mobile phone. The reader feeds the content to another application on the mobile device which may be a Short Messaging Service (SMS) application. When the SMS application is invoked, a SMS message is sent to the service provider. In like manner, applications may be invoked for Instant Messaging, Vicinity Card, Multi-Media Messaging.Service (MMS).
[0059] In another embodiment, the digitized data in the common data format may contain FM radio or TV tuner data indicated in the Type field 516 of FIG. 5 . The payload 514 would contain the frequency of the broadcast signal. The data would be parsed according to FIG. 6 and at the interface 626 , the identified frequency would be passed to an application and related hardware (FM or TV tuner).
[0060] In another embodiment, the digitized data in the common data format may contain satelite station settings or parameters in the payload, identified n the Type Field 510 ( FIG. 5 ) and after parsing of the data by the uniform architecture, passed to an application serving a satelite network.
[0061] In another embodiment, the digitized data in the common data format may contain vicinity card information in the payload, described in the Type field, for importation into a contact file in the memory.
[0062] In another embodiment the digitized data in the common data format may contain instructions in the payload, described in the Type field, for launching a software application stored in the memory.
[0063] The foregoing description of an exemplary embodiment has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiment to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. For example, it will be apparent to those skilled in the art from the foregoing description that the embodiment is equally applicable to optical sensing devices of all types; RF-ID devices for short range and long range communication; mobile or stationary devices and other current or future radio frequency identification technologies using, for example, electromagnetic/electrostatic coupling, and thus the present embodiment is not limited to “RFID” or bar-code technology as these terms are currently used. It is intended that the scope of the embodiment be limited not with this detailed description, but rather by the claims appended hereto. | A method and apparatus for capturing and processing bar code and RFID data by a uniform architecture contained in a mobile device including a combined bar code and RFID reader. The bar code data is captured by a sensor included in the mobile device. The RFID data is received from a module after interrogation by a RFID reader. The signals from the sensor are translated into digitized data having a first data format and a first identifier indicative of the first data format. The reader translates the RFID data into a second data format including a second identifier indicative of the second data format. The digitized data in the first or second data format is parsed to match a record layout of a common data format. The matched digitized data in the first or second data format is re-formatted into the common data format and passed to an application in the mobile device or to an external application in a network. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 35 U.S.C. §371 national phase application of PCT Application No. PCT/EP2005/052538, filed on Jun. 2, 2005, which claims priority from European Patent Application Serial No. 04103072.7 filed on Jun. 30, 2004, and which claims the benefit under 35 USC §119(e) of U.S. Provisional Application Ser. No. 60/585,979 filed on Jul. 7, 2004, the disclosures of which are incorporated by reference herein in their entireties. The above-referenced PCT International Application was published in the English language as International Publication No. WO 2006/003066.
FIELD OF THE INVENTION
The present invention relates generally hand-held radio communication terminals with built-in cameras, and in particular to the use of such terminals for video conference communication.
BACKGROUND
The cellular telephone industry has had an enormous development in the world in the past decades. From the initial analog systems, such as those defined by the standards AMPS (Advanced Mobile Phone System) and NMT (Nordic Mobile Telephone), the development has during recent years been almost exclusively focused on standards for digital solutions for cellular radio network systems, such as D-AMPS (e.g., as specified in EIA/TIA-IS-54-B and IS-136) and GSM (Global System for Mobile Communications). Currently, the cellular technology is entering the so called 3 rd generation 3G, providing several advantages over the former, 2 nd generation, digital systems referred to above.
Many of the advances made in mobile phone technology are related to functional features, such as better displays, more efficient and longer lasting batteries, and means for generating polyphonic ring signals. One functional feature which has been more and more common is built-in cameras. Cameras with video camera functionality are today available in several mobile phones. With the entrance of high bit-rate services, such as EDGE (Enhanced Data-rates for GSM) and 3G the usability for video-related services will increase. For one thing, mobile video telephony, with simultaneous communication of sound and moving images, has recently become commercially available.
For stationary use, video conference systems generally include a camera mounted on or beside a communication terminal, such as a personal computer PC, or integrated in an IP phone. Use of such a system is fairly straightforward, as the user is positioned in front of the terminal with the camera aiming towards the user. However, mobile video conferencing with face to face transmission suffers from one main drawback. When communicating through a mobile handheld terminal, the user has to hold the terminal steady in front of the face so that the receiving party can see the face of the user, i.e. the sending party. The terminal has to be aimed more or less 90° to the face, in order to get a usable image of the user. A problem is that the user will get tired in the arm, and thereby tend to tremble and also hold the terminal lower and lower. The result is that the image captured will show more of the neck and chin portion of the user, than the upper part of the face. This lowers the value of the service as it is experienced as difficult to use. Furthermore, it is appreciated that consumers may want to be able to view the surroundings when engaged in a video conference, but a mobile phone will block at least parts of the field of view if it has to be held in front of the face.
SUMMARY OF THE INVENTION
A general object of the invention is therefore to provide improved means for picture and video conference systems using mobile hand-held terminals. In particular, an object of the invention is to provide a more convenient method for video conferencing by means of hand-held mobile terminals, overcoming the identified drawbacks related to the prior art.
According to a first aspect, this object is fulfilled by a method for adjusting a picture of an object captured by a camera in a handheld radio communication terminal, comprising the steps of:
defining a first camera angle to the object;
capturing an image of the object by means of said camera from a second camera angle to the object, offset from said first camera angle;
storing image data relating to the captured image; and
generating an angularly adjusted image of said object, dependent on said image data, and an angular relation between said first camera angle and said second camera angle.
Preferably, said method comprises the steps of:
storing reference image data relating to a reference image of the object from said first camera angle, wherein said step of generating an angularly adjusted image of said object is also dependent on said reference image data.
In one embodiment, said method comprises the step of:
capturing said reference image of the object from said first camera angle.
In one embodiment, said captured image is a moving image, and wherein said step of generating an angularly adjusted image involves generating a moving adjusted image in real time.
In one embodiment, said step of generating the angularly adjusted image comprises the steps of:
digitally identifying corresponding structures in said captured image and said reference image;
establishing a mathematical transform from a mathematical relation between spatial image data of said image data and of said reference image data, for said corresponding structures; and
transforming said captured image to appear as captured from said first camera angle by applying said mathematical transform to said image data.
In one embodiment, said step of generating the angularly adjusted image comprises the steps of:
digitally identifying a key feature in said captured image and in said reference image;
detecting movement of said key feature in said captured image;
filtering out said movement from said captured image; and
applying said movement to said key feature in the reference image for obtaining an adjusted image.
In one embodiment, said step of generating the angularly adjusted image comprises the steps of:
slanting said captured image to compensate for the difference between said first camera angle and said second camera angle; and
zooming and cropping the slanted image.
In one embodiment, said first camera angle is a predetermined camera angle to the object.
In one embodiment, said first camera angle is selected from a plurality of selectable preset angles, by means of an input command to the terminal.
In one embodiment, said second camera angle is sensed by an angle sensor in said terminal.
In one embodiment, said second camera angle is selected from a plurality of selectable preset angles, by means of an input command to the terminal.
In one embodiment, said method comprises the steps of:
encoding said adjusted image into a radio signal; and
transmitting said radio signal from said terminal.
In one embodiment, said method comprises the steps of:
encoding the image data for said captured image, together with data for said angular relation between the first camera angle and the second camera angle, into a radio signal;
transmitting said radio signal from said terminal;
receiving said radio signal in a radio signal receiving device; and
generating said angularly adjusted image of said object in said device.
In one embodiment, said object is the face of a user holding the terminal.
According to a second aspect, the objects stated above is fulfilled by a mobile radio communication terminal, comprising a camera for capturing images, and means for generating and transmitting a radio signal comprising captured images to a recipient, characterised by an image adjusting mechanism, including a memory for storing an angle value for a first camera angle to an object, and an angle value for a second camera angle, offset from said first camera angle, said image adjusting mechanism further comprising an image processing system devised to process an image of said object captured by said camera from said second camera angle, including means for generating an angularly adjusted image of said object, dependent on image data for said image, and on an angular relation between said first camera angle and said second camera angle.
In one embodiment, said memory further includes reference image data relating to a reference image of the object from said first camera angle, wherein said means of the image processing system are devised to generate said angularly adjusted image of said object dependent on said reference image data.
In one embodiment, said camera is devised to capture moving images, and wherein said image processing system comprises means for generating a moving adjusted front image in real time.
In one embodiment, said image processing system comprises means for digitally identifying corresponding structures in said captured image and said reference image; means for establishing a mathematical transform from a mathematical relation between spatial image data of said image data and of said reference image data, for said corresponding structures; and means for transforming said captured image to appear as captured from said first camera angle by applying said mathematical transform to said image data.
In one embodiment, said image processing system comprises means for digitally identifying a key feature in said captured image and in said reference image; means for detecting movement of said key feature in said captured image; means for filtering out said movement from said captured image; and means for applying said movement to said key feature in the reference image for obtaining an adjusted image.
In one embodiment, said image processing system comprises means for slanting said captured image to compensate for the difference between said first camera angle and said second camera angle; and means for zooming and cropping the slanted image.
In one embodiment, said first camera angle is a predetermined camera angle to the object.
In one embodiment, said first camera angle is selected from a plurality of selectable preset angles, by means of an input command to the terminal.
In one embodiment, said second camera angle is sensed by an angle sensor in said terminal.
In one embodiment, said second camera angle is selected from a plurality of selectable preset angles, by means of an input command to the terminal.
In one embodiment, said image processing system comprises means for encoding said adjusted image into a radio signal; and means for transmitting said radio signal from said terminal.
In one embodiment, said object is the face of a user holding the terminal.
BRIEF DESCRIPTION OF THE DRAWING
The features and advantages of the present invention will be more apparent from the following description of the preferred embodiments with reference to the accompanying drawing, on which
FIG. 1 schematically illustrates use of a hand-held radio communication terminal in a typical video conference mode;
FIG. 2 illustrates the typical position of the terminal after a moments use according to FIG. 1 ;
FIG. 3 schematically an embodiment of a radio communication terminal on which the present invention may be used;
FIG. 4 schematically illustrates the terminal of FIG. 3 in a block diagram of functional elements which are relevant to different embodiments of the present invention;
FIG. 5 schematically illustrates capturing and storing of a reference image;
FIG. 6 schematically illustrates identification and storing of key features of a reference image;
FIG. 7 schematically illustrates identification and storing of key features of an offset image, and application of detected movements in the key features of the offset image to corresponding key features of a reference image;
FIG. 8 schematically illustrates a captured image of an object from a first angle;
FIG. 9 schematically illustrates a captured image of the same object from a second, offset, angle;
FIG. 10 schematically illustrates a slanted image of the image of FIG. 9 ; and
FIG. 11 schematically illustrates a zoomed and cropped image of the slanted image of FIG. 10 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present description relates to the field of hand-held radio communication terminals. The term radio communication terminal, or terminal in short, includes all mobile equipment devised for radio communication with a radio station, which radio station also may be mobile terminal or e.g. a stationary base station. Consequently, the term radio terminal includes mobile telephones, pagers, communicators, electronic organisers, smartphones, PDA:s (Personal Digital Assistants) and DECT terminals (Digital Enhanced Cordless Telephony). Furthermore, it should be emphasised that the term comprising or comprises, when used in this description and in the appended claims to indicate included features, elements or steps, is in no way to be interpreted as excluding the presence of other features elements or steps than those expressly stated.
Exemplary embodiments will now be described with references made to the accompanying drawing.
FIG. 1 illustrates the use of a hand-held radio communication terminal 10 comprising a built-in camera, in a typical video conference mode. User A holds the terminal 10 is held in front of him, for the purpose of capturing real time moving images of his face. The captured images are recorded and encoded in synchronicity with input sound, typically speech from user A. A radio signal carrying sound and video data is generated in terminal 10 and transmitted to a recipient, typically another user with a video communication terminal. User studies have shown that the obviously uncomfortable pose illustrated in FIG. 1 is not maintained for long, and after a while the user A begins to lower his terminal 10 to the position illustrated in FIG. 2 . The result is an image, snapshot or video, which is offset in angle to the initial image captured in the pose of FIG. 1 . An image captured in the pose of FIG. 2 will target the chin portion of user A, and will generally be perceived as less attractive than the intended image of the entire face as seen from the front.
In order to overcome this problem, the present invention provides a function in a hand-held radio communication terminal, such as a mobile phone, which allows the terminal to send a picture that looks like a front image of the face although the camera of the terminal is positioned with an offset angle to the face, as compared from a front view.
FIG. 3 illustrates a radio communication terminal in the embodiment of a clamshell cellular mobile phone 10 . It should be understood, though, that the invention is in no way restricted to clamshell terminals. Terminal 10 comprises a chassis or housing 15 , of which a lower portion carries a user audio input in the form of a microphone 11 , and where an upper portion carries a user audio output in the form of a loudspeaker 12 . The upper and lower portions are connected by means of a hinge 16 . A set of keys, buttons or the like constitutes a data input interface 13 , usable e.g. for dialling, according to the established art. A data output interface comprising a display 14 is further included, devised to display communication information, address list etc in a manner well known to the skilled person. Radio communication terminal 10 further includes an antenna and radio transmission and reception electronics (not shown). A camera 17 , preferably with video capability, has a lens facing the same way as display 14 .
FIG. 4 illustrates functional components of terminal 10 . A computer processor system includes an image processing system 20 for processing images stored in a memory 21 , and in particular images captured by means of camera 17 . Image processing system 20 is preferably controlled by a microprocessor with associated software, forming part of the computer processor system of terminal 10 .
In accordance with a first general embodiment, a front image is initially captured upon or before commencing a video conference, from a first camera angle as illustrated in FIG. 1 . Preferably this is performed in a special capture mode, which mode may be entered by means of keypad 13 . Data for the captured front image is stored in memory 21 as reference image data for the object in question, which is the face of user A. The reference image data may include image data representing the full front image, or only parts of the front image. During the subsequent video conference, moving images of the face of user A are captured by means of camera 17 . The image processing system 20 constantly monitors the captured images and compares them to the reference image. When terminal 10 , and thus camera 17 , is tilted, raised or lowered, such that an image is captured from a second camera angle which is offset at most 90° from the first camera angle, image processing system 20 is devised to automatically generate an adjusted front image from said offset image by using said reference image, which adjusted front image appears as captured from the first camera angle directly in front of the face. The adjusted front image is subsequently encoded into a radio signal by signal encoding means of a radio transceiver 22 , and transmitted from said terminal by means of an antenna 23 . Alternatively, adjustment data for the captured offset image is transmitted as meta data together with the reference image, which adjustment data is dependent on at least the angular relation between the first and second camera angles. An adjusted image is instead subsequently established by means of the received reference image and adjustment data at a recipients communication terminal, or in another device.
In a first specific embodiment, this generation of an adjusted front image is achieved by the image processing system digitally identifying corresponding structures in said reference image and said captured image. These structures may e.g. be contours, shades, colour separations and so on, as is well known in the art of image processing. Once the structures have been identified, a mathematical transform is derived from the mathematical relation between spatial image data of the reference image and of the captured image for said corresponding structures. The offset image is then transformed to appear as captured from said first angle by applying said mathematical transform to the image data of the captured image. Preferably, the adjusted image is established using the mathematical relation between discrete points in the images for establishing the transform, and subsequently applying the transform to every pixel in the offset image for performing the angular adjustment of the captured image.
In a second specific embodiment, illustrated in FIGS. 5-7 , the image processing system makes use of a digital filtering function. A reference image 50 of a user is first stored in memory 21 , as illustrated in FIG. 5 . Key features 51 , in the illustrated example the eyes and mouth of the user, are subsequently digitally identified in reference image 50 , according to FIG. 6 . Digital coordinate data and signal data for the key features are stored in Memory 21 . This may be an automatic process step. Alternatively, the key features may be selectively identified by the user. This may be achieved by displaying the reference image on display 14 , and marking selected areas in the reference image as key features by means of a cursor controlled by buttons on keypad 13 , a jog ball, or a joystick. For video conferencing purposes, such key features preferably include the user's eyes and mouth, as illustrated.
When live moving images are captured by camera 17 during a video conference, image processing system 20 is devised to monitor and detect movement of the said key features 51 , as is illustrated in FIG. 7 . The detected movement is then filtered out from the live image by means of image processing system 20 . Subsequently, the detected movement is applied to the key features 51 in reference image 50 . Thereby, an adjusted front image is generated, by applying movement of selected portions of a live image to the corresponding portions of a reference image 51 . In particular, even if the live image is taken from an angle which is offset from the first angle from which the reference image was captured, the resulting adjusted image will be perceived as captured from the front as illustrated in FIG. 1 .
Also in this case, a mathematical transform may be used for rotating the selected image portions with regard to the angle offset. In another specific embodiment, a morphing technique is instead used for applying movement to the selected key features in the reference image, based on detected spatial movement in the horizontal and vertical direction in the offset image.
A second general embodiment for avoiding undesired images is to slightly slant an image taken from an offset angle, which gives an impression of an angular adjustment of the captured image. This is described with reference to FIGS. 8-11 . This process may be a manual operation or an automatic operation in case the mobile phone is equipped with some kind of motion sensor, devised to sense how the camera is altered from an original perpendicular position. It is however preferable that this is made manually since it is a subjective image that is produced.
FIG. 8 illustrates an image 80 of an object in the shape of a cross, captured from a first perpendicular camera angle in front of the object. When the camera used for capturing the image is dropped, the image will reflect the perspective of the second camera angle in question, as illustrated in FIG. 9 . A slanted image may then be derived from captured image 90 , for compensating the angular difference between the camera angle of image 80 and image 90 . Such a slanted image 100 is shown in FIG. 10 . Finally, the slanted image 100 is zoomed and cropped to avoid the slanted image borders 101 , upon which a corrected image 110 is obtained, as illustrated in FIG. 11 .
When using video telephony it often happens that the users face is moved outside the camera viewfinder. The user may do something else while talking to the other party and can not focus on the mobile phone camera all the time. According to an embodiment of the invention, this problem is overcome by activating an optical tracking system in the terminal to track the users movement using the viewfinder image data. A tracking system identifies one or several tracking points, e.g. high contrast changes in an image could be a valid tracking point candidate, and tries to follow them as good as possible. The tracking system can handle zoom, pan and rotation. If the tracking system is used in addition to a motorized camera, the users face can be in focus even if it is slightly moved. The camera motor must be able to move its angle in horizontal and vertical led and rotation for such an embodiment.
The angular movement of the camera in relation to the object, i.e. between a first camera angle and a second camera angle, may be defined manually, e.g. by means of the terminal keypad. Alternatively, an angle sensor may be incorporated, such that tilting of the camera from a certain angle is sensed, e.g. by means of an accelerometer. Another alternative is to employ an absolute angle sensor, e.g. by means of a pendulum device. In one embodiment, an angle preset is selectable in the terminal. Selecting for instance a 45° preset indicates that the camera of the terminal will be held such that it is aimed from 45° below a horizontal position to an object. Image processing system 20 is thereby arranged to process captured images to generate adjusted images of captured images, to appear as taken from a horizontal position in relation to the object. This way, an entire video conference may be held with the terminal held at a 45° angle, which is more comfortable for the user. Any of the previously described methods for adjusting the image to appear as captured from a horizontal direction may be used. Needless to say, a preset angle may be selected from a plurality of different preset angles, such as e.g. +45°, −45°, and 0°, or even a more detailed range e.g. in steps of 10°. For the embodiment described with reference to FIGS. 8-11 , the reference image of FIG. 8 is not necessary for this specific embodiment using angle presets. If e.g. a camera angle preset of 45° is set in the terminal, a first camera angle is defined as 45° higher in a vertical plane than the capture camera angle, which is the second camera angle.
The principles of the present invention have been described in the foregoing by examples of embodiments and modes of operations. The main advantage with the invention is that a user in a mobile video conference can sustain a transmission without having to keep the terminal in a tiring position, and still provide an attractive picture of the face. It should be noted though, that the present invention is not restricted to images captured of the user by him- or herself. Indeed, the present invention is usable for capturing images of any type of object, in particular where it is of interest to depict the object from a certain angle. The invention should therefore not be construed as being limited to the particular embodiments discussed above, and it should be appreciated that variations may be made in those embodiments by persons skilled in the art, without departing from the scope of the present invention as defined by the appended claims. | Methods for adjusting a picture of an object captured by a camera in a mobile radio communication terminal include defining a first camera angle relative to the object and capturing an image of the object by means of the camera from a second camera angle relative to the object. The second camera angle is offset from the first camera angle. The methods further include storing image data relating to the captured image, and generating an angularly adjusted image of the object in response to the image data and an angular relation between the first camera angle and the second camera angle. Corresponding mobile radio communication terminals are also disclosed. The terminals include an image processing system configured to process an image of an object captured by a camera from a second camera angle by generating an angularly adjusted image of the object in response to image data for the image, and in response to an angular relation between the second camera angle and a first camera angle. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates improvements in or relating to a metal connector for building and also to a jointing structure of a building using such a metal connector.
2. Description of the Prior Art
A wooden building normally includes a large number of jointing structures at which two lumber blocks or wooden members are jointed to each other. Such jointing structures may be a jointing structure between a column and a beam, a jointing structure between a pair of beams extending in a serial direction or in perpendicular directions, a jointing structure between a column and a sill, a jointing structure at a principal rafter, that is, at the tops of a pair of left and right diagonal members forming a triangle of a truss together with a beam, a jointing structure between an outer end portion of a diagonal member and a top end of a column, or the like.
Various means are conventionally employed to connect two lumber blocks to each other in those jointing structures, including notches, holes and so forth formed on lumber blocks, metal connectors such as nails, bolts and nuts, dowels and flange plates, and bonding agents, or any combination of those means. Such various conventional connecting means have been developed and are adopted to joint general lumber members, that is, solid members to each other, and it is admitted that they exhibit anticipated effects as such.
The conventional connecting means, however, are not always satisfactory for a jointing structure in a large scale wooden building which draws much attention and which is built recently, and wherein structural assemblies are employed for main structural parts, because the connecting means are not sufficiently strong or because a metal connector is exposed to an outer side and, thus, presents a bad appearance.
Taking the above into consideration, the inventor has developed and proposed, in U.S. Pat. No. 5,061,111, a novel metal connector for a wooden building by which jointing structures of all types (not only in a wooden building which employs general lumber, but also in a large scale wooden building which employs structural assemblies) are provided with a satisfactory fastening strength without deteriorating the appearance as well as a novel jointing structure which makes use of such metal connectors.
The metal connector and the jointing structure disclosed in U.S. Pat. No. 5,061,111 are shown in FIGS. 18 and 19. Referring to FIGS. 18 and 19, the jointing structure shown is applied to connect a column and a beam to each other using the metal connector shown. The metal connector includes a metal connector body 1 which includes a rectangular bottom plate 2, a rectangular core plate 3 secured uprightly to an upper face of the bottom plate 2 along a center line, a mounting plate 4 secured uprightly to a longitudinal end of the bottom plate 2 and held in contact with and secured to an end face of the core plate 3, and a pair of wedge guide elements 5 and 6 mounted at symmetrical locations on the opposite faces of the core plate 3 adjacent the other longitudinal end remote from the mounting plate 4.
The metal connector is used to joint a column 7 and a beam 11 to each other. The column 7 has a recess 8 formed at a side face thereof at which it is to be jointed to the beam 11. The mounting plate 4 of the metal connector body 1 is fitted in the recess 8 of the column 7 and fastened to the column 7 by means of bolts 9 and nuts 10 to thereby rigidly secure the metal connector body 1 horizontally to the column 7.
The beam 11 has formed at an end portion thereof a fitting recess 12 which has a substantially same profile as an outer profile of the metal connector body 1 except the mounting plate 4.
Thus, in assembling the beam 11 to the column 7, the beam 11 is operated so that the metal connector body 1 secured to the column 7 may be fitted into the fitting recess 12 of the beam 11 so that the beam 11 may be supported on the bottom plate 2 of the metal connector body 1.
Then, in this condition, the beam 11 is moved horizontally toward the column 7 so that a pair of wedge receiving recesses 13 and 14 may be opened forwardly of the wedge guide elements 5 and 6 received in a pair of widened portions of the fitting recess 12 of the beam 11, that is, on the side adjacent the column 7.
Then, a pair of wedge members 15 and 16 are driven into the thus open wedge receiving recesses 13 and 14, respectively, whereupon the entire beam 11 is gradually moved toward the column 7 by a wedging action of the wedge members 15 and 16. Finally, an end face of the beam 11 is contacted closely with the opposing side face of the column 7, thereby establishing a required secured condition between the column 7 and the beam 11.
The above described conventional jointing structure has two significant disadvantages, as described in detail below.
In particular, when the beam 11 is to be fitted once with the metal connector body 1 secured to the column 7, such fitting operation is preformed at a position at which the end face 17 of the beam 11 is spaced sufficiently from the side face of the column 7, and then the beam 11 is moved axially to the column 7 to open the wedge receiving recesses 13 and 14, whereafter the wedge members 15 and 16 are driven into the wedge receiving recesses 13 and 14, respectively, to force the beam 11 to move further toward the column 7 until it is contacted closely with the column 7.
However, since the working spacing normally decreases as construction proceeds at a building site, it gradually becomes difficult to assure a room in which the beam 11 to be jointed to the column 7 is moved laterally from a position spaced by a required distance of even several centimeters to the column 7. In particular, in order to joint a beam to two columns such that it extends horizontally between the two columns, such a situation may take place that the two columns which have been installed in a prescribed condition must be deflected to open outwardly away from each other.
The jointing structure is also disadvantageous in the following respect. In particular, a necessary and sufficient fastening strength between a column and a beam in such jointing structure as described above is derived from a suitable degree (or depth) of driving of wedge members, and such fastening strength must not be insufficient nor excessive. However, it is a problem in this jointing structure that the fastening strength is difficult to determine quantitatively, i.e., it depends on the experience and skill of the person performing the connection.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a metal connector and a jointing structure with which a beam can be fitted with a metal connector body on a column almost only by an operation of placing the beam from above onto the metal connector body, so that spacing otherwise required for horizontal movement of such beam is minimized.
It is another object of the present invention to provide a metal connector and a jointing structure with which two members are jointed to each other with a sufficient fastening strength which can be quantitatively determined.
In order to attain these objects, according to one aspect of the present invention, there is provided a metal connector for jointing first and second members of a building to each other, which comprises a metal connector body including a bottom plate and a core plate secured vertically to an upper face of the bottom plate and having a threaded hole formed at an end face thereof, a bolt screwed at a base end portion thereof in the threaded hole of the core plate, the metal connector body being connected, at an end thereof remote from the bolt, to the second member, the first member having a fitting recess formed at a jointing end portion thereof in a profile suitable to closely receive the bottom plate and core plate of the metal connector body therein, the first member further having a working window hole formed at the jointing end portion thereof, the first member further having a bolt insertion hole formed therein to extend between the fitting recess and the working window hole, the bolt extending from the core plate of the metal connector body through the bolt insertion hole, when the metal connector body is received in the fitting recess of the first member, into the working window hole, and a nut screwed at the end portion of the bolt in the working window hole such that, when the nut is turned to move on the bolt toward the metal connector body, the nut forces the first member to move toward the second member until a longitudinal end of the first member is closely contacted with the second member.
The metal connector is thus simple in construction in that it comprises the metal connector body, a bolt and a nut. Accordingly, it can be produced readily, and a jointing operation with the metal connector can be performed readily by placing the jointing end portion of the first member from above in position onto the metal connector body mounted on the second member and then turning the nut on the bolt to force the first member to move to the second member. Further, with the metal connector, the jointing strength between the first and second members can be quantitatively determined. Consequently, the jointing strength can be adjusted suitably by adjusting the turning motion of the nut, and management and so forth of a building can be performed reasonably.
According to another aspect of the present invention, there is provided a metal connector for jointing first and second members of a building to each other, which comprises a metal connector body including a bottom plate and a core plate secured vertically to an upper face of the bottom plate and having a threaded hole formed at each of the opposite end faces thereof, a bolt screwed at a base end portion thereof in each of the threaded holes of the core plate, each of the first and second members having a fitting recess formed at a jointing end portion thereof in a profile suitable to closely receive corresponding longitudinal halves of the bottom plate and core plate of the metal connector body therein, each of the first and second members further having a working window hole formed at the jointing end portion thereof, each of the first and second members further having a bolt insertion hole formed therein to extend between the fitting recess and the working window hole, each of the bolts extending from the core plate of the metal connector body through the corresponding bolt insertion hole, when the metal connector body is received in the fitting recesses of the first and second members, into the corresponding working window hole, and a pair of nuts screwed at the end portions of the bolts in the working window holes such that, when the nuts are turned in a predetermined direction to axially move on the bolts toward the metal connector body, the nuts force the first and second members to move toward each other until opposing longitudinal ends thereof are closely contacted with each other.
The metal connector is thus simple in construction in that it comprises the metal connector body, a bolt and a nut. Accordingly, it can be produced readily, and a jointing operation with the metal connector can be performed readily by placing the jointing end portions of the first and second members from above in position onto the metal connector body and then turning the nuts on the bolts to force the first and second members to move toward each other. Further, with the metal connector, the first and second members are jointed in an end-to-end serial relationship to each other by turning the nuts in the predetermined direction, and the jointing strength between the first and second members can be graped quantitatively determined. Consequently, the jointing strength can be adjusted suitably by adjusting the turning motion of the nuts, and management and so forth of a building can be performed reasonably.
According to a further aspect of the present invention, there is provided a jointing structure for a building, which comprises a metal connector body including a bottom plate and a core plate secured vertically to an upper face of the bottom plate and having a threaded hole formed at an end face thereof, first and second members to be jointed to each other by means of the metal connector body, a bolt screwed at a base end portion thereof in the threaded hole of the core plate, means for connecting an end of the metal connector body remote from the bolt to the second member, the first member having a fitting recess formed at a jointing end portion thereof in a profile suitable to closely receive the bottom plate and core plate of the metal connector body therein, the first member further having a working window hole formed at the jointing end portion thereof, the first member further having a bolt insertion hole formed therein to extend between the fitting recess and the working window hole, the bolt extending from the core plate of the metal connector body through the bolt insertion hole, when the metal connector body is received in the fitting recess of the first member, into the working window hole, and a nut screwed at the end portion of the bolt in the working window hole such that, when the nut is turned to move on the bolt toward the metal connector body, the nut forces the first member to move toward the second member until a longitudinal end of the first member is closely contacted with the second member.
With the jointing structure, the first and second members are jointed to each other by placing the jointing end portion of the first member from above in position onto the metal connector body mounted on the second member and then turning the nut on the bolt to force the first member to move to the second member, and the jointing strength between the first and second members can be grasped quantitatively. Consequently, the jointing strength can be adjusted suitably by adjusting the turning motion of the nut, and management and so forth of a building can be performed reasonably. Accordingly, with the jointing structure, even an operator who is not skilled in the art can operate to obtain a suitable fastening strength between different members not only in a wooden building which employs general lumber but also in a large scale wooden building which employs structural assemblies as well as in a building of steel structure.
The above and other objects, features and advantages of the present invention will become apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings in which like parts or elements are denoted by like reference characters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a metal connector and a jointing structure between a column and a beam using the metal connector showing a first preferred embodiment of the present invention;
FIG. 2 is a fragmentary perspective view of the metal connector and jointing structure of FIG. 1;
FIG. 3 is a sectional view showing the jointing structure of FIG. 1 at a stage in assembling;
FIG. 4 is a side elevational sectional view showing a modification to a metal connector body of the metal connector shown in FIG. 1;
FIG. 5 is a similar view but showing another modification to the metal connector body shown in FIG. 1;
FIG. 6 is a similar view but showing a further modification to the metal connector body shown in FIG. 1;
FIG. 7 is a fragmentary perspective view of a metal connector and a jointing structure between a column and a beam using the metal connector showing a second preferred embodiment of the present invention;
FIG. 8 is a sectional view showing the jointing structure of FIG. 7 at a stage in assembling;
FIG. 9 is a perspective view of a metal connector and a jointing structure between a pair of beams in a series direction using the metal connector showing a third preferred embodiment of the present invention;
FIG. 10 is a fragmentary perspective view of the metal connector and the jointing structure shown in FIG. 9;
FIG. 11 is a perspective view of a metal connector showing a fourth preferred embodiment of the present invention;
FIG. 12 is a side elevational view, partly in section, of a jointing structure between a column and a sill using the metal connector shown in FIG. 11;
FIG. 13 is a side elevational view, partly in section, of a metal connector and a jointing structure between a column and a sill using the metal connector showing a fifth preferred embodiment of the present invention;
FIG. 14 is a fragmentary perspective view of the jointing structure shown in FIG. 13;
FIG. 15 is a front elevational view of a metal connector and a jointing structure between top ends of a diagonal members which form a principal rafter using the metal connector showing a sixth preferred embodiment of the present invention;
FIG. 16 is a front elevational view showing a jointing structure in an arch-shaped building;
FIG. 17 is a front elevational view showing a jointing structure wherein a pair of left and right diagonal members are mounted between a central ridge member and left and right columns, respectively;
FIG. 18 is a perspective view showing a conventional metal connector and a conventional jointing structure between and a column and a beam using the metal connector; and
FIG. 19 is a perspective view of the metal connector and the jointing structure of FIG. 18 but at a stage immediately before the column and the beam are finally secured to each other by means of wedge members.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 to 3, there are shown a metal connector and a jointing structure between a column and a beam using the metal connector according to a first preferred embodiment of the present invention. The metal connector shown includes a metal connector body 21 which includes a rectangular bottom plate 22, a rectangular core plate 23 secured uprightly to an upper face of the bottom plate 22 along a center line, and a mounting plate 24 placed securely and uprightly on an upper face of a longitudinal end portion of the bottom plate 22 and held in contact with and secured to an end face of the core plate 23. The bottom plate 22 extends, at a longitudinal outer end portion thereof, outwardly farther than the mounting plate 24 to form a lower flange 22'.
The mounting plate 24 has a width equal to the width of the bottom plate 22 and has a height equal to the height of the core plate 23.
The core plate 23 has a pair of rectangular window holes 25 perforated therein adjacent the mounting plate 24. The mounting plate 24 has a pair of bolt insertion holes 26 perforated therein in register with the window holes 25 of the core plate 23.
A pair of threaded holes 27 are formed at upper and lower locations on an end face of the core plate 23 remote from the window holes 25, and a pair of fastening bolts 28 are screwed at base end portions thereof in the threaded holes 27. A nut or nuts 29 are screwed at the other end portion of each of the fastening bolts 28 together with a washer 29'.
The core plate 23 has two threaded holes 30 formed in a predetermined spaced relationship on an upper end face thereof.
The metal connector body 21 can be produced readily either by individually preparing the bottom plate 22, core plate 23 and mounting plate 24 and assembling them by suitable means such as welding or fastening screws or by molding or casting them as a unitary member.
The metal connector is used to joint a column 31 and a beam 32 to each other.
The column 31 has a recess 33 formed at a side face thereof at which it is to be jointed to the beam 32. The recess 33 has a sufficient size to receive therein the mounting plate 24 and the lower flange 22' of the bottom plate 22 on which the mounting plate 24 is mounted.
The column 31 has two bolt insertion holes 34 perforated therein in an aligned relationship to the bolt insertion holes 26 of the mounting plate 24. The bolt insertion holes 34 extend from the bottom of the recess 33 to the opposite side face of the column 31.
The metal connector body 21 is attached to the column 31 in the following manner. In particular, inner end portions of a pair of fastening bolts 35 are individually inserted into the bolt insertion holes 26 of the mounting plate 24 of the metal connector body 21, and then a pair of nuts 36 are individually fitted with and screwed onto the inner end portions of the fastening bolts 35 in the window holes 25 of the core plate 23. Then, the fastening bolts 35 are inserted into the bolt insertion holes 34 of the column 31 until the mounting plate 24 and the lower flange 22' of the bottom plate 22 of the metal connector body 21 are received into the recess 33 of the column 31 and the other end threaded portions of the fastening bolts 35 are projected from the other side face of the column 31. Then, a pair of fastening nuts 37 are screwed onto and tightened to the thus projected end threaded portions of the fastening bolts 35 to rigidly secure the metal connector body 21 horizontally to the column 31 as seen in FIG. 3.
The beam 32 is jointed at a jointing end portion 38 thereof to the column 31 by means of the metal connector body 21. In particular, referring to FIG. 2, the jointing end portion 38 of the beam 32 has a fitting recess 39 formed therein which has a substantially same profile as that of the metal connector body 21 except the mounting plate 24 and the lower flange 22' of the bottom plate 22. The fitting recess 39 is thus composed of a horizontal flattened groove 40 formed in the jointing end portion 38 of the beam 32 and having a suitable size and shape to receive the bottom plate 22 of the metal connector body 21 therein, and a vertical slot 41 formed along the center line in the jointing end portion 38 perpendicularly and contiguously to the horizontal groove 40 and having a suitable size and shape to receive the core plate 23 of the metal connector body 21 therein. The horizontal groove 40 is opened to the bottom face and an outer end face of the jointing end portion 38 of the beam 32 while the vertical slot 41 is opened to the top face, bottom face and outer end face of the jointing end portion 38.
A pair of upper and lower working window holes 42 are formed in the jointing end portion 38 of the beam 32. The working window holes 42 extend vertically, and the upper working window hole 42 is opened to the top face of the jointing end portion 38 of the beam 32 while the lower working window hole 42 is opened to the bottom face of the jointing end portion 38. A pair of bolt insertion holes 43 are formed in the jointing end portion 38 of the beam 32 to individually extend between the vertical slot 41 of the fitting recess 39 and the working window holes 42.
The beam 32 is jointed to the column 31 in the following manner.
First, the fastening bolts 28 are installed in position into the jointing end portion 38 of the beam 32. More particularly, the fastening bolts 28 are inserted into the bolt insertion holes 43 in the jointing end portion 38 of the beam 32 to a position in which base end portions thereof at least do not extend into the vertical groove 41 as seen from the upper fastening bolt 28 in FIG. 3.
Then, the jointing end portion 38 of the beam 32 is placed from above onto the metal connector body 21 mounted on the column 31 so that the metal connector body 21 is received into the fitting recess 39. In the thus placed position of the jointing end portion 38 of the beam 32, the bottom plate 22 of the metal connector body 21 is fitted in the flattened groove 40 of the jointing end portion 38 of the beam 32 while the core plate 23 is fitted in the vertical slot 41, and the top face of the beam 32, that is, the top face of the jointing end portion 38, and the top face of the metal connector body 21, or more particularly the top face of the core plate 23, are aligned with each other.
In this instance, an operation of fitting the beam 32 with the metal connector body 21 does not require moving the beam 32 laterally in a horizontal direction, or in other words, even at a location where a spacing necessary for such lateral movement cannot be assured, such fitting operation can be performed readily by moving the jointing end portion 38 of the beam 32 downwardly from above, which is an advantage of a metal connector and a jointing structure according to the present invention.
Subsequently, base end portions of the fastening bolts 28 are operated to turn the fastening bolts 28 to move into the threaded holes 27 of the mounting plate 24, and then the washers 29' and the nuts 29 are fitted onto the base end portions of the fastening bolts 28 and the nuts 29 are turned to be tightened. In this instance, the nuts 29 are used as a double nut or a dual nut in order to prevent possible loosening of the nuts 29.
As a result of such tightening of the nuts 29, an end face of the jointing end portion 38 of the beam 32 is closely contacted with the opposing side face of the column 31, thereby obtaining an intended jointing structure.
In this instance, a pressing or fastening strength between the column 31 and the beam 32 can apparently be grasped quantitatively from an amount of movement of the nuts 29 on the fastening bolts 28, that is, an amount of turning motion of the nuts 29, which is another advantage of a metal connector and a jointing structure according to the present invention.
Finally, a cover plate 44 is placed onto the top face of the jointing end portion 38 of the beam 32 jointed to the column 31 as seen in FIG. 1, and screws 46 are inserted into perforations 45 formed in the cover plate 44 and are screwed tightly into the threaded holes 30 at the top end of the core plate 23 as seen in FIG. 1. It is to be noted that a packing plate 47 made of a same material as the beam 32 may additionally be inserted into each of the working window holes 42 of the beam 32 to fill up the working window holes 42.
While the jointing structure described above with reference to FIGS. 1 to 3 employs only one such metal connector as described above and joints a single column and a single beam to each other, a column to beam jointing structure may otherwise joint two, three or four beams in different directions to a column. In any case, each beam can be jointed to a column using such metal connector as described above. However, attention must naturally be paid so that fastening bolts may not interfere with each other in the column.
FIGS. 4 to 6 show three different modifications to the metal connector body 21 shown in FIGS. 1 to 3.
The modified metal connector body shown in FIG. 4 is denoted also at 21 and constructed such that it has, in addition to the lower flange 22' which is an extension of the bottom plate 22, an upper flange 48 extending from the top end of an outer face of the mounting plate 24 in parallel to the lower flange 22'. Thus, a column 31 to which the modified metal connector body 21 is to be assembled has a pair of flange receiving grooves 49 and 50 formed at upper and lower ends of the recess 33 such that they may receive the upper and lower flanges 48 and 22' of the metal connector body 21, respectively.
It is to be noted that a cutaway portion 51 is provided at a corner of the mounting plate 24 to reduce the overall weight of the metal connector body 21.
Meanwhile, the modified metal connector body 21 shown in FIG. 5 is a modification also to the modified metal connector body 21 shown in FIG. 4 in that it has the upper flange 48 on the mounting plate 24 thereof but does not have the lower flange 22'. Thus, a column 31 for use with the present modified metal connector 21 may only have the upper flange receiving groove 49 at the top end of the recess 33. Further, a cutaway portion 52 is provided at a vertical midpoint along the mounting plate 24 to reduce the overall weight of the metal connector body 21.
On the other hand, the modified connector body 21 shown in FIG. 6 is constructed such that it does not have either of the upper and lower flanges 48 and 22'. Thus, a column 31 for use with the present modified metal connector 21 may have no flange receiving groove formed therein. Meanwhile, a cutaway portion 53 is provided at a vertically mid portion of the mounting plate 24 to reduce the overall weight of the metal connector body 21.
Referring now to FIGS. 7 and 8, there are shown a metal connector and a jointing structure between a column and a beam using the metal connector according to a second preferred embodiment of the present invention. The metal connector and the jointing structure are a modification to the metal connector and the jointing structure shown in FIGS. 1 to 3, respectively, and since they have somewhat common construction, only differences of the former from the latter will be described below.
The mounting plate 24 of the connector metal body 21 has two pairs of bolt head receiving tubes or hubs 54 formed in a predetermined spaced relationship on and extending outwardly from an outer face thereof. Meanwhile, the core plate 23 has a height a little smaller than the height of the mounting plate 24.
Thus, a column 31 for use with the metal connector body 21 has two pairs of depressions 55 formed in a predetermined relationship on a side face thereof for receiving therein the bolt head receiving tubes 54 of the mounting plate 24 of the metal connector body 21. The depressions 55 are formed contiguously to and concentrically with the bolt insertion holes 34 formed in the column 31.
Meanwhile, a beam 32 for use with the metal connector body 21 has a shallow groove 56 formed on the top face of the jointing end portion 38 thereof for receiving the cover plate 44 therein. Further, the beam 32 has another shallow groove 57 formed on the outer longitudinal end of the jointing end portion 38 thereof for receiving the mounting plate 24 therein.
The metal connector body 21 in the present embodiment is assembled to the column 31 in the following manner. In particular, the metal connector body 21 is operated to insert the bolt head receiving tubes 54 on the mounting plate 24 thereof into the depressions 55 of the column 31 until the mounting plate 24 is contacted with the opposing side face of the column 21. Then, fastening bolts 58 are individually inserted into the bolt insertion holes 34 through round holes formed in the bolt head receiving tubes 54, and then nuts 59 are individually screwed tightly onto ends of the fastening bolts 58 which are projected outwardly from the opposite side face of the column 31, thereby to secure the metal connector body 21 to the column 32.
Then, the jointing end portion 38 of the beam 32 is fitted with the metal connector body 21 mounted on the column 31 in a similar manner as in the first embodiment described hereinabove. Consequently, the beam 32 is rigidly fastened to the column 31 by way of the metal connector body 21, thereby obtaining an intended jointing structure.
Finally, the cover plate 44 is fitted into and placed onto the bottom of the shallow groove 56 of the beam 32 and secured to the core plate 23 of the metal connector body 21 by means of the screws 46.
Referring now to FIGS. 9 and 10, there are shown a metal connector and a jointing structure between two beams in a serial direction using the metal connector according to a third preferred embodiment of the present invention. The metal connector of the present embodiment includes a metal connector body 60 which includes a rectangular bottom plate 61 and a rectangular core plate 62 secured uprightly to an upper face of the bottom plate 61 along a center line.
The core plate 62 has a pair of threaded holes 65 formed at upper and lower locations on each of the opposite longitudinal end faces thereof, and two pairs of bolts 63 and 64 are screwed at base end portions thereof in the threaded holes 65 of the core plate 62. A nut or nuts 66 are screwed at the other end portion of each of the fastening bolts 63 and 64 together with a washer 66'.
Four threaded holes 67 are formed in a predetermined spaced relationship at an upper end face of the core plate 62.
Similarly as in the case of the metal connector body 21 in the first embodiment described hereinabove, the metal connector body 60 can be produced readily either by individually preparing the bottom plate 61 and core plate 62 and assembling them by suitable means such as welding or fastening screws or by molding or casting them as a unitary member.
The metal connector is used to joint a pair of beams 68 and 69 to each other along a straight line. The beams 68 and 69 are jointed at jointing end portions 70 and 71 thereof to each other by means of the metal connector body 60. In particular, referring to FIG. 10, the jointing end portions 70 and 71 of the beams 68 and 69 have a pair of fitting recesses 72 formed therein which generally have a substantially same profile as that of the metal connector body 60. Each of the fitting recesses 72 is thus composed of a flattened horizontal groove 73 formed at the bottom of the jointing end portion 70 or 71 of the beam 68 or 69 and having a suitable size and shape to receive a longitudinal half of the bottom plate 61 of the metal connector body 60 therein, and a vertical slot 74 formed along the center line in the jointing end portion 70 or 71 and having a suitable size and shape to receive a longitudinal half of the core plate 62 therein. The horizontal groove 73 is opened to the bottom face and an outer end face of the jointing end portion 70 or 71 of the beam 68 or 69 while the vertical slot 74 is opened to the top face, bottom face and outer end face of the jointing end portion 70 or 71.
A pair of upper and lower working window holes 75 are formed in each of the jointing end portions 70 and 71 of the beams 68 and 69. The upper working window hole 75 is opened to the top face of the jointing end portion 70 or 71 while the lower working window hole 75 is opened to the bottom face of the jointing end portion 70 or 71.
Each of the jointing end portions 70 and 71 of the beams 68 and 69 has a pair of bolt insertion holes 76 formed therein such that they individually extend between the vertical slop 74 of the fitting recess 72 and the working window holes 75.
The beams 68 and 69 are jointed to each other in the following manner.
First, the fastening bolts 63 and 64 are installed in position into the jointing end portion 70 and 71 of the beams 68 and 69, respectively. More particularly, the fastening bolts 63 and 64 are inserted into the bolt insertion holes 76 in the jointing end portions 70 and 71 of the beams 68 and 69 to a position in which base end portions thereof at least do not extend into the vertical slots 74.
Then, the jointing end portions 70 and 71 of the beams 68 and 69 are placed from above onto the metal connector body 60 so that the metal connector body 60 is received into the fitting recesses 72 of the jointing end portions 70 and 71 while the jointing end portions 70 and 71 are placed onto the bottom plate 61 of the metal connector body 60.
Subsequently, base end portions of the fastening bolts 63 and 64 are operated to turn the fastening bolts 63 and 64 to move into the threaded holes 65 of the core plate 62, and then the washers 66' and the nuts 66 are fitted onto the base end portions of the fastening bolts 63 and 64 and the nuts 66 are turned to be tightened. In this instance, the nuts 66 are used as a double nut or a dual nut in order to prevent possible loosening of the nuts 66.
Finally, a cover plate 77 is placed onto the top faces of the jointing end portions 70 and 71 of the beams 68 and 69, and screws 79 are inserted into perforations 78 formed in the cover plate 77 and are screwed tightly into the threaded holes 67 at the top end of the core plate 62 as seen in FIG. 9. A packing plate 80 made of a same material as the beams 68 and 69 may additionally be inserted into each of the working window holes 75 of the beams 68 and 69 to fill up the working window holes 75.
Consequently, the two beams 68 and 69 are jointed to each other in a linear condition by means of the metal connector as seen in FIG. 10.
Referring now to FIGS. 11 and 12, there are shown a metal connector and a jointing structure between a column and a sill using the metal connector according to a fourth preferred embodiment of the present invention. The metal connector shown includes a metal connector body 83 which includes a rectangular bottom plate 84, a core plate 85 mounted uprightly on an upper face of the bottom plate 84 along a center line, and a pair of mounting plates 86 mounted on the bottom plate 84 adjacent the opposite longitudinal ends of the core plate 85 and having a greater height than the core plate 85. The bottom plate 84 extends at the opposite longitudinal ends thereof outwardly farther than the mounting plates 86 to form a pair of lower flanges 87. A pair of bolt insertion holes 88 are performed in each of the lower flanges 87 of the bottom plate 84. A pair of threaded holes 89 are formed on the top face of the core plate 85, and a pair of fastening bolts 90 are screwed at bottom end portions thereof in the threaded holes 89 of the core plate 85.
The metal connector body 83 is secured, at the bottom plate 84 thereof, to an upper face of a sill 82 by means of a plurality of fastening bolts 91 and nuts 91'.
A column 81 to be jointed to the sill 82 by means of the metal connector has a fitting recess formed at a joining end portion 92, that is, a lower end portion thereof for receiving the metal connector body 83 in a similar manner as the fitting recess 39 of the beam 32 in the first embodiment described hereinabove. The metal connector body 83 is fitted in the fitting recess of the column 81, and a lower end face of the jointing end portion 92 of the column 81 is held in contact with the top face of the bottom plate 84 on the sill 82.
A packing plate 93 similar to the packing plate 47 in the first embodiment is filled in each of a pair of working window holes 94 formed in the jointing end portion 92 of the column 81. A nut 90' is screwed to an end portion of each of the fastening bolts 90 extending into the corresponding working window hole 94.
Referring now to FIGS. 13 and 14, there are shown a metal connector and a jointing structure between a column and a sill using the metal connector according to a fifth preferred embodiment of the present invention. The metal connector shown includes a metal connector body 97 which includes a square bottom plate 98, and a core plate 99 mounted uprightly on an upper face of the square bottom plate 99 and having a cross shape in plan. Four bolts 100 are screwed vertically at base end portions thereof in threaded holes 99' formed at the top face of the cross-shaped core plate 99 while a pair of fastening bolts 101 are screwed horizontally at base end portions thereof in threaded holes formed in each of four outer end faces of the cross-shaped core plate 99 as seen in FIG. 14.
The metal connector body 97 is secured, at the bottom plate 98 thereof, to an upper face of a sill 96 by means of four anchor bolts 102 and four nuts 102'.
A column 95 to be jointed to the sill 96 by means of the metal connector has a fitting recess 105 formed at a joining end portion 103, that is, a lower end portion thereof and composed of a pair of vertical slots 104 which are opened to the four side faces of the jointing end portion 103 and cross each other in such a manner as to provide the fitting recess 105 with a cross shape in plan which conforms to the cross shape of the core plate 99 of the metal connector body 97. The column 95 further has four working window holes 106 formed therein in a spaced relationship above the vertical slots 104, and four bolt insertion holes 107 are formed between the working window holes 106 and the vertical slots 104.
The column 95 is assembled to the sill 96 in the following manner by way of the metal connector body 97. In particular, the column 95 is operated so that the cross-shaped core plate 99 of the metal connector body 97 mounted on the sill 96 is fitted into the fitting recess 105 of the column 95 while upper end portions of the fastening bolts 100 on the core plate 99 are individually inserted into the bolt insertion holes 107 of the jointing end portion 103 of the column 95 until they are projected into the working window holes 106 of the column 95. Then, nuts 108 are screwed to and tightened on the end portions of the fastening bolts 100 projected into the working window holes 106 thereby to fasten the jointing end portion 103 of the column 95 to the sill 96 with the bottom plate 98 of the metal connector body 97 interposed therebetween.
A packing plate 109 similar to the packing plate 47 in the first embodiment may be filled in each of the working window holes 106. A cover plate 109' similar to the cover plate 44 in the first embodiment is secured to each of the four side faces of the jointing end portion 103 of the column 92 by screwing nuts 109" to end portions of the fastening bolts 101 projected from the four side faces of the column 95.
Referring now to FIG. 15, there are shown a metal connector and a jointing structure between a pair of diagonal members using the metal connector according to a sixth embodiment of the present invention. More particularly, the metal connector is used to joint top portions of a pair of left and right diagonal members 110 and 111 which form a principal rafter.
The jointing structure is similar in a sense to the jointing structure between a pair of the beams in a serial direction using the metal connector of the third embodiment shown in FIGS. 9 and 10. In particular, the jointing structure of the present embodiment is only different from the jointing structure in the third embodiment in that a bottom plate 61 and a core plate 62 of a metal connector body 114 of the metal connector of the present embodiment each having a comparatively great length are bent in an inverted V-shape at an angle at which the left and right diagonal members 110 and 111 are to be jointed to each other at jointing end portions 112 and 113 thereof. A cover plate 115 is also bent in an inverted V-shape at the same angle as the metal connector body 114.
Referring now to FIG. 16, there is shown a jointing structure in an arch-shaped building. The arch-shaped building 116 employs, at a curved jointing portion thereof, a modification to the metal connector body 60 in the third embodiment described above, and employs, at a jointing portion between a column thereof and a sill, the metal connector body 83 in the fourth embodiment described above.
In particular, a modified metal connector body 120 and a pair of modified metal connector bodies 121 are employed for a top portion 117 and a pair of left and right curved portions 118 and 119, respectively, of the arch-shaped building 116. The metal connector bodies 120 and 121 are modifications to the metal connector body 60 in the third embodiment in that the bottom plate 61 and core plate 62 are curved with a curvature conforming to the curvature of the corresponding portion of the arch-shaped building. Meanwhile, the metal connector body 83 in the fourth embodiment is employed to secure each of a pair of left and right columns 122 of the arch-shaped building 116 to a sill 123.
FIG. 17 shows a jointing structure in a building 127 wherein a pair of left and right diagonal members 126 extend between a central ridge member 124 and a pair of left and right columns 125.
Referring to FIG. 17, a metal connector body 128 which is a modification to the metal connector body 21 in the first embodiment that is different from the modifications shown in FIGS. 4 to 6 is employed for jointing between the ridge member 124 of the building 127 and a top portion of each of the left and right diagonal members 126, and another metal connector body 129 which is another different modification to the metal connector body 21 in the first embodiment is employed for jointing between a lower end portion of each of the left and right diagonal members 126 and a top portion of a corresponding one of the left and right columns 125.
While the mounting plate 24 of the metal connector body 21 in the first embodiment is mounted perpendicularly to the bottom plate 22, the metal connector body 128 is constructed such that the mounting plate 24 is mounted in an inclined relationship at an obtuse angle with respect to the bottom plate 22. On the other hand, the metal connector body 129 is constructed such that the mounting plate 24 is mounted in an inclined relationship at an acute angle with respect to the bottom plate 22. The metal connector bodies 128 and 129 are thus shaped so as to have angles conforming to angles made by the jointing portions of the building 127.
The metal connector body 83 is employed to secure each of the left and right columns 125 to a sill 130.
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit and scope of the invention as set forth herein. | A jointing structure for connecting a horizontal first member with a vertical second member via a metal connector body by a simple operation requiring little or no horizontal movement of the first member, and wherein the two members are connected with a quantitatively determinable and sufficient fastening strength. The metal connector body includes a bottom plate and a vertically attached core plate, the core plate having a threaded hole formed at an end face thereof, an opposite end face of the metal connector body being provided with a mounting plate which is secured to the second member. A fitting recess is formed in the first member, as is a working window hole disposed outwardly of the fitting recess. A bolt insertion hole is formed in the first member between the fitting recess and the working window hole, and the bolt insertion hole corresponds to the threaded hole in the core plate, a bolt being inserted into the bolt insertion hole and moved away from the fitting recess towards the working window hole so that the first member can be moved downwardly against a surface of the second member and so that the bottom plate and the core plate of the metal connector body are received in the fitting recess, without requiring a longitudinal movement of the horizontal member. The bolt is then moved toward the metal connector body and secured into the threaded hole in the core plate, and a nut is secured to the opposite end of the bolt at the working window hole to tighten the first member against the second member. | 4 |
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/365,729, filed on Jul. 19, 2010, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to a system for closing a patent foramen ovale in heart tissue.
BACKGROUND
Referring to FIG. 1 , a patent foramen ovale (PFO) 2 is a flap-like opening in the wall 4 between the left atrium 6 and the right atrium 8 of the heart 10 . That opening typically closes at or shortly after birth. However, in an estimated 20-25% of people, the PFO 2 remains open into adulthood. The PFO 2 allows blood clots in the bloodstream to bypass the natural filtering mechanism of the lungs, which can lead to stroke. A person with a PFO 2 is generally asymptomatic, and generally does not know he or she has a PFO 2 until after a stroke. In addition, research suggests a correlation between PFO 2 and migraine, the mechanism of which is still unknown.
Currently, patients having a known PFO 2 are treated in one of two ways. The patient may be prescribed blood thinners such as coumadin, to reduce the risk of clot formation. However, this course of treatment requires lifelong dependence on that medication, which does nothing to close the opening between the atria. Alternately, a device may be placed through the PFO 2 and then unfurled like a tent on each side of the PFO 2 . Such a device may include a material such as polyester stretched over a wire frame, or stuffed inside a wire mesh. However, such devices can expose a significant amount of metal to the bloodstream, which is considered undesirable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section view of a heart.
FIG. 2 is a perspective view of the distal end of a PFO closure tool.
FIG. 3 is an end view of the distal end of a PFO closure tool.
FIG. 4 is a side view of a combination anchor of the PFO closure tool of FIGS. 2-3 in a deployed state.
FIG. 5 is a side view of the combination anchor of the PFO closure tool of FIGS. 2-3 in an undeployed state.
FIG. 6 is a side view of a first step in deployment of the combination anchor.
FIG. 7 is a side view of another step in deployment of the combination anchor.
FIG. 8 is a side view of another step in deployment of the combination anchor.
FIG. 9 is a side view of another step in deployment of the combination anchor.
FIG. 10 is a side view of another step in deployment of the combination anchor.
FIG. 11 is a side view of a step in the deployment of a staple.
FIG. 12 is a side view of another step in the deployment of a staple.
FIG. 13 is a side view of a completed staple deployment.
FIG. 14 is a side view of a first step in deployment of another embodiment of an anchor.
FIG. 15 is a side view of another step in deployment of the anchor of FIG. 15 .
FIG. 16 is a side view of another step in deployment of the anchor of FIG. 15 .
FIG. 17 is a side view of another step in deployment of the anchor of FIG. 15 .
FIG. 18 is a side view of another step in deployment of the anchor of FIG. 15 .
FIG. 19 is a side view of another step in deployment of the anchor of FIG. 15 .
FIG. 20 is a side view of a completed staple deployment.
The use of the same reference symbols in different figures indicates similar or identical items.
DETAILED DESCRIPTION
Commonly-assigned U.S. Patent Publication No. 2009/0093826 (Ser. No. 11/868,431) filed on Oct. 5, 2007 and published on Apr. 9, 2009 (the “PFO Document”) is hereby incorporated by reference herein in its entirety.
Combination Anchor
Referring also to FIGS. 2-4 , a combination anchor 20 is shown in a deployed state. The combination anchor 20 is a unitary structure that includes a first segment 22 and a second segment 24 . The first segment 22 is distal to and connected to the second segment 24 . As described in greater detail below, the first segment 22 is configured for introduction into the left atrium 6 of the heart 10 and the second segment 24 is configured for introduction into the right atrium 8 of the heart 10 . The combination anchor 20 also includes two or more fingers 26 . The first segment 22 is defined as the distal segments of the fingers 26 collectively, and the second segment 24 is defined as the proximal segments of the fingers 26 collectively. The distal end of each finger 26 may be blunt. Referring to FIG. 4 , in a deployed state, the free end of each finger 26 is located radially outward from the longitudinal centerline 28 of the combination anchor 20 . The finger 26 may then extend inward toward the longitudinal centerline 28 of the combination anchor 20 and distal to the free end of the finger 26 . Continuing to move along the finger 26 away from its free end, the finger 26 may curve such that an inflection point of the finger 26 is tangent to a line parallel to the longitudinal centerline 28 of the combination anchor 20 . Substantially at that inflection point is the division 30 between the first segment 22 and the second segment 24 . The finger 26 continues to curve outward, then extends proximally from and radially outward from the inflection point. The finger 26 may curve inward, then extend proximally and radially inward to a proximal end 32 . The proximal end of the finger 26 may be fixed to a base 34 that may be generally cylindrical or that may have any other suitable shape. The base 34 in turn may be received within the lumen of a guide catheter 36 or other flexible tube. The base 34 may be the proximal end of the combination anchor 20 .
The combination anchor 20 may include four fingers 26 arranged in an X-shape, where the fingers 26 are substantially evenly angularly arranged and radially symmetrically arranged about the longitudinal centerline 28 of the combination anchor 20 , as seen in FIG. 3 . However, more or less than four fingers 26 may be utilized. Further, the fingers 26 need not be evenly angularly arranged about the longitudinal centerline 28 of the combination anchor 20 , nor radially symmetrically arranged about the longitudinal centerline of the combination anchor 20 .
Advantageously, the combination anchor 20 is fabricated from nickel-titanium alloy. However, the combination anchor 20 may be constructed from any biocompatible superelastic alloy or material. Alternately, the combination anchor 20 may be fabricated from any material that is capable of self-expansion after removal of a constraining force.
A staple 38 may be held by the base 34 . The staple 38 , its retention by the base 34 , and its deployment may be substantially as described in the PFO Document. The staple 38 may be substantially X-shaped as viewed on end. Advantageously, the tines 40 of the staple 38 are angularly spaced apart from the fingers 26 of the combination anchor 20 to prevent interference between the staple 38 and the combination anchor 20 .
The operation of the combination anchor 20 will now be described. Referring to FIG. 5 , in an initial configuration, the base 34 is retracted far enough into the guide catheter 36 such that the guide catheter 36 constrains the fingers 26 of the combination anchor 20 radially, and such that the diameter of the base 34 and fingers 26 is substantially not greater than the diameter of the guide catheter 36 . In this initial configuration, the base 34 may be partially or completely withdrawn into the lumen of the guide catheter 36 .
As set forth in the PFO Document, the femoral artery, radial artery or other artery or vein in the vasculature remote from the PFO 2 may be punctured, and a standard introducer sheath may be placed into the puncture. A guidewire of the user's choosing may be inserted through the introducer sheath. Optionally, the guidewire may include a standard radiopaque feature at or near its distal end, to aid positioning of the distal end of the guide catheter 36 relative to the PFO 2 . The guidewire may be advanced through the vasculature to the PFO 2 , then completely through the PFO 2 into the left atrium 6 . The guide catheter 36 then may be inserted through the introducer sheath over the guidewire and advanced through the vasculature to the PFO 2 . The distal end of the guide catheter 36 then may be advanced completely through the PFO 2 into the left atrium 6 . Alternately, the guide catheter 36 and the guidewire may be inserted substantially simultaneously, in which case the guidewire may be located completely within a lumen of the guide catheter 36 , or may extend distally from the end of the guide catheter 36 , during this advancement. Advancement of the guide catheter 36 and at least one guidewire advantageously may be performed with the assistance of a fluoroscope or other imaging device that indicates the position of the guide catheter 36 and/or at least one guidewire in the patient. The use of such an imaging device in conjunction with a guide catheter 36 and/or at least one guidewire is standard in the art. The guidewire may then be removed from the guide catheter 36 . Alternately, the guide catheter 36 may be advanced to the PFO 2 , then through the PFO 2 into the left atrium, without the use of a guidewire.
Referring to FIG. 6 , the base 34 then may be pushed distally relative to the end of the guide catheter 36 . As the base 34 moves distally, the combination anchor 20 that is attached to the base 34 moves distally also. Continued motion of the base 34 causes the first segment 22 of the combination anchor 20 to move distal to the guide catheter 36 , such that the guide catheter 36 no longer restrains the first segment 22 . As a result, the distal ends of the fingers 26 self-expand radially outward to form the deployed first segment 22 . Referring to FIG. 7 , the guide catheter 36 and base 34 then may be retracted into the right atrium 8 . Consequently, the first segment 22 , which is positioned within the left atrium 6 , is moved into contact with the wall of the left atrium 6 in proximity to the PFO 2 . The expanded first segment 22 is too large to fit through the PFO 2 and thus holds the combination anchor 20 in place relative to the left atrium 6 .
Referring to FIG. 8 , the guide catheter 36 may be withdrawn further distally. As a result, the proximal ends of the fingers 26 self-expand radially outward to form the deployed second segment 24 . The deployed second segment 24 is located in the right atrium 8 , on the opposite side of the PFO 2 from the first segment 22 . Referring to FIG. 9 , the base 34 may then be advanced distally relative to the guide catheter 36 . As a result, the second segment 24 is compressed against the wall of the right atrium 8 relative to the first segment 22 , thereby compressing tissue adjacent to the PFO 2 between the first segment 22 and the second segment 24 of the combination anchor 20 . The second segment 24 may itself reduce in length longitudinally during this compression.
Referring also to FIG. 10 , the tines 40 of the staple 38 then may be splayed, as set forth in the PFO Document. The base 34 then may be advanced, driving the tips of the tines 40 into tissue adjacent to the PFO 2 . The staple 38 may then be separated from the base 34 . Alternately, the tines 40 need not be driven into tissue at all at this time. Alternately, the staple 38 may be completely deployed into heart tissue adjacent to the PFO 2 at this time. Referring to FIG. 11 , the base 34 then may be retracted proximally and/or the guide catheter 36 may be advanced distally, causing the second segment 24 to compress within the lumen of the guide catheter 36 . Further proximal motion of the base 34 and/or distal motion of the guide catheter 36 causes the first segment 22 to compress back into the lumen of the guide catheter 36 as well.
Referring also to FIG. 12 , the staple 38 is then closed to close the PFO 2 . Closure of the staple 38 may be as set forth in the PFO Document, or may be performed in any other suitable manner. Referring to FIG. 13 , the guide catheter 36 is then withdrawn from the heart 10 and from the insertion point into the patient, which itself is then closed in any suitable manner. The PFO 2 is closed and the procedure is complete.
One-Sided Anchor
As another example of an anchor 50 , the anchor 50 may be one-sided such that it expands only on a single side of the PFO 2 . Referring to FIG. 14 , one or more guidewires 52 are inserted through the patient's vasculature as set forth above, through the PFO 2 and into the left atrium 6 . Referring to FIG. 15 , the guide catheter 36 may be advanced over the guidewires 52 into the right atrium 8 .
Referring also to FIG. 16 , the guide catheter 36 then may be withdrawn proximally. As set forth above, a base 34 may be provided, with fingers 26 attached thereto that form a second segment 24 . Withdrawal of the guide catheter 36 allows the second segment 24 to self-deform radially outward. The first segment 22 set forth above may be omitted, such that the anchor 50 only includes a second segment 24 configured to deploy in the right atrium 8 ; in other respects, the anchor 50 may be substantially as set forth above with regard to the combination anchor 20 . The term “second segment 24 ” is used for convenience in description here, to be consistent with the description of the combination anchor 20 above, even though the anchor 50 only includes a single segment.
Referring also to FIG. 17 , the guide catheter 36 and base 34 are advanced distally to place the second segment 24 against tissue of the right atrium 8 adjacent to the PFO 2 . The second segment 24 is pushed against the tissue of the right atrium 8 to tension it and provide a suitable surface for staple deployment. Referring also to FIG. 18 , the staple 38 is splayed, as set forth in the PFO Document. Referring also to FIG. 19 , the staple 38 is advanced into tissue adjacent to the PFO 2 . The second segment 24 is then retracted proximally away from the PFO 2 , into the right atrium 8 . Referring also to FIG. 20 , the staple 38 is then closed to close the PFO 2 . Closure of the staple 38 may be as set forth in the PFO Document, or may be performed in any other suitable manner. The guide catheter 36 and guidewires 52 are then withdrawn from the heart 10 and from the insertion point into the patient, which itself is then closed in any suitable manner. The PFO 2 is closed and the procedure is complete.
While the invention has been described in detail, it will be apparent to one skilled in the art that various changes and modifications can be made and equivalents employed, without departing from the present invention. It is to be understood that the invention is not limited to the details of construction, the arrangements of components, and/or the method set forth in the above description or illustrated in the drawings. Statements in the abstract of this document, and any summary statements in this document, are merely exemplary; they are not, and cannot be interpreted as, limiting the scope of the claims. Further, the figures are merely exemplary and not limiting. Topical headings and subheadings are for the convenience of the reader only. They should not and cannot be construed to have any substantive significance, meaning or interpretation, and should not and cannot be deemed to indicate that all of the information relating to any particular topic is to be found under or limited to any particular heading or subheading. Therefore, the invention is not to be restricted or limited except in accordance with the following claims and their legal equivalents. | A surgical tool may include a self-expanding combination anchor, comprising a first segment connected to a second segment, wherein said first segment is distal to said second segment. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 512,481 filed Oct. 4, 1974, now abandoned.
FIELD OF THE INVENTION
This invention relates to the extraction of protease-inhibitor from animal tissues which contain such inhibitor and, more particularly, the trypsin-kallikrein inhibitor. Such protease inhibitors have interesting therapeutical properties, so that their use is now widespread in the medical and clinical practice.
BACKGROUND OF THE INVENTION
The principal object of this invention is to provide an improved and simplified method for extracting protease-inhibitors from animal tissues which contain such inhibitors.
Another object of this invention is to provide a method for extracting protease inhibitors which contain a very reduced percentage of pyrogenic substances and polyanionic pollutants such as mucopolysaccharides and nucleic acids.
Still another object of the present invention is to provide a method for extracting protease inhibitors from animal tissues which contain such inhibitors without interfering with other methods directed towards the extraction of other useful substances, such as heparin, from animal tissues; it will be appreciated that the method of the present invention permits to extract heparin, if so desired, from an intermediate fraction which contains heparin, it being however understood that the method according to this invention is directed essentially and predominantly to the extraction of protease inhibitors.
According to the preferred embodiment of this invention, a method is suggested for extracting a protease-inhibitor from protease-inhibitor-containing fresh or frozen organs of slaughtered animals, said organs showing no signs of incipient or progressed azymic autolysis, said method comprising the steps of
(a) comminuting said organs;
(b) subjecting said comminuted organs to enzymolysis by contacting them, within an aqueous medium, with at least one proteolytic enzyme selected from the group of the proteolytic enzymes which do not naturally occur in said organs and which are inactive towards said protease-inhibitor to be extracted;
(c) discontinuing said enzymolysis and collecting a lysate aqueous solution by subjecting the aqueous medium containing said comminuted organs and said at least one proteolytic enzyme to filtration;
(d) adding a quaternary ammonium base to said lysate aqueous solution to obtain the precipitation of an insoluble fraction;
(e) filtering off said insoluble fraction and collecting the inhibitor-containing filtrate, and
(f) recovering said protease-inhibitor from said filtrate.
It is preferred that the proteolytic enzyme referred to above be a member selected from the group consisting of papain, ficin bromelin, Alkalase (R.T.M.) and Neutrase (R.T.M.).
The enzymolysis is stopped, at the proper instant of time, by any of the method as conventionally used for such an operation: heating to 90° C. and over is a preferred method, but other methods can be used, such as the addition of a deproteinating agent or otherwise, since it matters to stop the enzymolysis when desired, rather than the means used for the discontinuation.
The enzymolysis should be conducted under the optimum conditions for the proteolytic enzyme selected. If papain is used, a temperature of 60° C.±2° C. with a pH from 5.0 to 6.0 are preferred conditions, and a pH of 5.5 is an optimum. If ficin is the selected proteolytic enzyme, the conditions preferred for papain apply again. If bromelin is used, a lower temperature, such as 37° C.±2° C. is preferred, the preferential pH being near 6.
If the proteolytic enzyme used is Alkalase (R.T.M.) the optimum temperature is 65° C.±2° C., the pH is preferred to be near 7.2 and the enzymolysis time does not exceed 150 mins. When using Neutrase (R.T.M.) the preferred temperature is 60° C.±2° C., the preferred pH in the neighbourhood of 6.7 and the time, again, does not exceed 150 mins. for the enzymolysis step.
According to the invention, the preferred quaternary ammonium bases are cetylipiridinium and cetyltrimethylammonium bromide.
Other features, properties and advantages of the invention will become apparent as the present description proceeds.
ABRIDGED REVIEW OF THE PRIOR ART
B. Kassel and coworkers, J.Biol.Chem. 219, 203, and
H. Kraut and coworkers, Z.physiol.Chem., 334, 236.
disclose that protease-inhibitors are not chemically attacked by several proteolytic enzymes; among these, pepsin, trypsin, chymotrypsin, kallikrein, plasmin, elastase, collagenase, A- and B-carboxypeptidase, ficin, papain and bromelin are listed. It is thus an acquired knowledge that papain, ficin and bromelin are not affected by the protease inhibitor and this is the reason why they are used in the present invention, the more so that the quantity of the inhibitor contained in the animal organs concerned is very small as compared with the quantity of enzyme which is employed.
Summing up, these references disclose the properties of the protease inhibitors and define them, but afford no teaching as to the use of enzymes for extracting such inhibitors.
On the basis of these prior teachings, it was reasonably unpredictable that enzymes which do not affect the protease inhibitor might indicate the first step of an efficient procedure for extracting the inhibitor from organs which contain it.
An exhaustive listing of proteolytic enzymes can be found in B. Kassel, Method of Enzymology, Vol. 19, pages 848-850.
The U.S. Pat. No. 3,451,996 to G. B. Sumyk et al, of June 24, 1969 discloses a method for the preparation of heparin and adopts what is called an "autolysis" step: from the perusal of this reference it would seem that by "autolysis" both an azymic and an enzymic lysis are indifferently intended. In the present specification, the term "autolysis" will never be used to indicate "enzymolysis, since it may be conducive to language confusion. By "autolysis", the present specification and the claims appended thereto, shall intend a process of azymic decomposition, either incipient or progressed, which is quite assimilable to a putrefaction or meat-ripening process, and animal tissues under such autolytic conditions shall never be used for this invention. In this invention, it is no question at all of adding, or not, "additional enzymes to the tissue because the enzymes present will complete the digestion process" as indicated by Sumyk on Col. 2, lines 11-13. Additionally, it is added that Sumyk works under definitely alkaline conditions with a pH of 6.5 to 8 for extracting heparin. Moreover, in the present invention, there is no digestion process to be completed, either.
An indication of "autolysis" in the proper acception can be found in the USSR Pat. No. 377.159 to L. B. Polonskaya et al, of Apr. 17, 1973: a "meat-ripening" process proper, which lasts as long as 17 hours is adopted. In this connection, be it understood that the present invention must, compulsorily and of necessity, be performed under such conditions as to exclude in an absolute and total manner, each and every phenomenon of "autolysis" of the animal organ tissue itself and the method of the invention must be carried out under the optimum conditions of the enzyme concerned, as specified above and specifically claimed hereinafter. As a matter of fact, the autolysis proper as suggested in the USSR patent above mentioned is conducive, with certainty, to the formation of histamine and pyretogens, does not permit that limpid filtrates may be obtained and the operations specified therein cannot be performed on an industrial scale, i.e. on large amounts of animal tissues. Upon autolysis, there is in the USSR patent cited above, a 2-hour step of centrifugation and washing: the experience of the present applicant has shown that 13 hours of centrifugation and washing are actually necessary.
Last, but not least, the method according to this invention, as will be seen, takes no more than 4 hours for the "enzymolysis" so that, in addition to being comparatively simple and inexpensive, it is also quick. Comparison test data will be given hereinafter, which fully support these views.
Other references, which may be of some interest are:
M. Kunitz and J. H. Northrop, J. Gen. Physiol. 19, 991
Werle E. and coworkers--Z. Naturforsch. 14b, 385
Astrup, T. Acta Physiol. Scand. 26, 243
German Patents: 1 084 433-1 148 352-1 011 576-956 907-950 959 and 954 284
British Patent 965 352
French Patent 1 566 777
Japanese Patents: 43-7328 and 44-8563.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order that the invention may be better understood, together with the best mode to carry it out into constructive practice, the ensuing examples will be given.
EXAMPLE 1
Ten (10) kilograms of ground beef lung have been slurried in 16 liters of distilled water. Upon gentle heating of the mass to 40° C. there has been added, with stirring, a suspension of 20 grams of papain in 4 liters of a 0.25 M buffer citrate at a pH of 5.5, containing 200 grams of magnesium sulphate. The temperature has been adjusted to 60° C. and the mass has been maintained in these conditions during 4 hours. Then the pH has been adjusted to 6.2 by increments of concentrated ammonia and the mass has been heated to 90° C. Subsequently, the whole has been filtered under pressure and the residue has been discarded. The clear liquid has been treated with cetylpiridinium until a complete flocculation of the polyanions has been obtained. Filtration has then been effected in order to collect the heparin-containing precipitate, while the liquid has been supplemented with trichloroacetic acid up to a final concentration of 3%. After 30 minutes pressure filtration has been carried out again while effecting the washing on the filter with 4 liters of 3% trichloroacetic acid. Thus, there have been obtained 32 liters of a clear liquid having an activity of 610 inhibiting I.U. per cubic centimeter (I.U.=inhibitor unit, see Z. Physiol.Chem. 182, 1-1930) equivalent to a yield of 1.95×10 6 I.U. per kg of starting organ. This solution has then been subjected to fractionation with ammonium sulphate between 0.5 and 0.9 of saturation by collecting the precipitate by centrifuging. At this state there have been obtained 85 grams of precipitate containing 1.9×10 7 I.U. (about 98% of the total activity as obtained in the lysis) whereas the contents of proteinic material was 36.5%, that which indicates a purity of 1.56 micrograms per I.U. The further purifications carried out with the methods which are conventional in the art have permitted to obtain 465 cubic centimeters of an apyrogenic solution having an activity as high as 32,000 I.U. per cubic centimeter, that is, a total of 1.49×10 7 I.U., a fact which indicates a yield of 76% as compared with the initial activity. The purity, as found in the analysis of the proteinic material, was 0.143 micrograms per I.U.
A comparative test on a corresponding portion of the same organ, in the ground state, by extraction with 70% ethanol in the presence of calcium chloride (see German Pat. No. 1 084 433) has given a yield of 0.875×10 6 I.U. per kilogram of organ at the level of raw product and 0.322×10 6 I.U. per kilogram of organ, with a purity of 0.14 micrograms per I.U. at a purified level. These data, compared with those obtained by the papainic lysis correspond to yields of 21.7% at a purified product level and of 46% at the level of raw product. Another test, still made on a corresponding amount of the same organ, but ground, applying the method as disclosed by B. Kassell in "Methods Enzymology" Vol. 19, page 845, has given a yield, in raw product, of 1.020×10 6 I.U. per kilogram of organ and of 0.418×10 6 I.U. per kilogram of organ at the level of a purified organ. These data, compared with those obtained by papainic lysis correspond to yields of 53.6% at raw product level and of 28% at the purified product level.
EXAMPLE 2
The same procedure as in example 1 has been adopted by replacing papain by ficin. The yields have been 2.03×10 6 I.U. per kilogram of lung at raw product level and 1.64×10 6 I.U. per kilogram of lung at purified product level.
EXAMPLE 3
Five (5) kilograms of ground beef lung have been slurried in 8 liters of water and there have been added 2 liters of a suspension containing 10 grams of bromelin in a phosphate buffer (0.1 M) at a pH of 6 containing 1% of ethylene diamino tetra acetic acid. The mass has been gently heated to 37° C. and under these conditions it has been maintained during 4 hours. At the end of this time, the temperature has been raised to 90° C. during 10 minutes. Subsequently, the mass has been filtered under pressure by washing on the filter with 2 liters of distilled water. The filtrate, upon cooling, has been treated with cetyltrimethylammonium bromide until complete flocculation of the polyanions has been achieved, the latter being collected on a filter in order to separate heparin. The clear filtrate has given 16 liters with an activity of 540 I.U. per cubic centimeter, that which corresponds to a yield of 1.735×10 6 I.U. per kilogram of starting organ. Purification has then been proceeded with as disclosed in example 1. The final yield of the purified product has been 1.18×10 6 I.U. per kilogram of lung. A comparison test carried out by extraction and fractionation with ammonium sulphate, as disclosed in the French Pat. No. 1 566 777, has given a final yield of purified product of 6.8×10 6 I.U. per kilogram of starting organ, that which corresponds to 57.7% of the yield as obtained with the method as described in this example.
EXAMPLE 4
2.5 kilograms of powdered dry beef lung have been extracted according to the outline of example 1. The final yield has been 3.2 by 10 6 I.U. per kilogram of powdered dry beef lung.
The following examples 5 and 6 show that the method of this invention can equally well be applied to two other enzymes now available on the market, i.e. Alkalase and Neutrase (Reg.Trade Marks).
EXAMPLE 5
5 kilograms of ground beef lung are slurried in 8 liters of water and the slurry is supplemented with two liters of a suspension containing 10 grams of Alkalase (Reg.Trade Mark of Novo Industrie A.S. of Bagsvaerd, Denmark) in a 0.1 molar, pH 7.2 triethanolamine buffer. On completion of this addition, the reaction mixture is heated to 65° C.±2° C. for 2 hours 30 mins. to effect the enzymolysis. On completion of this step, the procedure is the same as in Example 1 hereinabove. The yield is 1.8·10 6 I.U. per kilogram of raw material.
EXAMPLE 6
It is conducted under the very same conditions as in Example 6 above, the only exceptions being that the pH in the enzymolysis step is 6.7 and the temperature is 60° C.±2° C. The yield is 1.9·10 6 I.U.
The enzymolysis according to this invention is significant in that it does away, at the very outset, with the proteins which might block the protease-inhibitor in the final purification stages: matter-of-factly, by carrying out the enzymolysis as directed herein, proteins of the kind referred to just now are no longer present as such, but in the form of aminoacids and peptides, and these latter do not block the protease inhibitor at all.
In addition, to have removed the noxious proteins referred to above is a fact which drastically reduces any hazard of occurrence of anaphylactic shocks due to proteinaceous pollutants.
Two comparative test runs have been carried out, in order to compare the teachings of the present invention with the teachings of the prior art disclosures as represented by U.S. Pat. No. 3,451,996 to Sumyk et al, and the USSR Pat. No. 377 159 to Polonskaya et al. It is to be observed that the comparison with Sumyk et al has been made in spite of the fact that the teachings of Sumyk et al are prevailingly directed to the production of heparin.
COMPARISON TEST RUN 1
The test run has been made on 1 kilogram of bovine lung tissue having a homogeneous texture.
______________________________________ POLON- APPLI-Test data SUMYK SKAYA CANT______________________________________ Enzymic lysis time, 48 -- 3hrsAzymic autolysis 17time, hrsBacteriostasis required not indicated unnecessary (xylene)Filtration 1 6 1or centrifu-gation time, hoursType of filtrate limpid turbid limpidK.I.U. per kg, 130.000± 5% 480.000± 5% 440.000± 5%activityDegree of enzymic 0.56 -- 0.46lysisDegree of azymic 0.16autolysis______________________________________
The "degree of lysis" in its general acceptance is the ratio of the aminic nitrogen to the total nitrogen: here, the distinction between enzymic lysis and azymic autolysis has been expressly made, consistently with the considerations which have been made in the foregoing. At any rate, the above test run shows, without any doubt, that in three hours only of enzymolysis, the present method gives higher yields both in terms of kallikrein-inhibiting activity (K.I. Units) and in terms of the other parameters tabulated above.
COMPARISON TEST RUN 2
The tests have been repeated under different conditions and the results are individually tabulated below.
______________________________________Method of Polonskaya et alAzymic autolysis time, hrs 3 17Filtration or centrifugation time, hrs 14 13K.I.U. after filtration, per kg 431.000 480.000K.I.U. after final purification, per kg 109.000 100.000Method of Sumyk et al (pancreas) (papain)Enzymolysis time, hrs 48 24Filtration or centrifugation time, hrs 1 1K.I.U. after filtration, per kg 190.000 90.000K.I.U. after final purification, per kg 180.000 10.000Applicant's methodEnzymolysis time, hrs 1.5 3Filtration time, hrs 1 1K.I.U. after filtration, per kg 280.000 440.000K.I.U. after final purification, per kg 190.000 280.000______________________________________
The above tabulated results confirm, once again, both the rapidity and the versatility of the method of this invention. | Protease inhibitor is extracted from fresh or frozen organs of slaughtered animals by an enzymolysis operation which excludes any possibility of interference by azymic autolysis, the enzymolysis being stopped after a time not exceeding 4 hours, whereafter a lysate aqueous solution is obtained by filtration and a quaternary ammonium base is added to the lysate solution to precipitate insolubles, the filtrate being the fraction which contains the expected protease inhibitor. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of our earlier-filed, copending, commonly-assigned application, Ser. No. 520,249, filed Nov. 11, 1974 now abandoned.
BACKGROUND OF THE INVENTION
Photochromic glasses, or phototropic glasses as they have been variously called, are glasses which darken under the influence of actinic radiation, normally ultraviolet radiation, and which return to the clear state when the actinic radiation is removed. U.S. Pat. No. 3,208,860, which is the basic patent in the field, describes a family of silicate glass compositions containing submicroscopic crystals of a silver halide dispersed throughout the glassy matrix, which crystals are reversibly darkenable under the action of ultraviolet radiation, imparting to the glass the characteristic of variable light transmission depending upon the amount of ultraviolet radiation present in radiation incident thereupon.
U.S. Pat. No. 3,197,296 describes alkali boroaluminosilicate glasses containing submicroscopic silver halide crystals which exhibit properties which are very desirable for ophthalmic applications. Hence the glasses described in that patent have refractive indices (n D ) within the range of about 1.52-1.54, exhibit the desired degree of darkenability to be useful in ophthalmic thicknesses (about 2 millimeters), and demonstrate darkening and fading rates which are acceptable for ophthalmic lenses.
Most presently-available photochromic glasses utilized for ophthalmic and other applications exhibit a neutral gray color in the faded or unactivated state, and assume a darker but still neutral gray coloration upon activation with ultraviolet radiation. The color of these glasses is a function of the composition utilized to produce the photochromic glass, and of the thermal treatment utilized to convert the potentially-photochromic glass as formed into a photochromic article exhibiting the desired sensitivity to ultraviolet light.
Whereas prior art photochromic glasses for ophthalmic and other uses have been widely available in a gray coloration in the darkened and faded state, a demand for photochromic glasses of equivalent sensitivity and behavior, but exhibiting other colorations such as brown, has recently developed.
One method of modifying color in photochromic glasses comprises adding colorants to the base glass which are compatible with the photochromic constituents present therein. German Offenlegungsschrift No. 2,107,343, for example, described photochromic glasses containing additions of vanadium, chromium, manganese, and cobalt, which glasses exhibit a variety of colors in combination with photochromic properties. The use of colorants, however, necessitates changes in glass batch composition whenever a color modification is required, and the additives required to produce particular colors may add substantially to the cost of the batch.
It has also been proposed to subject photochromic glass of the silver halide type to "aftertreatments" which are designed to modify the color of the glass without substantial degradation of the photochromic properties thereof. Thus, U.S. Pats. Nos. 3,892,582 and 3,920,463 describe aftertreatments for already completely developed photochromic glasses wherein the glasses (containing microscopic particles of silver halide) are heated in a reducing atmosphere to impart yellow or brown coloration thereto. The need for supplemental treatments, however, can also add substantially to the cost of the photochromic product.
Thus there still exists a need for a simple, low-cost method for producing brown photochromic glass.
SUMMARY OF THE INVENTION
We have now discovered that potentially photochromic glass compositions of the kind similar to those compositions utilized in the prior art to produce gray photochromic glasses can be treated according to a specific time-temperature heat treatment to provide photochromic glasses exhibiting the desired brown coloration. The active crystal phase exhibiting ultraviolet sensitivity in these glasses is a silver halide, just as is the case with the gray photochromic glasses; however, a darkened and faded color which may be broadly characterized as brown rather than gray is observed in the photochromic product. This coloration is attributed primarily to effects of the modified heat treating procedure on the development of photochromic crystal phases in the glass, although glass composition also has an effect on color, particularly in the faded state.
In general, the method of the present invention differs from prior art methods in that a two-phase heat treatment is required. This treatment comprises the step of maintaining the potentially photochromic glass being treated in a temperature range below peak silver halide crystal growth temperatures for a specified period of time, and thereafter maintaining the article at temperatures in the temperature range of rapid silver halide growth to complete the development of the active silver halide phase. This procedure is believed to modify the number and size of the silver halide particles produced in the glass during heat treatment in a manner which affects the faded and darkened color of the glass.
The method of the invention is effective to produce brown photochromic glasses without the need for introducing colorants into the glass. However, the brown coloration can be modified or intensified through the use of conventional glass colorants if desired. Suitable colorants for this purpose are the transition metal colorants nickel, cobalt, and manganese.
DETAILED DESCRIPTION
Among the glass compositions which may be successfully treated in accordance with the present invention are those consisting essentially, in weight percent, of about 53-60% SiO 2 , 8-10% Al 2 O 3 , 15-18% B 2 O 3 , 1-3% Na 2 O, 1.5-3.2% Li 2 O, 5-9% BaO, 3.5-7.0% PbO, 0-4% ZrO 2 , 0.012-0.040% CuO, 0.14-0.22% Ag, 0.22-0.36% Cl, 0.10-0.20% Br, and 0-1% F.
The glasses may be prepared by melting glass batches of appropriate composition in pots, tanks, crucibles or the like at temperatures in the range of about 1400°-1500° C., utilizing conventional glass melting procedures. The batch ingredients may comprise any constituents, whether oxides or other compounds, which are converted to the above silver, oxide, and halogen composition components at the temperatures utilized for melting the batch. Preferably the batch constituents are ball-milled together prior to melting to aid in securing a homogeneous glass.
Glass melts prepared as described may be formed into glass articles of the required configuration by pressing, casting, drawing, rolling, or other conventional glass forming procedures while simultaneously cooling the melt below the transformation range of the glass. The articles thus produced may then be cooled to room temperature, or first annealed at temperatures in the 400°-480° C. range, if desired.
Glass articles produced as above described are referred to as potentially-photochromic articles in that they contain dissolved silver and halogen constituents which are not light-sensitive, but which are capable of being precipitated from the glass as light sensitive silver halide crystallites through the use of an appropriate heat treatment. These potentially photochromic articles are not generally photochromic as formed, since they do not contain developed silver halide crystallites which can interact with ultraviolet light. Moreover, when melted and cooled under normal conditions, the glasses are typically essentially colorless, the desired brown coloration being developed only subsequently, through controlled heat treatment of the potentially photochromic glass.
In accordance with the present invention, potentially photochromic glasses produced as above described are rendered photochromic by subjecting them to a heat treatment comprising heating the article to a temperature in the range of about 520°-580° C., maintaining the article at temperatures in that range for a time in the range of about 2-30 minutes, preferably 2-15 minutes, thereafter further heating the article to a temperature in the range of about 600°-660° C., maintaining the article at temperatures in that range for a time in the range of about 5-60 minutes, preferably 5-30 minutes, and finally cooling the article to room temperature.
Photochromic articles produced in accordance with the above-described process in general exhibit a coloration which may be characterized as brown rather than gray. The range of coloration may be precisely specified in terms of the 1931 C.I.E. trichromatic colorimetric coordinate system which is fully described by A. C. Hardy in the Handbook of Colorimetry, Technology Press, M.I.T., Cambridge, Mass. (1936). A glass produced in accordance with our invention has a chromaticity in 2.00 millimeter thickness such that light transmitted through the glass from a specified source (Illuminant C) has a color coordinate x in the range of about 0.3100-0.3700 and a color coordinate y in the range of about 0.3150-0.3600 on the C.I.E. chromaticity diagram. This chromaticity is exhibited irrespective of whether the glass is in the darkened, faded, or intermediate photochromic state. Because the perception of color is subjective, the individual observer may characterize colors in this region as red-brown, golden-brown, or green-brown, depending upon glass composition and/or heat treatment. However, the determination of whether the chromaticity of a particular glass falls within the above-defined chromaticity region is objective, and all such glasses are broadly characterized as having a brown coloration for the purposes of the present description.
The invention may be further understood by reference to the following detailed example.
EXAMPLE
A glass article composed of a potentially photochromic glass having an as analyzed composition, in parts by weight, of about 55 parts SiO 2 , 9 parts Al 2 O 3 , 16 parts B 2 O 3 , 2 parts Na 2 O, 3 parts Li 2 O, 5 parts PbO, 7 parts BaO, 2 parts ZrO 2 , 0.035 parts CuO, 0.15 parts Ag, 0.30 parts Cl, 0.15 parts Br, and 0.2 parts F is provided.
This article is placed in an electrically-heated furnace, heated at a rate of about 20° C. per minute to a temperature of 550° C., maintained at 550° C. for 10 minutes; further heated at a rate of about 20° C. per minute to a temperature of about 620° C., maintained at 620° C. for 20 minutes, and finally cooled to room temperature over a time interval of about an hour and removed from the furnace.
After heat treatment, the article is ground and polished to provide a sample 2.00 millimeters in thickness, having plane parallel surfaces, which is tested for color and photochromic properties. This sample has a light-tan color in the faded state and a faded visible light transmission of about 90%. Upon darkening for 20 minutes utilizing a blacklight blue fluorescent ultraviolet light source, the glass sample has a dark brown color and a darkened visible light transmission of about 50%. The darkened glass has a chromaticity (Illuminant C) of x = .3250 and y = .3200 on the C.I.E. chromaticity diagram.
The present invention offers substantial advantages over prior art processes for producing brown photochromic glass. First, as previously noted, no added colorants need be employed, and thus a single glass composition may be utilized to produce both gray and brown photochromic glasses.
Secondly, the coloration effect obtained in accordance with the invention is a bulk effect such that the entire volume of treated glass exhibits a brown color. Prior art coloring processes utilizing supplemental aftertreatments in a reducing atmosphere provide predominantly surface coloration, such that grinding and polishing can remove or substantially reduce the color imparted by the treatment. Thus these treatments are useful principally for essentially finished glass articles, whereas the present process produces bulk colored glass which is fully amenable to further treatment.
And, finally, the process of the present invention avoids the need for costly batch additions and supplemental heat treatments.
The criticality of heat treatment in providing brown photochromic glass in accordance with the invention as hereinabove described is illustrated by the following comparative example.
COMPARATIVE EXAMPLE
A glass article composed of a potentially photochromic glass having an analyzed composition, in parts by weight, of about 55 parts SiO 2 , 16 parts B 2 O 3 , 9 parts Al 2 O 3 , 2 parts Na 2 O, 3 parts Li 2 O, 5 parts PbO, 7 parts BaO, 2 parts ZrO 2 , 0.036 parts CuO, 0.16 parts Ag, 0.27 parts Cl, 0.15 parts Br, and 0.2 parts F is provided.
This article is placed in a furnace, heated at a rate of about 200° C. per minute to about 600° C., maintained at 600° C. for about 20 minutes, and finally gradually cooled to room temperature.
A glass article heat treated as described is fully photochromic following treatment, exhibiting a light transmittance in the faded state, in 2 millimeter cross-section, of about 90%, and exhibiting a light transmittance in the darkened state of about 50%. However, the glass will exhibit a gray rather than a brown coloration in the faded and darkened state. Hence, the glass will have a chromaticity (Illuminant C) such that component x is less than or equal to about 0.3010 and component y is less than or equal to about 0.3040 on the C.I.E. chromaticity diagram.
It will be recognized that numerous variations and modifications may be undertaken within the scope of the invention as hereinabove described. For example, in heat treating the potentially photochromic glass it may not be necessary to resort to specific holding times at temperatures in the lower 520°-580° C. or upper 600°-660° C. temperature ranges. Rather, the article may be continuously heated and/or cooled as it is passing through these ranges, provided that sufficient times in these ranges are provided by the heating and cooling rates employed.
Of course, it is also possible to vary the concentrations of composition constituents and/or to incorporate conventional colorants into the glass compositions during the manufacturing process in order to intensity or modify the brown coloration produced within the chromaticity limitations hereinabove set forth. Suitable colorants for this purpose include the transition metal colorants such as cobalt, nickel, and manganese. NiO is a particularly preferred colorant for enhancing the brown coloration while at the same time reducing the faded transmittance of the photochromic glass. It will be recognized from the foregoing examples, however, that neither these nor any other colorants comprise essential constituents of brown photochromic glasses provided in accordance with the invention.
Whereas the optimum heat treatments to be employed to obtain the most desired brown coloration will depend upon the particular glass composition selected within the above-described composition limitations, these composition and heat treatment variables can readily be determined through routine experimentation by one skilled in the photochromic glass art. | A silver-halide photochromic glass of alkali-boroaluminosilicate base composition, having a brown coloration in the faded and darkened state, is provided by treating a potentially photochromic glass of specified composition according to a defined two-phase heat treatment to develop photochromic properties therein. | 2 |
RELATION TO CORRESPONDING APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 12/592,825 filed Dec. 3, 2009, now abandoned, which, in turn, is a continuation-in-part of application Ser. No. 12/283,472 filed Sep. 12, 2008, now issued as U.S. Pat. No. 7,892,995, which, in turn, is a continuation-in-part of application Ser. No. 12/082,576 filed Apr. 11, 2008, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a lithium silicate glass ceramic material and a process for fabricating that material for the manufacture of blocks and subsequent fabrication of single crowns with the aid of a CAD/CAM process and hot pressing. The invention relates to an improved version of such glass ceramic containing germanium dioxide to make it more castable, with higher density, and with higher flexural strength than the lithium disilicate glass ceramic free of germanium dioxide.
2. Background Art
There are many products available that employ lithium disilicate glass ceramic covered by several U.S. patents. Some of these patents claim a process for the preparation of shaped translucent lithium disilicate glass ceramic products from a mixture of basic components (SiO 2 , Al 2 O 3 , K 2 O, Li 2 O, plus pigments and fluorescent oxides). The thermodynamic solid-liquid equilibrium of the system consisting of lithium oxide (Li 2 O) and silicon dioxide (SiO 2 ) has been extensively studied even before that material was used as a dental ceramic (1-3, 5-6).
For those skilled in the art this experimental solid-liquid equilibrium can explain with an extraordinary simplicity how different glass ceramics can be obtained using the same two components when they are combined in different proportions. The same solid-liquid equilibrium shows what type of stable crystal is produced as a final product of crystallization when a specific mix composition of the two components are blended, melted, and crystallized to achieve the final product.
The crystallographic data for intermediate crystal compounds in the Li 2 O—SiO 2 system is given by the Landolt-Bomtein tables. The following are the types of crystal compositions possible in the Li 2 O—SiO 2 system: Li 8 SiO 6 , Li 4 SiO 4 or lithium orthosilicate monoclinic and orthorhombic; Li 6 Si 2 O 7 , Li 2 SiO 3 or lithium silicate; Li 2 Si 2 O 5 or lithium disilicate monoclinic and orthorhombic; and Li 2 Si 3 O 7 lithium trisilicate.
Thus when the silicon dioxide to lithium oxide molar ratio (SiO 2 /Li 2 O) is greater than or equal to two, meaning two moles of SiO 2 are mixed with one mol of Li 2 O, the crystallized glass ceramic product will be mainly lithium disilicate (SiO 2 /Li 2 O). This molar ratio of two is equivalent to a molar composition of lithium oxide in the mixture of 33% (67% as SIO 2 ). When the same molar relationship is below 2.0, (e.g. 1.7) only lithium silicate crystals are produced (Li 2 O.SiO 2 ). The lithium oxide molar composition for a ratio of 1.7 is equivalent to 37% molar (63% SiO 2 ). The type of resulting crystal due to the specific composition ratios gives to the glass ceramic its own distinguishable chemical and physical properties. Surprisingly, the same behavior is obtained if these two main components (silicon dioxide and lithium oxide) maintain their molar ratio below two even if they are mixed with other oxides as additives and modifiers. The other common oxides mixed are aluminum oxide, potassium oxide, calcium oxide, zirconium oxide and coloring oxides that are incorporated into the glass matrix and give the glass ceramic its final color and translucency.
Due to the final composition of this invention using a molar ratio of SiO 2 /Li 2 O between 1.7 to 1.9, the only phase present is lithium silicate, instead of lithium disilicate, as a main constituent of the glass ceramic as a final product. For instance, a glass ceramic with a molar ratio of silicon dioxide to lithium oxide greater than or equal to two plus additional oxides will produce, after full crystallization a lithium disilicate glass ceramic with a melting temperature of 920° C. and a linear thermal coefficient of expansion of 10.5×10 −6 /° C. as a final product and composition. In addition, during the production of this type of glass ceramic the cast material is subjected to at least three different heat treatments: an annealing cycle for eliminating accumulated stresses, a nucleation cycle for the formation of lithium metasilicate or unstable lithium silicate, and finally a third thermal cycle to convert the unstable lithium silicate or metasilicate into a stable lithium disilicate. This is clearly shown in the following US patents:
Examples of those types of glass ceramics are claimed in Barret et al in U.S. Pat. No. 4,189,325 which discloses a lithium silicate glass ceramic where the raw materials are blended, melted at 1315° C. and held for 24 hours for homogenization, fritted and crushed, melted again and cast into preheated molds. They disclose a composition of silicon dioxide to lithium oxide molar ratio of two, producing a dental ceramic composed of lithium disilicate.
U.S. Pat. No. 4,480,044 to McAlinn discloses a glass ceramic formulation where the lithium silicate glass ceramic in their intermediate process stage has a thermal expansion of 13×10 −6 /° C. and the lithium disilicate has a thermal expansion of 11.4×10 −6 /° C. They disclose a machinable lithium disilicate glass ceramic with a percentage of silicon dioxide of 79.8%.
U.S. Pat. No. 4,515,634 to Wu et al discloses a castable glass ceramic composition useful as a dental restorative material. The components are blended and melted at 1400 to 1450° C., then quenched in water, dried, milled to a powder, and melted again at 1400° C. for 4 hours. Then the melt is cast into copper molds and transferred to the annealing process. The castable glass ceramic of the invention is lithium disilicate with a silicon dioxide to lithium oxide molar ratio of two, equivalent to silicon dioxide weight composition of 65%-74.7% and lithium oxide weight composition of 14.8-16.4%.
U.S. Pat. No. 5,219,799 to Beall et al discloses a lithium disilicate glass ceramic with silicon dioxide weight composition of 65%-80% and lithium oxide compositions of 8.0-19.0%. The blended raw materials are melted at 1450° C. for 16 hours and then poured into steel molds and annealed at 450° C.
U.S. Pat. No. 5,744,208 to Beall et al describes a lithium disilicate glass ceramic with silicon dioxide weight composition of 75%-95% and lithium oxide weight composition 3-15%. The raw materials are blended, and then melted in the range of 1450-1600° C. for about 6-10 hours. The glass is then poured into steel molds. The glass is then annealed, nucleated and crystallized to produce lithium disilicate glass ceramic in the range of 500° C. to 850° C.
U.S. Pat. No. 5,968,856 to Scheweiger et al discloses a lithium disilicate glass ceramic with compositions of silicon dioxide weight between 57%-80% and lithium oxide composition 11-19%. The components are blended and melted at 1500° C. for one hour and then quenched, dried, milled, dry pressed and sintered to form blanks. The composition requires the addition of lanthanum oxide to improve the flow properties, control the crystal growth and eliminate the strong reaction of the material with the investment material used.
U.S. Pat. No. 6,514,893 to Scheweiger et al discloses a lithium disilicate glass ceramic with silicon dioxide composition of 57%-75% weight and lithium oxide composition 13-19% weight and also containing lanthanum oxide. The components are blended and fused into granulates and comminuted to a powder. Coloring oxides are then added, and the ceramic is pressed and heat treated.
U.S. Pat. No. 6,455,451 to Brodkin et al discloses a lithium disilicate glass ceramic with silicon dioxide composition of 62%-85% weight and lithium oxide composition 8-19% weight. They disclose a method of making the lithium disilicate by melting the components at 1200 to 1600° C., followed by a quench, drying, and a heat treatment to form the glass ceramic, followed by comminuting to a powder, compacting and sintering to a blank and pressing to form the restoration.
U.S. Pat. No. 6,517,623 to Brodkin et al discloses a lithium disilicate glass ceramic pressable where the components are melted in the range of 1200 to 1600° C., quenched, heat treated, comminuting the glass ceramic to a powder, and then compacting the powder to a starting blank before sintering the blank or the restoration.
U.S. Pat. No. 6,606,884 to Scheweiger et al describes a lithium disilicate glass ceramic where the components are mixed and melted at 1200 to 1650° C., followed by pouring the glass into water, milling and compacting, and placing the blank in a heat treatment to sinter.
U.S. Pat. No. 6,802,894 to Brodkin et al shows a lithium disilicate glass ceramic with a silicon dioxide weight composition of 62%-85% and lithium oxide weight composition 8-19%. The components are mixed, melted at 1200 to 1600° C., and cast. The resulting glass is annealed at a range of 300 to 600° C., followed by subjecting the glass to a heat treatment from 400 to 1100° C.
U.S. Pat. No. 6,818,573 to Petticrew discloses a lithium disilicate glass ceramic with a silicon dioxide composition of 60%-80% weight and lithium oxide composition of 8-17% weight. The components are blended, melted, quenched, heat treated, milled to a powder, dry pressed, and hot pressed into the desired restoration.
U.S. Pat. No. 7,316,740 to Scheweiger et al claims a lithium silicate glass ceramic with silicon dioxide weight compositons of 64 to 73% and lithium oxide weight compositions of 13 to 17%. The lithium disilicate final product is demonstrated by means of a XRD pattern ( FIG. 6 ) and DSC phase transformation curve from lithium metasilicate to lithium disilicate ( FIG. 2 ). The DSC diagram shows the change in energy from the stage of metasilicate to disilicate, which is only necessary if lithium disilicate is desired to be the crystal phase used as a final product.
U.S. Pat. No. 7,452,836 to Apel et al discloses a lithium silicate glass ceramic with silicon dioxide composition of 64%-75% weight and lithium oxide composition of 13-17% weight producing lithium disilicate as a final product. They also describe a glass ceramic with a molar ratio of silicon dioxide to lithium oxide of at least 2.3.
U.S. Pat. No. 7,867,930 to Apel et al shows a lithium silicate glass ceramic with silicon dioxide composition of 64%-75% weight and lithium oxide composition of 13-17% weight producing lithium disilicate as a final product.
U.S. Pat. No. 7,871,948 to Apel et al describes a lithium silicate glass ceramic with silicon dioxide composition of 64%-75% weight and lithium oxide composition of 13-17% weight, producing lithium disilicate as a final product. The glass of the starting material is subjected to an initial heat treatment form lithium metasilicate or unstable lithium silicate and then goes through a second heat treatment to convert the lithium metasilicate to a lithium disilicate.
U.S. Pat. No. 7,867,931 to Apel et al discloses a lithium silicate glass ceramic with silicon dioxide composition of 64%-75% weight and lithium oxide composition of 13-17% weight producing lithium disilicate as the final product. They also describe a glass ceramic with a molar ratio of silicon dioxide to lithium oxide in the range of 2.3 to 2.5.
U.S. Pat. No. 8,042,358 to Schweiger et al discloses a lithium silicate glass ceramic with silicon dioxide composition of 65%-70% weight and lithium oxide composition of 14-16% weight producing lithium disilicate as the final product. In their specific process the raw materials such as carbonates, oxides and phosphates are prepared and melted in the range of 1300-1600° C. for 2 to 10 hours. They explain that in order to obtain a particularly high degree of homogeneity the glass melt obtained may be poured into water to form glass granulates and the glass granulates obtained are melted again.
For those skilled in the art it is understandable that the lithium oxide—silicon dioxide system has been extensively studied and several patents for dental glass ceramics have been granted in the last few years. However all the research so far falls in the range where lithium disilicate is formed as a final product and none of the references above disclose lithium silicate glass ceramic as a final product. For those skilled in the art it is evident that the type of crystal produced depends exclusively on the molar ratio of silicon dioxide to lithium oxide in the glass ceramic and not the additives or modifiers added to the mixture. This molar ratio controls the type of crystal formed in the final composition and furthermore give its name to the final glass ceramic.
Most of the existing patents in the dental field use the same basic components. The present invention uses germanium dioxide as a fundamental part of the formula. This oxide is broadly used in glass preparation for its good optical properties. The oxide has been well studied and has positive effects compared to common silicon glasses. It has been found that the addition of germanium oxide produces a melt with low viscosity, which facilitates the castability of the process and increases the thermal expansion and the refractive index of the resulting lithium silicate glass ceramic. More importantly, the addition of germanium dioxide increases the final density of the glass resulting in higher values of flexural strength than the lithium disilicate glasses free of germanium dioxide. U.S. Patent Application Publication No. 2004/0197738 to Ban et al discloses a process to make dental frame of zirconium-ytrium sintered ceramics and they describe dental porcelain with germanium oxide as a joint component different than the zirconium yttrium oxide frame. However germanium oxide is not used as a component of the framework ceramic network. It is used only in formulation of the ceramic joint and is just a part of a series of other oxides that can be joined to the framework material.
Due to the low silicon dioxide to lithium oxide molar ratio of 1.7 of the present invention, equivalent to 37% molar of lithium oxide (63% silicon dioxide) the ceramic has a lower melting point compared to the glass ceramic of the prior art. In addition, this new glass ceramic contains the lowest silicon dioxide weight percent compared to all of the noted prior art. Therefore, due to this specific composition of lithium oxide in the mixture, the type of resulting crystal after crystallization (lithium silicate) gives to the glass ceramic its own chemical and physical properties, which makes it completely distinguishable from the prior glass ceramics listed above. Due to this distinguishable composition, the present glass ceramic has a lower melting temperature and can be made even lower with the addition of germanium oxide. Germanium oxide replaces silicon dioxide in the glass network, causing it to have a negative effect on the resulting melting point compared to a glass ceramic containing only silicon dioxide. Thus the processing and optimal melting temperature is in the range of 1100° C. to 1200° C. instead of 1200° C. to 1650° C. of the U.S. patents cited above and specifically compared to U.S. Pat. No. 6,514,893 to Schweiger et al. The glass ceramics listed in the prior art patents cannot be cast in the range of 1100° C. to 1200° C. because they are too viscous due to their high silicon dioxide content, therefore the processes disclosed in prior art patents with higher melting temperatures should be used. The present process will result in a more economical production because the energy employed for melting the glass is considerably lower and there are lower energy loses by radiation compared to the Schweiger process.
In addition to having a process with lower energy consumption, another significant improvement of the inventive process is related to the mixing and reaction of the components. In all of the previously cited prior art patents, the mix of the components is blended and melted at 1400 to 1650° C. and then cast or quenched in water. The quenched glass powder is dried, milled, and melted again in order to improve the homogeneity and the quality of the product. Surprisingly, it was found that the first melting and casting process can be avoided if one performs a calcination process on the mixture of raw materials to a temperature in the range of 700 to 800° C. without melting the components. At this stage, all the raw materials in the form of salts (like lithium carbonate as the source of lithium oxide, calcium carbonate as the source of calcium oxide, and di-ammonium phosphate as the source of phosphorous oxide) are decomposed, eliminating gases such carbon dioxide and ammonia, producing a ceramic powder free of gases. After cooling down, the calcined mix is milled again, producing a homogeneous powder with a very small particle size. The final step is melting and casting in the range of 1100° C. to 1200° C., resulting in a homogeneity of all the components. In addition, by eliminating the gases during the calcination process, the glass cast becomes bubble free, making this a significant advantage over the processes described in the prior art.
The present invention is also unique compared to those listed in the prior art due to its composition. The use of a low melting temperature is only possible with the present glass ceramic because of the low content of silicon dioxide and the high content of lithium oxide. This translates to a molar oxide ratio (SiO 2 /Li 2 O) below 2.0, (i.e., 1.7) in which only lithium silicate crystals are produced (SiO 2 —Li 2 O). In addition to the composition, the present invention implements a process for a glass ceramic that produces a homogeneous product and that can be used only with the specific formulation. This process cannot be used with the other listed glass ceramics due to the lower operating temperatures.
The present invention emphasizes that in the inventive glass ceramic the silicon dioxide and lithium oxide molar ratio content (SiO 2 /Li 2 O) is less than 2, specifically the oxide molar ratio is preferably about 1.7. This is specifically equivalent to 63% molar of silicon dioxide and 37% molar of lithium oxide, and specifically equivalent in the overall formulation of about 56% weight percent of all of the glass ceramic as silicon dioxide and 16.0% weight percent as lithium oxide and the remaining 28% composed of the oxide additives and modifiers. In all of the glass ceramic, only lithium silicate (Li 2 O—SiO 2 ) crystals are produced as the final crystal phase product. During the heating process of the glass, the first crystals formed are stable lithium silicate and they remain stable through the end of the growing process. This means that there is no need for a third thermal process for producing the final crystal of lithium silicate making this an additional characteristic unique to the present invention. This new ceramic has softening temperature of about 700 to 800° C. and a linear thermal coefficient of expansion of about 12 to 12.5×10 −6 /° C. as a final product and a composition yielding completely different chemical and physical properties compared to the prior art. This is easily demonstrated in commonly assigned U.S. patent application Ser. No. 12/592,825, paragraph [0012], FIG. 1 showing a XRD pattern diffraction where only lithium silicate crystals are present in the final product and paragraph [0013] where the glass ceramic has a percentage linear change of 0.55% measured at 500° C. and an equivalent coefficient of thermal expansion of 11.5×10 −6 /° C.
The following is a list of non-patent references noted herein:
1. MARCUS P. BOROM et al, Strength And Microstructure In Lithium Disilicate Glass-Ceramics, J. Am. Ceram. Soc., September-October 1975, Vol. 58, No. 9-10, pp 385-391. The authors prepare lithum disilicate glass ceramics and measured the differences between the thermal expansion of the lithium disilicate with a value of 13×10 −6 /° C. and lithium silicate with a value of 11.4×10 −6 /° C. After the heat treatment above 800° C. the only phase present is lithium disilicate for a glass ceramic composition of 71.8% of silicon dioxide and 12.6 of lithium oxide. 2. R. A. EPPLER, Glass Formation And Recrystallization In The Lithium Metasilicate Region Of The System Li 2 O—Al 2 O 3 —SiO 2 , J. Am. Ceram. Soc., February 1963, Vol. 46, No. 2, pp 97-101. 3. F. A. HUMMEL, Thermal Expansion Properties Of Some Synthetic Lithia Minerals, J. Am. Ceram. Soc., August 1951, Vol. 34, No. 8, pp 235-239. 4. LANDOLT-BÖRNSTEIN (LB), Group IV Physical Chemistry—Phase Equilibria, Crystallographic And Thermodynamic Data For Intermediate Compounds in the Li 2 O—SiO 2 System. 5. S. CLAUS et al, Phase Equilibria In The Li 4 SiO 4 —Li 2 SiO 3 Region Of The Pseudobinary Li 2 O—SiO 2 , Journal of Nuclear Materials, Vol. 230, Issue 1, May 1996, pp 8-11. 6. HERMAN F. SHERMER, Thermal Expansion Of Binary Alkali Silicate Glasses, Journal of Research of the National Bureau of Standards, Vol. 57, No. 2, August 1956. The author prepares lithium silicate glasses with silicon oxide and lithium oxide molar ratio below 2.0 being lithium silicate with thermal expansion between 12 and 14.77×10 −6 /° C. There is no lithium disilicate using this chemical molar composition.
SUMMARY OF THE INVENTION
The present invention relates to preparing an improved lithium silicate glass ceramic for the manufacture of blocks for dental appliance fabrication using a CAD/CAM process and hot pressing. The lithium silicate material has a chemical composition that is different from those reported in the prior art, especially because of the use of germanium dioxide in the formulas and its low silicon dioxide content. The softening points are close to the crystallization final temperature of 800° C. indicating that the samples will support the temperature process without shape deformation.
The initial components are chemical precursors, specifically aluminum hydroxide for aluminum oxide, boric acid for boron oxide, lithium carbonate for lithium oxide, ammonium hydrogen phosphate or calcium phosphate for phosphorus pentoxide, zirconium silicate or yttrium stabilized zirconia for zirconium oxide, calcium carbonate for calcium oxide, lithium fluoride for lithium oxide and fluoride, and potassium carbonate for potassium oxide. The remaining elements are single oxide precursors of silicon, cerium, titanium, tin, erbium, vanadium, germanium, samarium, niobium, yttrium, europium, tantalum, magnesium, praseodymium, and vanadium oxides.
The components are carefully weighed and then mechanically blended using a V-cone blender for about 5 to 10 minutes. Then in order to achieve uniform particle size of the components, the mixture undergoes a ball mill process for two hours. The powder obtained is put into large alumina crucibles and undergoes calcination to 800° C. for about 4 hours. In this stage the carbonate precursors, lithium carbonate, calcium carbonate, potassium carbonate, decompose releasing carbonic gas and producing the corresponding pure oxides, lithium oxide, calcium oxide and potassium oxide, respectively. In the same process the other chemical precursors, ammonium phosphate, aluminum hydroxide and boric acid also release nitrogen gases and water producing the corresponding pure oxides, phosphorous pentoxide, aluminum oxide and boron oxide, respectively. At this stage of calcination the original powder mix loses approximately 25% of its original weight due to the evaporation losses. Also, the first reactions between the pure oxides are taking place in this stage but there is never any melting of the components and no reaction takes place with the alumina crucible. After cooling down, the blend of components undergoes ball milling again, producing a homogeneous, gas free, fine powder with a particle size below 30 microns. The calcined powder can be safely stored in plastic containers for extended periods of time without any gas release and can be used anytime for the next step of the process.
In the final stage of the process the calcined powder is melted in a platinum crucible at a temperature of 1200° C. with a holding time of about 2 hours before casting. The melt with the appropriate viscosity is cast continuously over graphite molds. Surprisingly, the glass cast is bubble free due to the prior elimination of the gases during the calcination step. This constitutes a significant advantage over the processes described in the prior art. Due to the calcination process step, there is no need for a second re-melting process for improving homogeneity. The glass cast is then subjected to an annealing step followed by an intermediate crystallization step or a full crystallization step depending on what is desired as a final product.
Due to the specific molar ratio of silicon dioxide and lithium oxide (1.7/1) used in the present invention, the only preferred crystal structure formed is lithium silicate (SiO 2 .Li 2 O) in the intermediate or full crystallized product. Surprisingly it was found that in this invention, the crystal growth process can be momentarily stopped at any temperature interval between the ranges of 350° to 800° C. and then the crystal can continue growing by heating it again to reach the optimal size at 800° C. Above 800° C. the sample starts melting and the reverse process of dissolving the crystals in the glass matrix takes place.
Thus in the present invention, the intermediate crystallization process step is easily controlled by stopping the heating process at 600° C. and cooling down to room temperature. It can then be heated again to 800° C. for achieving the full crystallized product. Thus if one takes the intermediate block material of lithium silicate, after the thermal heat process from room temperature to 600° C., it can be milled to a dental restoration using conventional CAD/CAM devices and then it can be heated up again to 800° C. continuing towards maximum crystal growth and achieving the optimal physical properties. Surprisingly, the same formulation, after a thermal process from room temperature to 800° C., can be easily hot pressed in the range of 800-840° C. using conventional all ceramic dental investments and commercial press furnaces (i.e Whip Mix Pro-Press 100). For the hot press process, the dental restoration is milled in a wax block, followed by investing the wax pattern using commercial all ceramic investments. After firing the investment, the wax is burned out, allowing the cavity of the restoration to become available to fill with the ceramic. After hot pressing the restoration achieves the optimal physical properties.
The same formulation produces the same lithium silicate crystalline phase through all the thermal process steps and the dental restoration can be optimally achieved by using either CAD/CAM or hot press techniques. Being able to achieve this with the same formulation is a unique and advantageous characteristic over the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the present invention, as well as additional objects and advantages thereof, will be more fully understood herein after as a result of a detailed description of a preferred embodiment when taken in conjunction with the following drawings in which:
FIG. 1 is an XRD diffraction pattern of a sample of the invention after the intermediate crystallization step (from room temperature to 600° C.) showing the presence of lithium silicate as a main constituent phase in the glass ceramic composition;
FIG. 2 is an XRD diffraction pattern of a sample of the invention after the full crystallization step (from room temperature to 800° C.) showing the presence of lithium silicate as a main constituent phase in the glass ceramic composition. Because the molar ratio of SiO 2 /Li 2 O is between 1.7 to 1.9, the crystallized phase of the final material shows the presence of only lithium silicate and no lithium disilicate;
FIG. 3 is an XRD diffraction pattern of a sample of this invention after hot pressing in the interval of 800° C. to 840° C. showing the presence of lithium silicate as a main constituent phase in the glass ceramic composition. Because the molar ratio of SiO 2 /Li 2 O is between 1.7 to 1.9, the crystallized phase of the final material shows the presence of lithium silicate and no lithium disilicate; and
FIG. 4 is a graphical illustration of a dilatometric measurement of a sample of the invention resulting from full crystallization. The softening temperature of the intermediate step is lower than the temperature after full crystallization. This is due to the crystal growth after heating the glass in the intermediate stage from room temperature to 800° C.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The prior art materials are based on the formation of lithium disilicate materials. A principal object of the present invention is to prepare a controlled lithium silicate glass ceramic using in the formulation a specific silicon dioxide and lithium oxide molar ratio with excellent physical properties for manufacturing dental restorations. The glass material subjected to a heat treatment produces an optimal lithium silicate crystal forming a glass ceramic product with outstanding mechanical properties, excellent optical properties, a very good chemical solubility, little contraction and high flexural strength values.
The lithium silicate of the present invention preferably comprises the following components and compositions:
weight % composition
Component
minimum
maximum
SiO 2
53.0
57.0
Al 2 O 3
3.0
5.0
K 2 O
3.0
5.0
CaO
0.0
1.0
B 2 O 3
0.0
2.0
CeO 2
0.0
1.0
MgO
0.0
1.0
Fluorine
0.0
1.0
Li 2 O
14.0
17.0
ZrO 2
4.0
5.0
TiO 2
0.0
3.0
P 2 O 5
2.0
3.0
SnO
0.0
1.0
Er 2 O 3
0.0
2.0
V 2 O 5
0.0
1.0
GeO 2
0.5
8.0
Ta 2 O 5
0.0
3.0
Sm 2 O 3
1.0
6.0
Pr 2 O 3
0.0
1.0
Eu 2 O 3
0.0
2.0
Y 2 O 3
0.0
5.0
Nb 2 O 5
0.0
1.0
The invention is explained in more detail below with the following examples:
The sample preparation and its elemental oxide composition are listed in Table 1.
TABLE 1
Components % weight.
Example 1
Example 2
Example 3
Example 4
Example 5
SiO 2
55.03
56.19
56.21
56.21
53.88
Al 2 O 3
4.09
4.18
4.18
4.18
3.11
K 2 O
4.42
4.52
4.52
4.52
3.44
CaO
0.94
0.96
0.96
0.96
0.00
B 2 O 3
1.58
1.61
1.61
1.61
0.00
CeO 2
0.21
0.65
0.34
0.41
0.63
MgO
0.22
0.23
0.23
0.23
0.00
Fluorine
0.49
0.50
0.50
0.50
0.00
Li 2 O
15.81
16.14
16.15
16.15
14.81
ZrO 2
4.70
4.79
4.80
4.80
4.88
TiO 2
2.40
0.80
0.80
0.80
0.63
P 2 O 5
2.52
2.58
2.58
2.58
2.94
SnO
0.22
0.07
0.13
0.12
0.00
Er 2 O 3
0.37
0.76
0.36
0.21
1.26
V 2 O 5
0.39
0.22
0.26
0.11
0.03
GeO 2
0.90
0.92
0.92
0.92
7.75
Ta 2 O 5
0.07
0.15
0.22
0.01
0.00
Sm 2 O 3
2.03
4.09
4.07
4.09
5.71
Pr 2 O 3
0.03
0.33
0.04
0.00
0.88
Eu 2 O 3
0.00
0.00
0.00
1.25
0.05
Y 2 O 3
3.13
0.11
0.61
0.36
0.00
Nb 2 O 5
0.46
0.22
0.53
0.00
0.00
TOTAL
100.00
100.00
100.00
100.00
100.00
Example 6
Example 7
Example 8
Example 9
Example 10
SiO 2
54.08
54.49
56.17
53.49
56.19
Al 2 O 3
3.12
3.86
4.18
3.98
4.18
K 2 O
3.45
4.20
4.52
4.30
4.52
CaO
0.00
0.00
0.96
0.92
0.96
B 2 O 3
0.00
0.00
1.61
1.53
1.61
CeO 2
0.95
0.64
0.00
0.20
0.62
MgO
0.00
0.00
0.23
0.22
0.23
Fluorine
0.00
0.00
0.50
0.48
0.50
Li 2 O
14.85
15.25
16.15
15.37
16.14
ZrO 2
4.89
4.88
4.80
4.56
4.79
TiO 2
0.63
0.64
0.80
0.78
0.80
P 2 O 5
2.95
2.97
2.58
2.45
2.58
SnO
0.00
0.00
0.00
0.00
0.07
Er 2 O 3
1.52
1.28
0.05
0.16
0.61
V 2 O 5
0.06
0.04
0.00
0.48
0.15
GeO 2
7.77
7.70
0.92
0.87
0.92
Ta 2 O 5
0.00
0.00
2.33
0.00
0.18
Sm 2 O 3
4.82
3.34
1.83
4.90
4.05
Pr 2 O 3
0.90
0.72
0.00
0.23
0.24
Eu 2 O 3
0.00
0.00
0.05
0.00
0.00
Y 2 O 3
0.00
0.00
2.33
4.90
0.24
Nb 2 O 5
0.00
0.00
0.00
0.18
0.45
TOTAL
100.00
100.00
100.00
100.00
100.00
A particularly preferred lithium silicate material as described in the examples 1 to 10 comprises 53 to 59 wt % of SiO 2 , 14 to 19% wt of Li 2 0 and 1 to 9% of GeO 2 , where after nucleation only lithium silicate is formed and then after complete crystal growth only lithium silicate crystals are formed.
The lithium silicate material of this invention is preferably produced by a process which comprises the following steps:
(a) A mix of the precursors of the final components of the table 1, are blended together for 10 to 30 min until a mechanical mix is obtained. (b) The mix is ball milled dry or wet using zirconia media for about 1 to 2 hours to homogenize the components and achieve almost the same particle size in all the components. (c) The sample is calcined at 800° C. for about 1 to 4 hours in order to decompose the precursors to their primary oxides and eliminate any possibility of formation of gas after the process. (d) Ball-mill the sample of step (c) in order to produce a powder with an average particle size below 30 microns. (e) The powder of step (d) is melted in a platinum crucible at a temperature between 1100 to 1200° C. for 1 to 2 hours. It is then poured into cylindrical or rectangular graphite molds and cooled down to room temperature. (f) The glass ceramic of step (e) is then subjected to an intermediate crystal growth process at a temperature of from room temperature to 600° C. for 10 to 60 min. The growth of the lithium silicate crystals is temporarily stopped for the desired intermediate size by cooling the glass ceramic to room temperature. (g) The glass ceramic of step (f) is subjected to a single step heating cycle from room temperature to 800° C. to achieve full crystallization. (h) For use in a CAD-CAM milling device, the dental restoration is made using a block after intermediate process step (f). After milling, the restoration is heated again from 350° C. to 800° C. or to full crystallization step (g) where the optimal lithium silicate crystal growth in the glass ceramic is achieved in a single step program. (i) For an alternative hot pressing technique, the sample after [step (g)] is pressed into a dental restoration at a temperature of 800-840° C., where the optimal lithium silicate crystal growth in the glass ceramic is achieved.
Coefficient of Thermal Expansion and Softening Point
The percentage linear change vs. temperature was measured using an Orton dilatometer. The coefficient of thermal expansion at 500° C. and the softening point were calculated for all the samples. For this purpose a rectangular rod of approximately 2 inches long was cast and then subjected to the intermediate crystallization cycle at 600° C. for 40 min. After this process the rod is cut into two parts. One part is used for measuring transition temperature, softening point temperature, and coefficient of thermal expansion of that process step. The second part is fully crystallized at 800° C. for about 10 minutes and is used for measuring the same properties. It is expected that after the crystallization step, the softening temperature point increases for the samples due to the formation of larger lithium silicate crystals. Test results are displayed in Table 2.
Flexural Strength.
Biaxial flexural strength tests (MPa) were performed following ISO-6872 procedures. Ten round samples were cut, grinded gradually and polished to a mirror finish in the intermediate stage or step (f). The samples were then fully crystallized in a single stage program from 350° C. to 800° C. for 10 minutes. Then the biaxial flexural strength was measured. For the hot pressing technique the glass ceramic of sample of step (g) is hot pressed into round discs in the interval of 800 to 840° C. Then the discs are grinded gradually and polished to a mirror finish, heated as a simulated glaze cycle, and tested. Test results expressed in MPa are displayed in Table 2.
Chemical Solubility.
A chemical solubility test was performed according to ISO-6872. Ten discs samples subjected to step (g) are placed in a glass flask with an aqueous solution of 4% (V/V) of acetic acid analytical grade (Alfa Aesar). The flask is heated to a temperature of 80+/−3° C. for 16 hours. The change in weight before and after the test is determined and then the chemical solubility expressed as μg/cm 2 is calculated and shown in Table 2.
TABLE 2
Physical Properties of the Lithium silicate glass ceramic.
Example
Example
Example
Example
Example
#2
#3
#4
#5
#8
Softening temperature, ° C.,
689
618
690
766
711
Intermediate stage at 600° C.
Softening temperature, ° C.,
727
744
717
789
724
crystallized sample at 800° C.
Coefficient of expansion, X10 −6 /° C.
11.81
12.58
12.27
11.30
11.61
Crystallized sample at 800° C.
Flexural strength, MPa,
350 +/− 28
402 +/− 56
359 +/− 40
365 +/− 60
370 +/− 50
Crystallized at 800° C.
Flexural strength, MPa
393 +/− 48
423 +/− 61
523 +/− 39
345 +/− 20
397 +/− 57
Hot pressed sample
Chemical Solubility, μg/cm 2
72
58
65
39
58
Crystallized sample at 800° C.
The preferred range composition (in % wt) of this glass ceramic material is the following:
TABLE 5
Preferred Range of Composition Components
weight % composition
Component
minimum
maximum
SiO 2
53.5
56.2
Al 2 O 3
3.1
4.2
K 2 O
3.4
4.5
CaO
0.0
1.0
B 2 O 3
0.0
1.6
CeO 2
0.0
1.0
MgO
0.0
0.2
Fluorine
0.0
0.5
Li 2 O
14.8
16.1
ZrO 2
4.6
4.9
TiO 2
0.6
2.4
P 2 O 5
2.5
3.0
SnO
0.0
0.2
Er 2 O 3
0.1
1.5
V 2 O 5
0.0
0.5
GeO 2
0.9
7.8
Ta 2 O 5
0.0
2.3
Sm 2 O 3
1.8
5.7
Pr 2 O 3
0.0
0.9
Eu 2 O 3
0.0
1.3
Y 2 O 3
0.0
4.9
Nb 2 O 5
0.0
0.5
One preferred example of this material has the following specific composition:
TABLE 6
Preferred Composition
Component
Weight %
SiO 2
55.74
Al 2 O 3
4.15
K 2 O
4.48
CaO
0.95
B 2 O 3
1.60
MgO
0.23
Fluorine
0.50
Li 2 O
16.01
ZrO 2
4.76
TiO 2
0.80
P 2 O 5
2.56
GeO 2
0.91
Coloring oxides
7.32
Having thus disclosed a number of embodiments of the formulation of the present invention, including a preferred range of components, a preferred formula thereof and a preferred fabrication process, those having skill in the relevant arts will now perceive various modifications and additions. Therefore, the scope hereof is to be limited only by the appended claims and their equivalents. | The present invention relates to a method of fabricating an improved lithium silicate glass ceramic and to that material for the manufacture of blocks for dental appliances using a CAD/CAM process and hot pressing system. The lithium silicate material has a chemical composition that is different from those reported in the prior art with 1 to 10% of germanium dioxide in final composition. The softening points are close to the crystallization final temperature of 800° C. indicating that the samples will support the temperature process without shape deformation. | 2 |
[0001] The present invention relates generally to electronic data processing systems and more particularly to electronic data processing systems having application cache memory.
BACKGROUND OF THE INVENTION
[0002] Improvements in electronic data processing systems have generally been directed toward reduction in the time required to service applications and process information along with the related costs of the infrastructure in support of the faster processing. A wide variety and number of memory and storage designs have been implemented as electronic data processing systems have evolved. One such implementation is the use of cache memory in one form or another to improve response times for data access. Applications having access to such caching technology benefit through the reduction in data access times.
[0003] The size of cache memory is often less than desired for a particular application. The size allocated for a cache is determined by a trade off between the cost of the device and the performance to be attained. The realization that a complete application and its data cannot usually reside in a cache leads to cache management techniques. The cache size constraints mean that decisions have to be made regarding cache content during application execution time.
[0004] The value of a cache increases with the applicability of the data contained therein. The applicability of the data is determined by the referencing of the data. Ideally only the recently used or most likely to be accessed data should be maintained in the cache.
[0005] Prior implementations of caching have used a variety of techniques to determine what data should be cached and how long that data should remain in the cache if it is not referenced. These implementations have been targeted towards various specific situations resulting in varying levels of success.
[0006] Typically there is a need to flush a cache to remove unwanted data. Whenever a cache is flushed it is effectively offline to the users of that cache. This results in downtime for the cache and increased response time for users requesting data managed through the cache while waiting for the cache recovery. Having flushed the cache, it then needs to be reloaded with data for use by the application users. Some implementations employ a “lazy” technique of allowing the cache to be populated over time by the data requests, while other implementations attempt to prime the cache before use.
[0007] All of these actions take time and therefore reduce the effectiveness of the cache while it is effectively “offline” or “marginally on-line. It would therefore be highly desirable to have a method and software allowing a faster more efficient means of returning a cache to productive service.
SUMMARY OF THE INVENTION
[0008] Conveniently, software exemplary of the present invention allows for a reduction in system processing and user response time spikes normally associated with cache flushes and adds to the effectiveness of the cache returned to service through pre-loading of data implemented on a staging server.
[0009] In an embodiment of the present invention there is provided a computer implemented method for updating application data in a production data cache, comprising: capturing statistical data representative of the application data usage; analysing the statistical data in accordance with customizable rules; generating candidate data from the statistical data; pre-loading the candidate data; and pushing the pre-loaded candidate data into the production data cache.
[0010] In another embodiment of the present invention there is provided a computer system for updating application data in a production data cache, comprising: a means for capturing statistical data representative of the application data usage; analyser for analysing the statistical data in accordance with customizable rules; generator for generating candidate data from the statistical data; a means for pre-loading the candidate data; and a means for pushing the pre-loaded candidate data into the production data cache.
[0011] In yet another embodiment of the present invention there is provided an article of manufacture for directing a data processing system update application data in a production data cache, comprising: a computer usable medium embodying one or more instructions executable by the data processing system, the one or more instructions comprising: data processing system executable code for capturing statistical data representative of the application data usage; data processing system executable code for analysing the statistical data in accordance with customizable rules; data processing system executable code for generating candidate data from the statistical data; data processing system executable code for pre-loading the candidate data; and data processing system executable code for pushing the pre-loaded candidate data into the production data cache.
[0012] Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the figures, which illustrate embodiments of the present invention by example only,
[0014] FIG. 1 is a block diagram showing the components in a preparation phase in support of an embodiment of the present invention;
[0015] FIG. 2 is a block diagram showing components in an activation phase in support of the embodiment described in FIG. 1 .
[0016] FIG. 3 is a block diagram of the tooling components as may be used in support of the embodiments of FIGS. 1 and 2 .
[0017] Like reference numerals refer to corresponding components and steps throughout the drawings.
DETAILED DESCRIPTION
[0018] Significant information may be extracted from the various web servers or other similar servers as these servers generate most of the information relevant to the task at hand. The web server data is collected and aggregated on a form of database server for ease of processing and to avoid the processing load being placed on the production server. The database server is a reasonably good candidate because it would typically have the space and tools associated for data analysis.
[0019] In one example the specific information being sought from the web servers is the URL information for pages referenced by users and typically captured in the web server log files. All of the parametric data associated with the URLs is also of interest. In fact, the harvesting of this type of information can be managed by an automated scheduled process or performed manually.
[0020] Logs from a caching proxy or web server can be used in most cases, but sometimes more detailed information is needed when a lot of user based personalization is used. This can be done using site logging that captures the user's detailed information, but this requires the application to capture this data and supply it to the capture phase of the caching pre-load tooling. In some sites it may not be necessary to actually capture this data but knowledge of the site can be used to load the cache by using a userid that acts similar to an actual user on the site. Using simulated userids or userids that belong to groups may be an important means to load pages that are personalized or are only viewed by groups of users. In some cases, if fragments are being used, then loading a portion of a page and leaving the personalized portion for the user to actually execute is much better than not loading anything and provides great value in reducing the cost of first execution.
[0021] Once the log data has been made available in the database server, various tools as are known in the art for data analysis may be used to analyse the data. The purpose of the data mining activity is to discover patterns or trends in the data that may be useful in determining page activity to identify candidates for caching. The data may have been analysed in a number of suitable ways such as frequency of use, duration of time on web server, related pages and other means of categorizing and comparing the data.
[0022] Making sure that the right cache data is pre-loaded is important to the success of maximizing the hit ratio on the cache. Now that the database has been loaded with the information on what pages had been viewed, the power of a database query language such as SQL can be used to extract data from the database to produce the pre-load data based on many different algorithms. The tooling allows the user to also input criteria in the SQL they wish to use, thus giving the flexibility to the user to use their domain knowledge. Some of the selection criteria that can be used are listed below.
[0023] Select the top viewed pages since the start of the site.
[0024] Select the top viewed pages this month, week, day, quarter, and half year.
[0025] Select the top pages for this month based on last year's data or several years of data.
[0026] Select the top pages for the day of week based on all the data for this day.
[0027] Select the top pages for this holiday period based on the last holiday period or periods.
[0028] Select the top pages for the end/beginning/middle of the month as people may shop differently during the month.
[0029] Select the top pages when you have a sale based on the last time you had a sale.
[0030] Select the pages you know are the most common for your site or load a complete catalog.
[0031] Having completed an analysis of the data and produced lists of candidates of varying types the pre-load is then initiated from a database server to a staging server. It is to be noted that placement of data onto the staging server should not affect a production server. Further, all work done in preparing the data for caching has been performed off the production server to avoid any unnecessary load on the production server.
[0032] With a completion of the pre-load activity on the staging serve, the data from the cache-only portion of the staging server is then “pushed” out and onto the production server. This minimizes the outage on the production server to the time required to push the new data into the production server cache. Further the newly received data has been optimized for ready use.
[0033] FIG. 1 illustrates in block diagram form the components of an embodiment of the present invention as used in the preparation phase of the process. Web servers 100 provide “pages” of data on request to application users of application servers 110 . Web logs from web servers 100 are readily available and provide an excellent source of information to aid in the discovery and understanding of data access patterns. Database servers 120 are used by the process of staging servers 115 to receive data from web servers 100 . Data collection can be automated and scheduled based on some time frequency or triggered by some other event such as manual initiation. Ideally data filtering is used to cause only needed data to be extracted from web servers 100 . Data is then made ready on staging serves 115 for replacement on production application servers 110 .
[0034] Referring now to FIG. 2 the activation phase of the process is shown. The cache of production server 110 has been flushed and is therefore ready to receive caching data from staging server 115 . The process reduces the stress on production server 110 that might have been caused by data collection and analysis work being performed on production server 110 . The cache flush operation can then be performed relatively quickly as the replacement data is already prepared for use on staging server 115 .
[0035] FIG. 3 is a simplified view of an overall tooling used during the process in a preferred illustrative embodiment of the present invention. Capture tool 300 is responsible for gathering all required data from sources such as web logs 310 and caching proxy logs 320 . Web logs 310 and caching proxy logs 320 can be found on web servers 100 and similar servers. Capture tool 300 sends output to database 120 , which acts as a repository for all of the retrieved data and provides an environment for analysis tools to be used. The collected data is assembled, combined or aggregated into a form suitable for further processing. Relevant data may be determined in any number of accepted and known manners, but ideally should be application specific to address the caching targets of the application server. As stated earlier, URLs of previously referenced pages served by web servers 100 may be of particular interest but they are only one form of statistic that might be relevant.
[0036] Extraction tool 330 performs activities related to data mining and analysis. The intent of this activity is to determine candidate data for caching. Data stored in database servers 120 may be sifted, sorted, analysed to discover trends, relationships or other usage patterns of particular value. Extraction tool 330 allows the use of SQL to be used on the stored data providing a robust query environment in which to perform data analysis and reduction. Having the full power of SQL provides an easier means of selection of various criteria to be used on the data of interest. The result of performing of SQL queries is the production of pre-load logs 340 that may be in the form of “lists” or clusters of data. As previously discussed, URLs might be one type of information of interest and can be categorized by frequency of use, by trend, by association or relationship with other respective URLs or a specific product affinity perhaps or categorized in some other meaningful manner.
[0037] The capability to pre-populate a JSP (Java server pages) cache based on web log data provides a powerful means to improve the performance and value of the cache. The use of the database provides an opportunity to introduce customizable log analysis rules that are supported through SQL queries. The actual web log data can also be merged with other business related data as might be found in a data mart. Specific and customizable rule sets can then be developed to exploit initially non-obvious trends or patterns. The results of such custom queries on the newly aggregated data can lead to unique cache pre-population instances. SQL capability can be further exploited to handle the more complex situations in resolving grouping users and respective URL requests. Analysis can then use one or more predetermined or customized SQL queries based on a merger of web log data and business data.
[0038] Having produced such lists or clusters of pre-load data on staging server 115 , this data is then made available to pre-load tool 350 . After a cache flush has been initiated and completed on production server 110 , the data pre-loaded on staging server 115 is “pushed” onto web server 100 as shown in FIG. 3 or onto production servers 110 as shown in FIG. 2 by pre-load tool 350 and the process is completed.
[0039] Web servers 100 or production servers 110 have then received cache data that has been analysed and “tuned” to provide a more effective hit ratio than might have been otherwise available, thereby improving the value of the caching service. The fact that the data has been moved as a transfer operation without having to create such data during the move minimizes the cache downtime to only that time needed to effect the transfer. Once the load has been completed the cache is immediately ready for use.
[0040] Data transfer might have occurred through web servers 100 or directly from staging servers 115 to production servers 110 as desired by the installation. Data collection and analysis can be performed regularly so as to have a ready set of caching candidates available for use, subject to a cache flush and re-load request. Advance preparation of candidate data is required to maintain effective response times for cache reload and is recommended to avoid potential problems of “stale” data being used in cache reload. Although database servers 120 are used in the embodiment just described it can be appreciated that any suitable form of data storage and file handling mechanism that supports the aggregation of data and tools to analyse such data can be used. Further the “lists” that were prepared can in fact not be lists but other forms of output prepared by tools of convenience. Ideally the data reduction and analysis tools should prepare output ready for use by the staging operation to reduce further processing requirements. The servers mentioned might or might not exist on a single system, as they may be easily networked together with the only requirement being to move data quickly into the production server 110 cache from staging server 115 . A single system of sufficient capacity might support the servers of the embodiment shown.
[0041] Of course, the above described embodiments are intended to be illustrative only and in no way limiting. The described embodiments of carrying out the invention are susceptible to many modifications of form, arrangement of parts, details and order of operation. The invention, rather, is intended to encompass all such modification within its scope, as defined by the claims. | The invention reduces the system processing and user response time spikes normally associated with cache flushes and adds to the effectiveness of the cache returned to service through pre-loading of cache data on a staging server. Statistical data is captured representative of application data usage and analyzed in accordance with customizable rules. Candidate data for caching is determined from the statistical data and pre-loaded onto the staging server. This pre-loaded, staged data is then pushed into the production data cache, thereby reducing downtime of the cache. | 6 |
FIELD OF THE INVENTION
The present invention relates to an electric sewing machine, particularly to an electric sewing machine provided with a button hole sewing control device.
BACKGROUND OF THE INVENTION
The button hole stitch consists of upper side tacking stitches T1, a lower side tacking stitches T2, left side stitches T3 and right side stitches T4 surrounding a button hole H as shown in FIG. 1.
There have been proposed various types of electrically operated sewing machines which provide a number of patterns a zig zag sewing. However, in the conventional zig zag sewing machines, when sewing a button hole, an operator operates one of the select switches corresponding to said upper side tacking stitches T1 first, after the tacking stitches T1 are completed the operator must operate other select switch corresponding to the left side stitches T3. In a similar manner as described above, the operator must operate different select switches for the lower tacking stitches and the right side stitches.
Such operation is troublesome for the operator.
SUMMARY OF THE INVENTION
It is, therefore, an essential object of the present invention to provide a button hole sewing device for use in an electric zig zag sewing machine being capable of sewing the tacking stitches and the side stitches of a button hole with simple operation of at least one switch of button hole sewing machine.
It is another object of the present invention to provide a button hole sewing device being capable of selecting left side stitching and right side stitching operation with a single select switch.
The other objects and features of the present invention will be apparent from the description made hereinafter in connection with a preferred enbodiment of the present invention with reference to the attched drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing an example of button hole stitches;
FIG. 2 is a perspective view of a sewing machine according to the present invention;
FIG. 3 is a fragmentary view of a control panel provided in a frame of the sewing machine;
FIG. 4 is a schematic view of a needle actuating mechanism and a cloth moving mechanism which are incorporated in the sewing machine shown in FIG. 2;
FIG. 5 is a plan view of a disc shown in FIG. 4;
FIG. 6 is a plan view of a cam for controlling the cloth movement;
FIG. 7 is a block diagram of an electric control circuit arrangement incorporated in the sewing machine;
FIG. 8 is a circuit diagram showing the detailed circuit arrangement shown in FIG. 7, said circuit arrangement being divided into two parts which are respectively shown in FIG. 8a and FIG. 8b;
FIG. 9 is a flow chart showing the operation of the circuit arrangement shown in FIG. 8;
FIG. 10 shows various waves forms appearing on the essential portions of the circuit arrangement shown in FIG. 8;
FIG. 11 shows various waveforms appearing on essential portions of the circuit arrangement shown in FIG. 8;
FIG. 12 is a plan view of a cam for controlling tack stitching;
FIG. 13 is a plan view of a cam for controlling left side stitching;
FIG. 14 is a plan view of a cam for controlling right side stitching; and
FIG. 15 is a plan view showing an example of button hole stitches.
FIG. 16 is a perspective view showing an example of the cam follower releasing arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals throughout the accompanying drawings.
Referring to FIG. 2, a sewing machine 1 includes a bed 2 from which rises a standard 4 supporting a bracket arm 6 over hanging the bed 2. The arm 6 supports a head 8 which has a needle 10 projecting outwardly and downwardly towards the bed 2. Disposed on the front surface of the standard 4 is control panel 12, as best shown in FIG. 3, including a plurality of, for example, eight buttons 14a to 14h, eight indication lamps 18a to 18h for the selected buttons 14a to 14h, respectively, a sewing pitch control dial 20 and a button 22 for effecting a retreat movement of the cloth. The sewing pitch control dial 20 has an index arrow 20a which is, as the dial 20 is rotated, selectively brought in register with character S and numerical markings scaled adjacent to and around the dial 20. When the arrow 20a points "0", the cloth under the needle 10 is held standstill so that the needle 10 can carry out the sewing repeatedly on the same place of the cloth. Upon rotation of the dial 20 to bring the index arrow 20a in register with one of the numerical markings, the cloth is advanced in a predetermined sewing pitch determined by the position of the dial 20 so rotated. The sewing pitch is greater as the weight of the numerical markings increases larger. When the dial 20 is rotated to a position S, the sewing pitch is controlled to cause the cloth to advance at a varying pitch. Indication lamps in a shape of an arc are provided around the dial 20 adjacent the numerical markings so that each indication lamp may indicate a predetermined range in the numerical markings. For example, the indication lamp 24a, 24b, 24c and 24d cover the numerical range 0 to 0.5, 0.5 to 1, 1 to 2.5 and 2.5 to 4, respectively. Each time the sewing pattern is selected by pushing one of the buttons 14a to 14h, one or more indication lamp is lit to indicate a range of pitch suited for the selected pattern.
Two groups of sewing patterns are shown one on each side of a column of the indication lamps 18a to 18h. The sewing patterns of one group shown on the right-hand side of the respective lamps 18a to 18h are obtained when the arrow 20a is in register with one of the numerical markings whereas the sewing patterns of the other group shown on the left-hand side of the respective lamps 18a to 18h are obtained when the arrow 20a is in register with the character S.
Referring to FIG. 4, there is shown a mechanism of the sewing machine 1. The mechanism can be briefly divided into first and second sections, the first section being a needle actuating mechanism while the second section is cloth moving mechanism. Each of such mechanism is actuated by a motor 26 which is controlled by a foot-switch 28 connected to the machine 1 through a cable 30, as shown in FIG. 2. The rotation of the motor 26 is transmitted to a fly-wheel 32 through an endless belt 34. The fly-wheel 32 is rigidly mounted on a shaft 36 which is in common with a main shaft for the cloth moving mechanism. This shaft 36 is connected to another shaft 38 for the needle actuating mechanism through an endless belt 40 so that the shafts 36 and 38 can be rotated simultaneously with each other during rotation of the motor 26. Each mechanism is described in detail hereinbelow.
Needle actuating mechanism
The thread carrying needle 10 is affixed to a needle bar 42 which is slidably supported by an F-shaped framework 44 having an up-right bar 44a and two parallel bars 44b and 44c extending laterally from the bar 44a. The needle bar 42 is slidably inserted through holes formed in the bars 44b and 44c. A rectangular spring plate 46 has one end connected to the upper end of the up-right bar 44a and the other end connected to the frame of the sewing machine, whereby the F-shaped framework can undergo a swinging motion. At an intermediate portion between the bars 44b and 44c, the needle bar 42 is tightly held by a link 48 which is connected to a crank 50 mounted on the shaft 38. Therefore, the rotation of the shaft 38 is converted into the reciprocal movement of the needle bar 42 by the crank 50. The lateral jogging movement of the needle 10 can be obtained by the swing motion of the F-shaped framework 44. This swing motion is controlled by a cam mechanism.
The cam mechanism includes a plurality of cams 52 placed one above the other and rigidly connected to each other. Such cam arrangement 52 is also rigidly connected to a spur gear 54 and is rotatably mounted on a shaft 56 so that the gear 54 rotates together with the cam arrangement freely about the shaft 56. A rod 64 having a rectangular cross section is provided adjacent the cam arrangement 52 with its opposite ends rotatably journalled to the frame of the sewing machine. Mounted on the rod 64 is a cylindrical arm carrier 70 which slidably displaces along the rod 64. A step-formed drum 58 is rigidly mounted on the shaft 56 while a timing cam 60 is also rigidly mounted on the shaft 56. Since an upper annular end of the drum 58 is formed with a generally helical cam face composed of a plurality of steps 58a and a corresponding number of slopes 58b each positioned between every adjacent two of the steps 58a, the arm carrier 70 having its lower end resting on the upper annular end face of the drum descends or elevates along the rod 64 as the drum 58 is rotated in a direction as shown by the arrow X or in a direction as shown by the arrow Y, respectively, about the shaft 56 by a motor 62 connected to the shaft 56. The step-formed drum 58 is provided for supporting the cylindrical arm carrier 70 at a desired level. The position of the drum 58 shown in FIG. 4 supports the carrier 70 at the highest level. Upon rotation of the drum 58 in the direction X by the actuation of the motor 62, the carrier 70 is gradually lowered.
An arm 66 is mounted on the rod 64 at a position adjacent the timing cam 60 by means of a clicking clutch means (not shown), said clicking clutch means being so designed as to enable the arm 66 to rotate clockwise about and independently of the rod 64 and also to rotate counterclockwise together with the rod 64. A free end of the arm 66 remote from the rod 64 is engaged to the timing cam 60.
A spring 68 is connected to the arm 66 to bias the arm 66 and the rod 64 to rotate in a clockwise direction when viewed from top. The cylindrical shaped arm carrier 70 is slidably mounted on the rod 64 and carries an arm or cam follower 72 also mounted on the rod 64. A coil spring 74 mounted on the rod 64 biases the arm 72 and the arm carrier 70 downwardly with a bottom end of the arm carrier 70 held in contact with a stepped upper edge of the drum 58. Since the upper edge of the drum 58 is provided with steps 58a and slopes 58b, the rotation of the drum 58 moves the carrier 70 along the rod 64 to vary the level of the carrier 70. When the carrier 70 is slid along the slope 58b defined between every two neighboring steps 58a in the drum 58 for changing the level thereof, the arm 66 slides over a corresponding projecting portion of the timing cam 60. Thus, the arm 66 is pivoted by the rotation of the shaft 64 in a counterclockwise direction. In other words, during the movement of the carrier 70 along the rod 64 with its lower end sliding in contact with any one of the slopes 58b in the drum, a free end of the arm 66 slides over a corresponding one of the projections of the timing cam 60. Therefore, during the displacement of the cam follower 72 in the vertical direction, the cam follower 72 is disengaged from the cam arrangement 52.
On the other hand, when the carrier 70 is in contact with a flat edge or step 58a of the drum 58, the arm 66 is positioned in a recess defined between the two neighboring projections of the timing cam 60 and, hence, the cam follower 72 is held in contact with one of the cams in the cam arrangement 52. Rigidly mounted at upper portion of the shaft 64 is a disc plate 76 having a projection 78. This projection 78 is pivotally connected to a bar member 80 which extends to the bar 44c of the F-shaped framework 44.
The operation of the needle actuating mechanism is described hereinbelow.
Upon one rotation of the shaft 38, the needle 10 undergoes one reciprocation. Also the rotation of the shaft 38 causes the rotation of the cam arrangement 52 through the engagement between the worm gear 82 and the spur gear 54. The rotation of the cam arrangement 52 causes a jogging movement of the cam follower 72 by following projecting lobes or recessed stations and, thus, the projection 78 is jogged accordingly. This jogging movement is transmitted to the F-shaped framework 44 through the bar member 80 to swing the needle 10 laterally. Thus, the zig-zag sewing can be effected according to a pattern determined by the selected cam in the cam arrangement 52 to which the arm 72 is then engaged. When it is necessary to change the cam, that is, to change the level of the arm 72, the motor 62 is turned on by a suitable switch means such as the one electrically coupled to the buttons 14a to 14h in a manner as will be described in detail later with reference to FIG. 8. When the motor 62 is so turned on the shaft 56 is rotated to rotate the drum 58 and the timing cam 60. The rotation of the timing cam 60 causes the arm 66 to jog accordingly while the rotation of the drum 58 moves the cam follower 72 up or down together with the carrier 70 along the shaft 64. Since the verical displacement of the cam follower 72 is carried out during the movement of the arm 66 over the projecting portion of the timing cam 60, the cam follower 72 is held clear of the cam arrangement 52.
Cloth moving mechanism
A rack member 90 having a pair of saw tooth edges 92a and 92b and an elongated bar portion 90a is movably accommodated in the bed 2 of the sewing machine 1. An L-shape block 96 journalled to the frame of the sewing machine has one end portion held in contact with one side edge of the bar portion 90a while the other end portion thereof is held in contact with a disc 98 which is eccentrically rigidly mounted on the shaft 36. The L-shaped block 96 is normally biased in one direction by a spring 100 with said other end portion thereof held in contact with the disc 98. Upon rotation of the shaft 36, the L-shaped block 96 is rocked to provide a lateral movement force to the rack member 90 in a direction as indicated by the arrow A1 in FIG. 4.
An elongated seesaw plate 102 pivotally supported at its substantially intermediate portion by a pin is provided adjacent the L-shaped block 96. This plate 102 has one end overlaying and engaged to a peripheral face of a disc 104 which is eccentrically rigidly mounted on the shaft 36. The other end portion of the plate 102 is hingedly connected to one end of an arm 106. The other end of the arm 106 is also hinged to a bar 108 which extends from a cubic block 110 slidably accommodated in a casing 112 of a substantially U-shaped cross section. The end of the bar portion 90a of the rack member 90 remote from the saw tooth edges 92a and 92b is hinged to one end of an arm 114 while the other end of the arm 114 is also hinged to the bar 108. In this construction, during the rotation of the shaft 36, the plate 102 undergoes a seesaw motion to move the bar 108 vertically in a direction as indicated by the arrow A2 in FIG. 4.
When the groove in the casing 112 is vertically oriented such as shown in FIG. 3, the bar 108 vertically moves as the cubic block 110 reciprocates in the groove of the casing 112. In this case, the rack member 90 is moved only in a vertical direction A2. Therefore, the cloth positioned above the saw tooth edges is held standstill. When the groove in the casing 112 is slant-d in one direction as a result of rotation of a shaft 116 connected to the casing 112 in a direction as indicated by an arrow A3, the cubic block 110 reciprocates accordingly along the groove in the casing 112. In this case, the arck member 90 undergoes such a motion that an end portion of the bar 90a of the rack member 90 adjacent the toothed edges 92a and 92b describes an oval orbit in a counterclockwise direction, when viewed from the right-hand end, whereby the cloth is advanced. The pitch of advance is controlled by the setting of the sewing pitch control dial 20 which determines the angle through which the casing 112 reciprocately rotates together with the shaft 116.
On the other hand, when the groove in the casing 112 is slanted in the other direction as a result of rotation of the shaft 116 in a direction as indicated by the arrow A4, the cubic block 110 reciprocates accordingly along the groove for causing the rack member 90 to move following a similar oval orbit in a clockwise direction when view from the right-hand end. In this case, the cloth is retreated. The manner in which the rotation of the shaft 116 is controlled is described hereinbelow.
An elongated plate 120 is rigidly connected to the end of the shaft 116 remote from the casing 112. One end portion 120a of the plate 120 is pivotally connected to a plate 122, so that the plate 122 moves laterally as a result of rotation of the plate 120. The other end portion of the plate 120 is pivotally connected to a plate 124 which has a pin projection 126 at the end thereof remote from the plate 120. This pin projection 126 is engaged to an edge of a detent recess 128 formed in a disc plate 130. The recess 128 as best shown in FIG. 5 has a predetermined pattern defined by portions 128a, 128b, 128c and 128d. The disc 130 is eccentrically connected to a shaft 132 which in turn is connected to the dial 20 described above. Since the plate 120 is biased by a spring 134 about the shaft 116 in a clockwise direction when viewed from right, the pin projection 126 is held in contact with an upper edge of the detent recess 128. When the disc 130 is held in a position as shown in FIG. 3, the edge portion 128b of the recess 128 is held in contact with the pin projection 126. It is to be noted that the engagement of the pin projection 126 at the portion 128b brings the casing 112 in a position with the groove thereof oriented in a vertical direction as shown. At this time, the dial 20 is in position with the arrow 20a held in register with the "0" marking. Upon rotation of the disc 130 in a direction A5, the pin projection 126 comes into contact with the portion 128a of the recess 128. Therefore, the plate 124 is raised upwardly to allow rotation of the shaft 116 in the direction A3. Thus, the casing 112 is slanted to effect the orbitary movement of the rack member 90 in such a manner as to advance the cloth. At this time, the dial 20 is in position with the arrow 20a held in register with one of the numeral markings.
The disc 130 is coupled with an auxiliary disc 130a having a smaller diameter than that of the disc 130. This auxiliary disc 130a is also eccentrically connected to the shaft 132. Provided under the auxiliary disc 130a is an arm 134 having one end portion pivotally connected to the frame of the sewing machine while the other end is held in contact with a platform 136 slidably mounted on a shaft 138 extending in parallel to the shaft 56. An arm 140 extends from the platform 136 with the free end thereof normally terminating adjacent and above a face 122a formed in the plate 122. Since the arm 140 is rigidly connected to the shaft 138, the rotation of the arm shaft 140 accordingly results in rotation of the arm 140. Another arm 142 is also rigidly mounted on the shaft 138 at upper portion thereof. This arm 142 is held in contact with a hinged V-shaped block 144 which is in turn held in contact with the uppermost cam 52a in the cam arrangement 52. The uppermost cam 52a is provided for controlling the cloth movement. The rotation of the cam arrangement 52 results in a jogging motion of the V-shaped block 144 and also the arm 142. Therefore, the shaft 138 is rotated. This rotation of the shaft 138 is transmitted to the arm 140. Normally, since the arm 140 is free from any element, the rotation or jogging movement of the arm 140 is not transmitted to further element. When the dial 20 is turned to a direction A6, however, the recess 128 is rotated to push down the plate 124 as the pin projection 126 slides along the portion 128c. Therefore, the plate 122 is forcibly pushed to a direction A7. The further rotation of the dial 20 in the direction A6 pushes down the arm 134 by the auxilary disc 130a, so that the platform 136 is pushed down to lower the arm 140. Thereafter, the pin projection 126 slides into the position 128d to substantially raise the plate 124 for moving the plate 122 towards the direction A8. As a consequence, the face 122a of the plate 122 comes into contact with the free end of the arm 140. It is to be noted that this is effected as the dial 20 is brought to a position with the arrow 20a registered with the "S" marking. The establishment of such connection between the arm 140 and the face 122a transmits the jogging movement of the arm 140 through the plates 122 and 120 to the shaft 116, so that the casing 112 is slanted in the direction A3 or A4 with respect to the jogging of the arm 140. Thus, the movement of the cloth is varied.
Referring to FIG. 6, there is shown one example of the cloth moving cam 52a having most projecting portion 53a, normal level portion 53b and recessed portion 53c. When the V-shaped block 144 slides over the projecting portion 53a, the shaft 116 is turned to the direction A4 to retreat the cloth. When the V-shaped block 144 slides over the normal level portion 53b, the shaft 116 is held in such a position as to maintain the casing 112 vertically as shown in FIG. 3, and when the V-shaped block 144 slides over the recessed portion 53c, the shaft 116 is turned to the direction A3 for advancing the cloth.
An elongated plate 150 is pivotally supported by a pin 152 with upper end thereof held in contact with a cam 154 positioned under the timing cam 60 and rigidly mounted on the shaft 56. The other end of the plate 150 is provided with a pin projection 156 which is slidably accommodated in an elongated grooves 122b formed in the plate 122. A spring 158 is provided for urging the upper end of the plate 150 to the cam 154. Since the biasing force of the spring 158 is larger than that of the spring 136, the movement of the plate 122 particularly in the direction A8 is restricted by the plate 150. In other words, the pin projection 156 limits the lateral movement of the plate 122 within a distance defined by the effective length of the groove 122b between the pin projection 156 and the left end of the groove 122b. For example, when carrying out a straight stitch, the upper end of the plate 150 will be held in contact with the most projecting portion of the cam 154 so that the effective length of the groove 122b between the pin projection 156 and the left end of the groove 122b will be considerably large. Thus, upon rotation of the dial 20 to a large numbered position, the shaft 116 can be turned to the direction A3 through a large angle. In other words, stitching is effected at an interval of a relatively large pitch while the cloth is advanced. By all means, it is possible to advance the cloth with a small pitch for this straight stitch by simply turning the dial 20 to a smaller number. On the other hand, when carrying out a button hole stitch, it is necessary to stitch the same place repeatedly. In this case, the upper end of the plate 150 will be held in contact with the most detent portion of the cam 154 so that the effective length of the groove 122b between the pin projection 156 and the left end of the groove 122b will be zero. Therefore, the plate 122 will not be moved to the direction A8 so as to incline the casing 112 in the direction A3, regardless of turning of the dial 20.
The button 22 is positioned adjacent the upper end of the plate 120 for allowing, when the button 22 is pushed the shaft 116 to rotate in the direction A4. Thus, the retreat movement of the cloth can be effected during the pushing of the button 22.
In order to ensure to disengage the cam follower 72 from the cam 52 during rotation of the timing cam 60, as shown in FIG. 16, there may be provided a cam follower releasing arrangement 180 having an arm 75 mounted on the rod 64 for rotation simultaneously with the rod 64 and an electromagnet 182 which is provided with a solenoid 235, an armature 184 having an L-shaped free end 184a being detouchably engaged with the free end of the arm 75 and a spring 186 biassing the armature 184 so as to raise the L-shaped end 184a when the solenoid 235 is not excited. In this case the arm 66 is mounted on the rod 64 through one way clatch (not sown).
By this arrangement, when the solenoid 235 is not excited, the L-shaped end 184a of the armature is raised by the force of the spring 186, so that when the arm 75 is rotated in the direction A10 corresponding to the rotation of the rod 64 caused by the oscillation of the arm 66, the free end of the arm 75 is engaged with the L-shaped end 184a. Therefore, the arm 75 and the cam follower 72 are prevented from rotation, and only the arm 66 can be oscillated corresponding to rotation of the timing cam 60.
On the other hand, when the solenoid 235 is excited, the armature 184 is attracted onto the core of the electromagnet 182, so that the arm 75 is disengaged from the L-shaped end 184a to allow the arm 75 and the cam follower 72 to contact onto the cam 52.
Electric Control Circuit Arrangement
Referring to FIG. 7, there is shown a block diagram of the electric control circuit arrangement employed in the embodiment of the present invention, wherein a cam follower detector 210 operates to produce coded signals B of four bits in binary form representing the position of the cam follower.
The cam follower detector 210 is adapted to count the number of the pulses generated every time when the cam follower 72 moves from one cam to the other cam located adjacent to said one cam so as to produce signals representing the number of cam to which the cam follower 72 is opposed.
A cam instructor 220 produces coded signals A of four bits in binary form representing one of the select switches 14a through 14i operated by an operator. For example, when the operator select the switch 14a, the cam instructor 220 produces signals "0001". While no select switch is operated the cam selector 220 produces "0000".
The respective coded signals of the cam follower detector 210 and the cam instructor 220 are fed to a comparator 230 in which the data A are compared with the data B. As a result of the comparison, the comparator 230 produces a signal on any one of the out put terminals 01, 02 or 03 depending on whether the data A are greater than the data B, whether A are equal to B or whether A are smaller than B.
The output signal of the comparator 230 is applied to a motor drive circuit 240 to drive the motor 62 for moving the cam follower 72. Specifically, when the motor drive circuit 240 receives the output signal from the comparator 230 generated through the terminal 01, the cam follower 72 is moved in the downward direction, but when it receives the output signal from the comparator 230 generated through the terminal 03, the cam follower 72 is moved in the upward direction.
By this operation, the cam follower 72 is set on a position corresponding to any one of the cams defined by any one of the select switches 14a through 14i selected by the operator.
After a required cam is selected, upon operation of the foot switch 28, a speed control signal is fed from a speed setting circuit 290 to a speed control circuit 300, the output of which is fed to a motor drive circuit 400 for rotating the motor 26.
The rotation speed of the motor 26 is fed back to the speed control circuit 300 so that the motor 26 is rotated with such rotation speed as set by the foot switch 28.
By rotation of the motor 26, the cam 52 is rotated and the cam follower 72 is oscillated with the amplitude defined by the shape of the cam thus selected, so that the needle 10 is jogged and the cloth is transferred by the motion of the sew tooth 92a and 92b as hereinbefore described.
Thus, stitches with required pattern are formed on the cloth.
For sewing button hole stitch, it is required to form a predetermined number of so called tacking stitches on the both ends of the button hole.
For this purpose, a counter circuit 250 is provided for counting the number of tacking stitches by counting the number of pulses fed from a pulse generator 270 which produces one pulse per one complete rotation of the shaft 38, that is, upon sewing of one stitch.
The pulse generator 270 is composed of a magnet 84 being so mounted on the shaft 38 that the detecting means 86 can produce the pulse at the moment when the needle 10 reaches the most raised point.
When the contents of the counter 250 reaches six, that is to say six tacking stitches are formed on the cloth, the counter 250 produces a pulse, which is fed to a speed control circuit 300 so as to stop the rotation of the main motor 26.
A row selector circuit 260 is provided for selecting either the left side stitching or the right side stitching during the button hole stitching operation. The row selector circuit 260 is provided with a flip flop actuated by the signal fed from the button switch 14a and operable alternately change in two states one at a time. These two states include a reset state and a set state of the flip flop.
When the flip flop is in the reset state, the indicator 16a is lit for indicating that the left side stitching is operable. After the left side stitching is completed, upon operation of the button switch 14a, the flip flop is set. When the flip flop is in the set state, the indicator 16b is lit for indicating that the right side stitching is operable.
Where the flip flop is in the set state, the row selector circuit 260 acts to supply to the comperator 230 the coded signal "0010" representing the third cam 52-2 for the right side stitching.
After the right side stitching is completed, upon operation of the button switch 14a, the flip flop is reset again.
Operation
Before the description proceeds, it is assumed that the upper most cam 52-0 is for left side stitch for button hole sewing, the second cam 52-1 for tacking stitch and the third cam 52-2 for right side stitch.
Referring to FIGS. 8a and 8b, when the button hole stitching switch 14a is pressed, coded signals "0001" indicating the "tack cam" 52-1 is produced from the encoder 221. By this coded signal, the OR gate 222 supplies "1" signal through the OR gate 501 to the trigger circuit 502, which produces a delayed "1" signal to the AND gate 281 (see FIG. 10(j)).
Assuming that the motor 62 is not driven, no "1" signal is applied to the NAND gate 243, so that the NAND gate 243 produces "1" signal, which is fed to the AND gate 503. On the other hand, since the foot switch 28 is not operated, the output of the one shot multi vibrator circuit 302 is "0", so that the output "1" of the OR gate 303 is fed to the AND gate 503 which receives SEQ signal of "1", at the remaining input thereof, so that the AND gate 503 sends out a "1" signal to the AND gate 281 through the OR gate 504. Said SEQ signal is adapted to be "0" only while the straight stitching is indicated immediately after the power switch of the sewing machine is ON.
The "1" output of the AND gate 281 is fed to the latch 223 for allowing to memorize the signal "0001" fed from the encoder 221 therein. The "1" output of the AND gate 281 is also fed to the flip flop circuit 282, which remains uncharged since no read-in signal is fed thereto from the AND gate 505.
Assuming that the contents of the counter 211 is "α" of four bits, the outputs "α" are fed to the B input terminals of the comparator 231 and the "b" input terminals of the comparator 232.
The outputs of the latch 223 are fed to the input terminals A of the comparator 231, so that both values A and B are compared in the comparator 230. If α<0001, i.e., the cam follower 72 is located higher than the position of the cam 52-1 for tacking stitch, the output terminal 01 of the comparator 230 becomes "1".
This "1" output signal is fed to the motor control circuit 242 to drive the motor 62 so as to rotate the drum 58 in X direction, for moving the cam follower 72 downward direction.
If α>0001, i.e., the cam follower 72 is located lower than the tacking cam 52-1, the output 03 of the comparator 231 becomes "1".
This "1" output signal is fed to the motor control circuit 241 to drive the motor 62 so as to rotate the drum 58 in Y direction for moving the cam follower 72 upward direction.
During the rotation of the drum 58, the arm 66 is swung in correspondence with the passage of the respective projections of the timing cam 60 causing the microswitch 168 ON and OFF. When the free end of the arm 66 is engaged in one of the recesses of the timing cam 60, the microswitch 168 changes to "b" contact from "a" contact, so that the OR gate 212 of the flip flop 214 including the OR gate 213 generates "1" output acting as a CLOCK pulse of up/down counter 211.
In case of the upward movement of the cam follower 72, the counter 211 acts as a down counter since the input terminal T1 is kept "1" by the signal fed from the motor control circuit 242, so that the contents "α" of the counter 211 are decreased one by one in response to the "1" signal fed from the OR gate 212 to the CLOCK input terminal corresponding to the displacement of the cam follower 72 from one of the cams to other cam existing just above said one cam.
Through this operation, when the cam follower 72 reaches the position corresponding to the cam 52-2 existing just below the "tacking" cam 52-1, the cam position detector 232 operates to cause the transistor 234 ON to excite the solenoid coil 235 for allowing the cam follower 72 to contact the periphery of the cam 52. When the cam follower 72 reaches the position corresponding to the "tacking" cam 52-1, the contents of the counter 211 become "0001" to produce "1" signal only at the terminal 02 of the comparator 231, therefore the motor 62 is stopped.
The output terminals of the counter 211 are connected to the input terminals of the decoder 261 so that the decoder 261 produces one of the output terminals "0", "1" or "2" corresponding to the contents of the counter 211. Thus, in the above case the decoder 261 produces "1" signal at the "1" terminal connected to the OR gate 262 and the AND gate 251 receiving SEQ signal of "1".
Thus, the OR gate 262 supplies "1" signal to the AND gates 263 and 264. Since the flip flop 282 is reset as described above, and the output of the AND gate 283 is "0", and in turn the output of the inverter 284 is "1", the AND gate 285 supplies "1" signal to the AND gate 264 to cause the transistor 265 to be conducted for illuminating the photo emissive diode 266 i.e., the indicator 16a for the left side stitching of the button hole shown in FIG. 1. These operations are shown by the respective steps S1 through S7 of the program shown in FIG. 9.
Under such states, the operator of the sewing machine operates the foot switch 28 to rotate the variable resistor 291 in the direction shown by the arrow mark R to increase the voltage of the base of the transistor 506 and the input voltage of the analogue comparator 292.
Since the transistor 507 is conducted by the "1" signal fed from the OR gate 262, the transistor 506 amplifies the input base signal and supplies a speed control signal with valve proportional to the value of the resistor 291 to the collector of the transistor 304 and the input terminal of the comparator 305 through the diode 306.
The output voltage of the comparator 305 is supplied to the input terminal of the gate control circuit 401 through the comparator 307 so as to control the rotational speed of the main motor 26 by way of controlling the conduction angle of the thyristor 402 and/or 403 connected with the main motor 26 through the diode 404 relative to the phase angle of A.C. power source fed from the power circuit 405.
Said comparator 305 compares the speed control signal fed from the transistor 506 and the detected speed signal representing the actual rotational speed of the motor 26 obtained by the speed detecting circuit 406 and produces a pulse train as shown in FIG. 11(G) with various pulse widths changing in proportion with the value of the speed control signal fed from the foot switch 22.
The output pulses of the comparator 305 are supperimposed with the speed control signal as shown in FIG. 11(H), being in turn fed to the comparator 307.
Said comparator 307 compares the superimposed signal and saw tooth signals (see FIG. 11(G)) with a frequency twice that of the power supply produced by the saw tooth generator 410, and generates the pulses as shown in FIG. 11(C). Said detecting circuit is adapted to produce the detected speed signal in response to the output voltage of the photo coupler 407 having a photo emissive diode 409 connected with the main motor 26 and a photo sensitive diode 408 receiving the light from the photo emissive diode 409.
When the load of the main motor 26 is large, D.C. voltage component induced in the main motor 26 during the turn-OFF periods of the thyristors 402 and/or 403 becomes low, and then the output voltage of each of the pulses of the speed detecting circuit 406 becomes low. Accordingly, the widths of the output pulses of the comparator 307 during the high level period become large as shown in FIG. 11(G), so that the A.C. power supplied to the main motor 26 becomes high, thereby causing the main motor 26 to drive with higher rotational torque.
In addition, when the foot switch 22 is pushed down deeper, the rotational speed of the main motor 26 becomes faster.
When the main motor 26 is rotated under the speed control as described above, the needle bar 42 is reciprocally oscillated by the rotation of the main shaft 38 and the cam 52 is rotated by the rotation of the main shaft 38, so that the cam follower 72 contacting the "tacking" cam 52-1 oscillates in correspondence with the shape of the cam as shown in FIG. 12. Since the oscillation of the cam follower 72 reciprocally rotates the rod 64, the projection 78, the needle bar 42 and needle 10 are jogged laterally, whereby the "tacking" stitches T1 are formed in the upper end portion of the button hole H on the cloth as shown in FIG. 15.
During oscillation of the needle bar 42, every time when the needle bar 42 reaches the uppermost position, the senser 86 produces a series of pulses representing uppermost position of the needle bar, each pulse is fed to the AND gate 272 through the inverter 273 and integration circuit 274. Said AND gate 272 produces a series of pulses as shown in FIG. 10(C). The output pulses of the AND gate 272 are fed to the hexa system counter 250 comprising three flip flops 252, 253 and 254 connected in series so as to count the input pulses for detection of the number of stitches formed on the cloth.
When the counter 250 counts 6, the AND gate 256 supplies "1" signal to the AND gates 510 and 511. Since the flip flop 282 is reset so long as the operation for making left side stitching is indicated, the AND gate 511 allows to pass the "1" signal, which are fed to the trigger circuit 502 through the OR gate 501 and to the AND gate 281 through the OR gate 504, thereby the trigger circuit 502 producing "1" signal delayed a predetermined time to the AND gate 281. The output of the AND gate 281 is fed to the latch 223 for enabling to read-in the data fed from the encoder 223 therein. Since none of the select switches 14a through 14i is operated at this time, the data "0000" fed from the encoder 221 are stored in the latch 223.
Although the output of the AND gate 281 is fed to the flip flop 282, due to the "0" output of the AND gate 505, the flip flop 282 is kept reset.
The outputs "0000" of the latch 223 are fed to the comparator 231 so as to be compared with the data "0001" fed from the counter 211. As a result of this comparison, the output terminal 03 of the comparator 230 becomes "1" and others 01 and 02 remain "0".
On the other hand, a part of the output of the AND gate 256 is fed to the AND gate 512 through the OR gate 513 to produce "1" signal. The "1" output of the AND gate 512 is fed to the inverter 514 to close the NAND gate 515 to cause the AND gate 308 to supply a set signal to the one shot multi vibrator 301. The output of the one shot multi vibrator 301 is fed to the OR gate 310 and through an integration circuit to the AND gate 309.
The output signal "1" of the gate 515 is also fed to the base of the transistor 304, so that the transistor 304 is turned ON to inhibit the application of the speed control signal fed from the transistor 506 to the comparator 305.
On the other hand, the output of the one shot multi vibrator 301 is fed to the input terminal of the comparator 305 through the OR gate 310, whereby the main motor 26 is rotated at a low speed defined by the voltage fed from the OR gate 310.
As described above, when five tacking stitches are formed on the cloth, the main motor 26 is forced to rotate at low speed defined by the output voltage of the OR gate 310, so that the sixth tacking stitch is formed substantially over-lapping the fifth tacking stitch.
The output of the OR gate 312 is also supplied to the motor control circuits 241 and 242 through the gate 303 for disabling the circuits to inhibit the cam selecting operation.
After the completion of the sixth tacking stitch when the needle bar 42 reaches the uppermost position, the NAND gate 257 is opened by "0" signal fed from the least significant flip flop 255, so that the the output of the OR gate 516 causes the transistor 293 to be cut off to disappear the output voltage of the resistor 291 regardless of the operation of the foot switch 28 to render the output of the comparator 292 to be 0 volt. In addition the output of the senser 86 is supplied to the inverter 517, output of which is differentiated by the differential circuit 518 and then the differential output is fed to the NAND gate 310 which receives the "1" output of the NAND gate 515 to which the "0" output of the comparator 292 is fed. Thus the "1" output of the OR gae 311 is fed to the one shot multi vibrator 301 to reset it and the output of the NAND gate 310 is inverted by the inverter 312 and in turn is fed to the one shot multi vibrator 302 through the AND gate 309 to effect the one shot multi vibrator 302 to produce a pulse with predetermined period as shown in FIG. 10(G).
The output pulse of the one shot multi vibrator 302 is fed to the brake circuit 412 to conduct the thyristor 413 connected with the main motor 26 through the diode 414 so that the main motor 26 is braked by the effect of a dynamic braking to stop the main motor rapidly and stop the needle 10 at the uppermost position.
After the main motor is stopped, the one shot multi vibrator 302 is reset and the OR gate 312 is closed, then the NOR gate 303 supplies "1" output, which is fed to the motor control circuit 241 and 242 for enabling the circuit 241 or 242.
Since the output data of the counter 211 are "0001" and the output data of the latch 223 are "0000" as described above, the comparator 231 produces "1" output at the terminal 03. This "1" output is fed to the motor control circuit 242 so as to drive the motor 62 and the drum 58 in Y direction, so that the cam follower 72 is raised. By the rotation of the drum 58, the arm 66 oscillate and the microswitch 168 is changed over to produce a CLOCK pulse which is to be fed to the counter 211.
When the cam follower 72 reaches the cam 52-0 for the left side button hole stitching, the counter 211 is decreased one by the clock pulse fed from the flip flop, and the counter 211 becomes "0000", so that the comparator 231 produces the "1" output at the terminal 02, and the motor 62 is stopped. The outputs "0000" of the counter 231 cause the decoder 261 to produce "1" signal at the terminal "0", and the output of the AND gate 251 is disappeared then the flip flops 253 to 254 i.e., the counter 250 is reset. Therefore, the transistor 293 is conducted by the "0" signal fed from the OR gate 516 for enabling the resistor 291 to generate the speed control signal. Now the sewing machine is ready to sew the left side button hole stiching. Then, the operator pushes the foot switch 28 down with a suitable depth, the main motor 26 is rotated with the given speed defined by the voltage of the speed control signal. Thus, the cam follower 72 is reciprocally oscillated along the peripheral shape of the cam 52-0 so that the needle bar 42 and the needle 10 are vertically oscillated and jogged with the amplitude defined by the peripheral shape of the cam 52-0.
On the other hand the cloth placed on the sew tooth 92a and 92b is advanced by a predetermined pitch, then the zig zag stitches T3 are consecutively formed on the cloth along the left side of the button hole.
When the left side stiching as described above is completed and the operator release the foot switch 28, the output voltage of the comparator 292 becomes "0", and then the one shot multi vibrator 301 and 302 are set so as to stop the main motor 26 rapidly in a similar manner as described above.
In order to form zig zag stitches on the cloth along the right side of the button hole, the operator pushes the button switch 12a again. By this operation, the encoder 221 produces "0001" signals, which is fed to the comparator 231 through the latch 223.
By the output of the encoder 221, the OR gate 222 sends "1" signal to the trigger circuit 502 which in turn applies "1" signal to the flip flop 282 to set "1" at the output terminal Q. The set output is fed to the transistor 267 through the AND gates 286 and 263 to light the lamp 268 for displaying the right side stitching.
Since the cam follower 72 is located at the uppermost cam 52-0, and the contents of the counter 211 is "0000", so that the comparator 231 produces "1" output at the terminal 01 to effect the motor control circuit 241 for downward movement of the cam follower 72.
Upon arrival of the cam follower 72 at the second cam 52-1, the comparator 231 produces "1" signal on the output 02 and the output terminal 01 becomes "0".
Accordingly the motor 62 is stopped and the tacking cam 52-1 is selected.
Thus, the "tacking" stitches T2 are formed on the cloth along the lower end of the button hole in a similar manner as described above.
When the counter 250 counts six, i.e., the fifth tacking stitch is completed, the "1" signal is fed to the second input terminal of the latch through the AND gate 510 and the OR gate 224 to write in the latch "0010" representing the third cam 52-2 provided for the right side stitching.
Accordingly the latch 223 applies "0010" to the counter 231, and then the output terminal 03 becomes "1" to enable the motor control circuit 242 for downward movement of the cam follower 72.
After the third cam 52-2 for the right side stitching is selected, zig zag stitches T4 are formed on the cloth along the right side of the button hole in a similar manner as described above.
When the operator pushes the button switch 14a again, the flip flop 282 is reset again in response to the application of "1" signal from the AND gate 281 so that the left side stitching now can be operable again.
It is advantageous for an operator that the left side stitching or the right side stitching can be selected simply by operation of the same select button switch so that the operation becomes easy.
In the event that an operator wishes to select other pattern of stitch, for example, the sixth pattern cam 52-5, the operator may operate the push button switch 14f. Then the encoder 221 supplies "0101" to the comparator 231 in which the data "0101" and the data fed from the counter 211 are compared so as to produce "1" signal at one of the terminals 01 or 03. Thus, one of the motor control circuits 241 or 242 becomes effective to drive the motor 62 and to move the cam follower either upward or downward direction. When the cam follower reaches the sixth cam 52-5, the contents of the counter 211 reaches "0101", thereby causing the comparator 231 to produce "1" output signal at the terminal 02. Thus, the motor control circuit 241 or 242 acts to stop the motor 62, and the cam follower 72 is allocated to the sixth cam 52-5. | The present invention is directed to an electric sewing machine provided with a button hole sewing device which comprises a plurality of cams each individually bearing information of tacking stitches, left side stitches of a button hole and right side stitches of the button hole, means for instructing button hole stitching operation and an electric control circuit arrangement which operates to select the cam for tacking stitches upon operation of the instructing means and to select the cam for one of the side stitches automatically after a predetermined number of the tacking stitches are perfected. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to four co-pending and commonly-owned application filed on even date herewith, the disclosure of each is hereby incorporated by reference in its entirety:
[0002] “Applier For Fastener For Single Lumen Access Anastomosis”, Ser. No. ______ to Mark Ortiz;
[0003] “Unfolding Anastomosis Ring Device”, Ser. No. ______ to Jean Beaupre;
[0004] “Single Lumen Access Deployable Ring for Intralumenal Anastomosis”, Ser. No. ______ to Mark Ortiz; and
[0005] “Single Lumen Anastomosis Applier for Fastener”, Ser. No. _____ to Mark Ortiz, Robert McKenna, Bill Kraimer, Mike Stokes, and Foster Stulen.
FIELD OF THE INVENTION
[0006] The present invention relates, in general, to surgery and, more particularly, to a method of performing a surgical procedure on the digestive system.
BACKGROUND OF THE INVENTION
[0007] The percentage of the world population suffering from morbid obesity is steadily increasing. Severely obese persons are susceptible to increased risk of heart disease, stroke, diabetes, pulmonary disease, and accidents. Because of the effect of morbid obesity to the life of the patient, methods of treating morbid obesity are being researched.
[0008] Numerous non-operative therapies for morbid obesity have been tried with virtually no permanent success. Dietary counseling, behavior modification, wiring a patient's jaws shut, and pharmacologic methods have all been tried, and though temporarily effective, failed to correct the condition. Further, introducing an object in the stomach, such as an esophago-gastric balloon, to fill the stomach have also been used to treat the condition; however, such approaches tend to cause irritation to the stomach and are not effective long-term.
[0009] Surgical treatments of morbid obesity have been increasingly used with greater success. These approaches may be generalized as those that reduce the effective size of the stomach, limiting the amount of food intake, and those that create malabsorption of the food that it is eaten. For instance, some patients benefit from adjustable gastric bands (AGB) that are advantageously laparoscopically placed about the stomach to form a stoma of a desired size that allows food to fill an upper portion of the stomach, causing a feeling of satiety. To allow adjustment of the size of the stoma after implantation, a fluid conduit communicates between an inwardly presented fluid bladder of the AGB to a fluid injection port subcutaneously placed in front of the patient's sternum. A syringe needle may then inject or withdraw fluid as desired to adjust the AGB.
[0010] Although an effective approach to obesity for some, other patients may find the lifestyle changes undesirable, necessitated by the restricted amount of food intake. In addition, the medical condition of the patient may suggest the need for a more permanent solution. To that end, surgical approaches have been used to alter the portions of the stomach and/or small intestine available for digesting food. Current methods of performing a laparoscopic anastomoses for a gastric bypass include stapling, suturing, and placing biofragmentable rings, each having significant challenges. For instance, suturing is time consuming, as well as being technique and dexterity dependent. Stapling requires placement of an anvil, which is a large device that cannot be introduced through a trocar port. Having to introduce the port through a laparotomy presents an increased incidence of wound site infection associated with intralumenal content being dragged to the laparotomy entry site.
[0011] As an example of the latter approach, in U.S. Pat. No. 6,543,456 a method for gastric bypass surgery includes the insertion of proximal and distal anastomosis members (e.g., anvils) transorally with grasping forceps. The stomach and the small intestine are transected endoscopically by a surgical severing and stapling instrument to create a gastric pouch, a drainage loop, and a Roux limb. An endoscopically inserted circular stapler attaches to the distal anastomosis member to join the drainage loop to a distal portion of the intestine, and the circular stapler attaches to the proximal anastomosis member to join the Roux limb to the gastric pouch. Thereafter, the anastomosis members are removed to create an orifice between joined portions of the stomach and intestine. This method reduces the number of laparoscopic ports, avoids a laparoscopic insertion of an anastomosis instrument (e.g., circular stapler) into an enlarged surgical port, and eliminates the need for an enterotomy and an enterotomy closure.
[0012] While methods such as that described are a marked improvement over generally known gastric bypass and similar surgical treatments for morbid obesity, it would be desirable to achieve a gastric bypass with yet fewer procedural steps and with fewer laparoscopic insertions. Such an approach is described in U.S. Pat. Appl. Publ. No. US 2003/0032967 to Park et al., wherein gastrointestinal or enteric (including biliary) anastomosis is achieved by insertion of a sheath that perforates the walls of two tissue passages, such as the stomach and small intestine. A three-dimensional woven tube of wire of having a thermal shape memory effect (SME) (“generally-known nitinol ring device”) is presented by a cannula of the sheath on both sides of the openings. Deployment of the woven tube causes the outer loops or ends of the tube to fold or loop back to hold the lumenal interface of the anastomosis site in apposition. Thereby, the need for a mechanical compression component in a delivery system is reduced or avoided, reducing the size and complexity of the delivery device.
[0013] While the generally-known nitinol ring device is a significant advancement in the treatment of morbid obesity, it is believed that further improvements would be desirable. For instance, the continuous interlocking petals are difficult to manufacturer, especially since the depicted woven tube is of a continuous wire loop bent into a pattern of interlocking triangles.
[0014] In addition, the generally-known nitinol ring device is a woven tube, or stent, that is purported to be a self-actuating anastomotic ring. However, the disclosed stent sometimes will not actuate or transform completely from its stressed cylindrical state to its relaxed clamping state, perhaps due to irregularities in undulations of its weaved designs create friction. One particular difficulty of known SME anastomotic rings are that they are designed to move from a generally cylindrical shape to a hollow rivet shape (“ring shape”) by having wires that form the device move across one another. In particular, wires must move within a nodal point (i.e., an indentation or valley) created by the wire bend and must climb back out of the indentation. In some instances, the device fails to fully actuate on its own due to these sources of friction.
[0015] Consequently, there is a general need for an approach to anastomosis that will use existing trocar ports (e.g., 12 mm size) with a minimum of suturing. Moreover, aspects of the method should have application to endoscopic surgery. To that end, a significant need exists for an anastomosis device that reliably and effectively deploys and actuates to eliminate the need for surgical stapling and suturing to form an anastomosis.
BRIEF SUMMARY OF THE INVENTION
[0016] The invention overcomes the above-noted and other deficiencies of the prior art by providing an anastomosis device woven from one or more strands with end disconnected from other ends, providing a more economical manufacture.
[0017] In one aspect of the invention, a woven tube anastomotic device has each longitudinal end of its constituent strands terminate in circumferential petals. The unactuated position of the tube is of a generally cylindrical shape and the actuated position of a hollow rivet shape for insertion through and for forming an anastomotic attachment between two proximate tissue walls, respectively. An actuation force is provided by weaving a helical coil spring into the woven tube. Thereby, enhanced actuation force may be achieved without relying solely or at all upon the rest of the woven tube.
[0018] These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0019] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.
[0020] FIG. 1 is perspective view of an applier having an anastomotic ring device installed thereon being inserted laparoscopically to an anastomosis target site on each of two portions of a patient's small intestine.
[0021] FIG. 2 is a perspective detail view of the applier with sheath retracted and anastomosis target site of FIG. 1 , depicting the anastomotic ring device in its undeployed, unactuated state.
[0022] FIG. 3 is a perspective, exploded and partially cutaway view of a distal portion of the applier of FIG. 1 .
[0023] FIG. 4 is a perspective, exploded view of a proximal portion of the applier of FIG. 1 with a left housing half omitted.
[0024] FIG. 5 is perspective view of the applier of FIG. 1 with the left housing half omitted and an outer tube of the cannula partially cutaway to expose an intermediate tube and inner rod that actuate a molded actuating member that actuates the omitted anastomotic ring device, also to expose a deployment illuminator that allows confirming actuation of an anastomotic ring device by viewing through the translucent tissue walls.
[0025] FIG. 6 is a perspective view of the applier of FIG. 5 with the triggers and molded actuating member in an actuated position.
[0026] FIG. 7 is a perspective view of the applier of FIG. 1 in a partially actuated state.
[0027] FIG. 8 is a detail perspective view of a distal portion of the applier of FIG. 7 with tissue walls partially cutaway.
[0028] FIG. 9 is a perspective view of the applier of FIG. 1 in a fully actuated state.
[0029] FIG. 10 is a detail perspective view of the distal portion of the applier of FIG. 9 with tissue walls partially cutaway.
[0030] FIG. 11 is a detail perspective view of the distal portion of the applier returned to unactuated state and withdrawn proximally to deploy the actuated anastomotic ring device.
[0031] FIG. 12 is a detail perspective view of the distal portion of the applier of FIG. 1 in an unactuated position holding an anastomotic ring device advantageously fabricated with a ball end discontinuous weave.
[0032] FIG. 13 is a detail perspective view of the distal portion of the applier of FIG. 12 in a partially actuated position.
[0033] FIG. 14 is a detail perspective view of the distal portion of the applier of FIG. 12 in a fully actuated position.
[0034] FIG. 15 is an end view of the anastomotic ring device of FIG. 12 after actuation, depicted as a single strand discontinuous weave with a pair of ball ends.
[0035] FIG. 16 is an end view of the anastomotic ring device of FIG. 12 after actuation, depicted as a dual strand discontinuous weave, each strand with a pair of ball ends.
[0036] FIG. 17 is a detail view of a ball end of the anastomotic ring device of FIG. 12 in atraumatic contact with a tissue wall.
[0037] FIG. 18 is a detail perspective view of the distal portion of the applier of FIG. 1 in an unactuated position holding an anastomotic ring device advantageously fabricated with a loop end discontinuous weave.
[0038] FIG. 19 is a detail perspective view of the distal portion of the applier of FIG. 18 in a partially actuated position.
[0039] FIG. 20 is a detail perspective view of the distal portion of the applier of FIG. 18 in a fully actuated position.
[0040] FIG. 21 is an end view of an anastomotic ring device after actuation, depicted as a dual strand discontinuous weave each strand with straight ends.
[0041] FIG. 22 is an end view of the anastomotic ring device of FIG. 18 after actuation, depicted as a dual strand discontinuous weave, each strand with a pair of loop ends.
[0042] FIG. 23 is a detail view of a loop end of the anastomotic ring device of FIG. 18 in atraumatic contact with a tissue wall.
[0043] FIG. 24 is a detail perspective view of the distal portion of the applier of FIG. 1 in an unactuated position holding an anastomotic ring device advantageously fabricated with a hook end discontinuous weave.
[0044] FIG. 25 is a detail perspective view of the distal portion of the applier of FIG. 24 in a partially actuated position.
[0045] FIG. 26 is a detail perspective view of the distal portion of the applier of FIG. 24 in a fully actuated position.
[0046] FIG. 27 is an end view of an anastomotic ring device after actuation, depicted as a dual strand discontinuous weave each strand with a pair of hook ends.
[0047] FIG. 28 is a detail view of a loop end of the anastomotic ring device of FIG. 24 in traumatic contact with a tissue wall.
[0048] FIG. 29 is a side view of an anastomotic ring device including a helical actuation coil and constrained within a sheath.
[0049] FIG. 30 is a perspective view of the anastomotic ring device of FIG. 30 in an actuated condition.
[0050] FIG. 31 is a side view of a generally known anastomotic ring having converging distal petals.
[0051] FIG. 32 is a detail view of the generally-known anastomotic ring of FIG. 31 .
[0052] FIG. 33 is a perspective view of an anastomotic ring device incorporating diverging petals.
[0053] FIG. 34 is a side detail view of the diverging petals of the anastomotic ring device of FIG. 33 .
[0054] FIG. 35 is side view of two arcuate members with a reduced radius point for an anastomotic ring device.
DETAILED DESCRIPTION OF THE INVENTION
[0055] Turning to the Drawings, wherein like numerals denote like components throughout the several views, FIG. 1 depicts an applier 10 that advantageously laparoscopically or endoscopically deploys and actuates an anastomotic ring device 12 from a generally cylindrical shape to one having properties of a hollow rivet, or ring, capable of forming an astomotic attachment at an anastomosis target site, such as in a bariatric gastric bypass of a morbidly obese patient 16 . In the illustrative version, the anastomotic ring device 12 comprises a shape memory effect (SME) material such as nitinol that further assists in actuation to an engaging hollow rivet shape. As will be described in greater detail below, various improvements to the configuration of the anastomotic ring device 12 simplify manufacturer as well as adding therapeutic features. Moreover, configuration improvements further assist in actuating the anastomotic ring device 12 without wholly relying upon SME properties of the anastomotic ring device 12 .
[0056] It will be appreciated that the terms “proximal” and “distal” are used herein with reference to a clinician gripping a handle of the applier 10 . It will be further appreciated that for convenience and clarity, spatial terms such as “right”, “left”, “vertical” and “horizontal” are used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and absolute. In addition, aspects of the invention have application to surgical procedures performed endoscopically and laparoscopically, as well as an open procedure. Use herein of one of these or similar terms should not be construed to limit the present invention for use in only one category of surgical procedure.
[heading-0057] Anastomotic Ring Device Applier.
[0058] In FIG. 2 , the applier 10 has the anastomotic ring device 12 advantageously retained in a generally cylindrical shape distal to an outer tube 18 upon a molded actuation member 20 forming a cannula 22 that distally terminates in a tapered tip 24 . This tapered tip 24 presents a distal piercing surface 26 to form an anastomotic opening 28 through apposite tissue walls 30 , 32 of two gastrointestinal passages. As discussed below, the tapered tip 24 may advantageously include illumination features that allow confirmation of placement and actuation of the anastomotic ring device 12 when viewed from a proximal direction through translucent tissue walls 30 , 32 .
[0059] With reference to FIGS. 2-5 , a handle 34 , proximal to the cannula 22 , includes a pair of longitudinally aligned triggers 36 , 38 . The proximal trigger 36 , shown at its most proximal, unfired position, is coupled to proximal leaves 40 of the molded actuation member 20 via an intermediate tube 42 of the cannula 22 . Distal movement of the proximal trigger 36 thus causes longitudinal distal movement of the intermediate tube 42 and proximal leaves 40 , which outwardly actuate like an umbrella by a hinged relationship to a central portion 44 of the molded actuation member 20 . Similarly, the distal trigger 28 , shown at its most distal, unfired position, is coupled to distal leaves 46 of the molded actuation member 20 via an internal rod 48 that is coupled for movement within the intermediate tube 42 . Proximal movement of the distal trigger 38 causes longitudinal proximal movement of the rod 48 and distal leaves 50 of the molded actuation member 20 , which outwardly actuate by a hinged relationship to the central portion 44 .
[0060] As best viewed in FIGS. 4-5 , within the handle 34 , a cavity 52 includes proximal and distal apertures 54 , 56 to allow the longitudinal movement of the proximal and distal triggers 36 , 38 respectively. Each trigger 36 , 38 includes a right opening aperture 58 that engage for longitudinal movement a leftward projecting track 60 formed within the cavity 52 of a right half shell of the handle 34 .
[0061] Moving from most distal to most proximal, a first, second and third lateral ridge 62 , 64 , 66 across the bottom of the cavity 52 define a first, second, third, and fourth cavity segment 68 , 70 , 72 , 74 respectively. A first block 76 , formed from left and right halves 78 , 80 is positioned for movement within the first cavity segment 68 . A longitudinal central hole 82 defined between the two halves 78 , 80 engages and moves with a terminating proximal end 84 of the intermediate tube 42 . The internal rod 48 passes on through the first block 76 into the second, third and fourth cavity segments 70 - 74 into sliding contact with a hole 86 passing through a proximal end 88 of the handle 34 . A second spacer block 90 locked within the second cavity segment 70 has a longitudinal central hole 92 defined between its left and right halves 94 , 95 that slidingly contacts and support the internal rod 48 . A third sliding block 96 has a longitudinal central hole 98 defined between its upper and lower halves 100 , 102 that engage and move with the internal rod 48 . A lower portion 104 of the distal trigger 38 is attached to a distal face of the third sliding block 96 . A fourth sliding block 106 within the fourth cavity segment 74 has a longitudinal central hole 108 that slidingly contacts the internal rod 48 . A lower portion 114 of the proximal trigger 36 is attached to a proximal face of the fourth sliding block 106 . A link 116 is attached to the left sides of the first and fourth sliding blocks 76 , 106 .
[0062] In FIG. 6 , the triggers 36 , 38 have been slid toward one another to actuate the molded actuating member 20 . Specifically, the distal trigger 38 has been moved proximally, moving the third sliding block 96 and internal rod 48 , the distal terminating end of the latter being attached to tapered tip 24 . The tapered tip thus moves toward the distal end of the intermediate tube 42 . The proximal trigger 36 has been moved distally, moving fourth sliding block 106 , link 116 , first sliding block 76 , and intermediate tube 42 also distally. The molded actuating member 20 is compressed between the inwardly moving tapered tip 24 and intermediate tube 42 . The distal leaves 50 actuate lateral to the longitudinal axis, and move toward and interdigitate with the proximal leaves 40 . This movement expedites actuating of an anastomotic ring device (not shown in FIG. 6 ).
[0063] In use, the tapered tip 24 of the applier 10 is inserted through a trocar port into a tissue passage that has been placed proximate to another tissue passage that are to be anastomotically joined (See FIGS. 1-2 ). The tapered tip 24 and a distal half of the molded actuating member 20 and anastomotic ring device 12 are inserted through an anastomotic opening 28 formed therebetween and then the applier is actuated, with a partially actuated applier 10 being depicted in FIGS. 7-8 . With particular reference to FIG. 8 , the proximal and distal leaves 40 , 50 are shown as having gripping slots 118 that grip respective petals 120 of the anastomotic ring device 12 , especially in its unactuated, generally cylindrical shape. An inwardly directed retention tip 121 or other gripping features in the gripping slots 118 may be incorporated to enhance retention. These gripping slots 118 assist in preventing the anastomotic ring device 12 from slipping off of the applier 10 or being inappropriately placed thereon for actuation. In FIGS. 9-10 , the applier 10 has been fully actuated, forming the anastomotic ring device 12 into a hollow rivet shape to form the anastomotic attachment between tissue walls 30 , 32 . The fully actuated proximal and distal leaves 40 , 50 cause the petals 120 to disengage from the gripping slots 118 . Thereafter, the applier 10 is returned to an unactuated condition and the actuated anastomotic ring device 12 deployed by withdrawing the tapered tip 24 from the anastomotic opening 28 and ring device 12 , as depicted in FIG. 11 .
[heading-0064] Deployment Illumination.
[0065] In FIGS. 7, 9 , a distal portion of the anastomotic ring device 12 are depicted in phantom to illustrate their actuated position. This phantom depiction is also suggestive of a clinical advantage of being able to view the deployment condition from a proximal point of view. Typically, an endoscope will view the anastomotic opening 28 from a proximal position. Returning to FIGS, 2 - 7 , adding a deployment illumination feature to the applier 10 provides this ability to view deployment through translucent tissue walls. Specifically, an illumination power source (e.g., battery) 150 and control (e.g., switch) 152 are incorporated into the handle 34 with a conductor, depicted as a twisted wire pair 154 passing through the internal rod 48 to the tapered tip 24 , which includes a proximally directed electroluminescence device 156 . Alternatively conductive ink traces may be applied longitudinally down portions of the applier 10 to provide an electrical circuit to the tapered tip 24 . An externally accessible push button 158 drives the power source 150 against the control 152 , creating an illumination circuit with the electroluminescence device 156 .
[0066] Alternatively or in addition, the molded actuating member 20 may be formed of a fluorescent or electroluminescent material that is either stimulated prior to insertion or receives light from a light source of the applier 10 .
[heading-0067] Discontinuous Weave Anastomotic Ring Device.
[0068] Forming an anastomotic ring device with a continuous wire loop poses a difficult manufacturing process that includes joining the ends of the woven wire strand or forming a weave from a continuous wire loop. In FIGS. 12-17 an advantageous approach to fabricating an anastomotic ring device 212 includes adding ball ends 214 to each wire strand 216 . In an illustrative embodiment, a hole is laser formed in each ball end 214 and then the ball end 214 is crimped onto the wire strand 216 . The ball ends 214 assist in preventing unraveling of petals 218 formed by the woven strands 216 . In addition, the ball ends 214 form an atraumatic contact with a tissue wall 220 , as depicted in FIG. 17 .
[0069] As an alternative discontinuous weave, an anastomotic ring device 312 in FIGS. 18-23 is formed by one or more wire strands 316 whose ends are not attached to one another but instead positioned within the confines of petals 318 of the anastomotic ring device 312 . Specifically, in FIG. 21 , each strand 316 terminates in a generally straight end 322 . In FIGS. 18-20 , 22 - 23 , each strand terminates in a loop end 324 . In each instance, positioning each end 322 , 324 within petals 318 of the anastomotic ring device 312 avoids interference with an applier while also simplifying manufacturer.
[0070] As yet a further alternative discontinuous weave, an anastomotic ring device 412 in FIGS. 24-28 is formed by one or more wire strands 416 whose ends are not attached to one another but instead are positioned outside of petals 418 of the woven strands 416 . In a depicted version, each strand 416 traumatically engages a tissue wall 420 with hook ends 426 interdigitated between the petals 416 .
[heading-0071] Spring Closed Ring Anastomotic Device.
[0072] In FIGS. 29-30 , an anastomotic ring device 512 includes a helical wire assist spring 530 fabricated from an SME material (e.g., nitinol) or from spring steel. Thus, the woven material of a stent portion 532 of the anastomotic ring device 512 need not be of an SME material, or at least need not rely entirely upon its SME properties to effect actuation. The helical wire assist spring 530 enables selection of a stent portion 532 of a desired wire thickness and of a desired material. For instance, the stent portion 532 may even be of plastic or longitudinally cut discrete sections of a continuously woven wire braid that provide no inherent actuating capability.
[0073] In FIG. 29 , the wire assisted anastomotic ring device 512 is depicted in a generally cylindrical shape constrained by a lumen 534 , which may be an applier. It will be appreciated that the wire assisted anastomotic ring device 512 may advantageously be implanted by use of the applier 10 described above, which would advantageously affirmatively grip the wire assisted anastomotic ring device to hold it in the stressed, unactuated position prior to implantation.
[heading-0074] Deflected Petal Anastomotic Ring Device.
[0075] The generally-known nitinol ring device 600 includes converging looped petals 602 whose distal end flare lateral to the longitudinal axis when viewed in their stressed, generally cylindrical state, and interdigitate when viewed in their relaxed, actuated state, as depicted in FIGS. 31-32 . It is believed that such deflected petals 602 engage the tissue walls in a beneficial fashion. However, the resulting increase in outward slope of each petal 602 imposes an increasing amount of friction to self-actuation of the generally-known nitinol ring device 600 , negating any advantage of engagement, requiring more force to self-deploy generally-known nitinol ring device 600 .
[0076] As generally-known nitinol ring device 600 deploys, portions of wire forming generally-known nitinol ring device 600 move relative to each other while in contact. The curvature of the wire winding of generally-known nitinol ring device 600 forms local maxima and minima for a contacting wire to traverse. The converging looped petals cause a local minimum for a contacting wire portion that the contacting wire portion must overcome. An increasing force gradient opposing deployment occurs, and must be overcome by the internal stored energy of the generally-known nitinol ring device 600 to complete deployment.
[0077] In FIGS. 33-34 , an anastomotic ring device 712 advantageously includes distal looped petals 714 that are divergent (flared away) from each other when the ring device 712 is in its relaxed, hollow rivet (ring) shape as depicted. It is further believed that deflecting the distal portions of each petal 714 away from the tissue walls may decrease excessive pressure at the anastomotic attachment site without significant degradation to its required amount of attachment forces. Moreover, for anastomotic ring devices 712 that are not formed of an absorbable material, this configuration may advantageously later more readily detach after the anastomotic attachment is permanently formed between tissue walls.
[0078] Anastomotic ring device 712 , with divergent (flared away) petals, will a cause a maximum in force tending to urge the anastomotic ring device 712 towards the actuated ring state.
[0079] With reference to FIG. 35 , an anastomotic ring device 812 includes petals 814 whose distal portion 816 is formed with a small radius relative to its more proximal portions 818 that overlap each other and slide across each other during actuation. As depicted, straight portions 820 between the distal and proximal portions 816 , 818 may be shaped such that in the stressed, cylindrical shape of the ring device 812 that the petals 814 are urged toward the actuated ring state.
[0080] It should be appreciated that the divergent position of the petals may further be enhanced by SME treatment of these distal portions wherein the stressed, generally cylindrical state of the ring device 814 may include a straight petal or even a converging petal for purposes such as enhancing user of an applier 10 and/or achieving a good anastomotic attachment immediately upon actuation with an eventual steady-state actuation position being as depicted.
[0081] While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications may readily appear to those skilled in the art.
[0082] For example, although bariatric procedures for bypassing portions of a gastrointestinal tract are depicted, it should be appreciated that other surgical procedures may benefit by an anastomotic ring device having aspects described herein.
[0083] For another example, although an applier 10 has been advantageously depicted that assists in actuating the anastomotic ring device 10 , it should be appreciated that the anastomotic ring device 10 includes enhanced reliability and performance in self-actuating and thus may be inserted by other means, to include insertion through the opening and released without the application of an external actuating force.
[0084] For yet a further example, various improvements disclosed herein may be used in various combinations. | An anastomotic ring device for forming a hollow rivet (ring) attachment between tissue lumens facilitates laparoscopic or endoscopic implantation by including features that facilitate actuation from a stressed, generally cylindrical shape. Economical manufacturer is achieved by weaving open ended strands into a generally cylindrical stent shape that is imparted with a Shape Memory Effect (SME) to actuate to a hollow rivet (ring) shape. Alternatively or in addition to SME inherent in the woven strands, an actuating force may be received from a helical spring element incorporated into the ring. Self-actuating ring devices are enhanced by forming woven strands into petals that diverge from opposing petals such that the strands encounter less friction when actuating. Each of these features alone or in combination enhance clinical use of anastomotic ring devices, such as a bariatric gastric bypass procedure. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional application of application Ser. No. 10/808,506, filed Mar. 25, 2004 (now U.S. Pat. No. 7,200,916), which is a divisional application of application Ser. No. 10/428,834 filed May 5, 2003 (now U.S. Pat. No. 6,989,186), which is in turn a continuation-in-part of application Ser. No. 10/180,102, filed Jun. 27, 2002 (now U.S. Pat. No. 6,647,610), the entire content of each being hereby incorporated by reference in this application.
FIELD OF THE INVENTION
The present invention relates generally to the field of upholstery fabric tack strips and methods of making the same, especially tack strips that are used to attach upholstery fabric to an underlying furniture frame member.
BACKGROUND AND SUMMARY OF THE INVENTION
Conventional upholstery tack strips are made from flat metal (e.g., metal) ribbons by a punch-press operation. Specifically, generally triangularly-shaped nails are formed by punching out correspondingly shaped, partially cut-out sections from the metal ribbon at spaced-apart locations along the ribbon's length and then bending the sections so each is at substantially a right angle relative to the ribbon stock. Thus, the nails remain unitarily attached to the metal ribbon, but project outwardly therefrom.
In use, the metal from which conventional tack strips are made can physically mar and/or abrade the upholstery fabric. For example, the ribbon, if formed from metal, may rust over time which might in turn visibly discolor the fabric. Furthermore, the edges of the metal tack strip may abrade or cut the upholstery fabric. In order to prevent such problems, it has been conventional practice to provide upholstery tack strips with a separate C-shaped plastic sleeve which slides over the tack strip along its length. The plastic sleeve, however, is itself problematic in that it involves a separate manufacturing step to slideably mate it with the tack strip. Furthermore, unless some means are provided to restrict relative lengthwise movement between the metal tack strip and the sleeve, the latter can become separated from the former during use and/or installation.
In our recently issued U.S. Pat. No. 6,537,646 B2 (the entire content of which is expressly incorporated hereinto by reference), novel upholstery tack strips are provided which include a thermoplastic sleeve and a metal ribbon embedded within the sleeve. The sleeve itself includes a plurality of removed material sections forming opposed pairs of sleeve windows, while the metal ribbon integrally includes nail sections which protrude outwardly from the tack strip through respective ones of the sleeve windows. Most preferably, the sleeve is extrusion-coated onto the metal ribbon stock using a cross-head die with a screw extruder. The thus-coated metal strip preform may then be transferred to downstream fabrication operations whereby the sleeve windows and nail portions are formed. Since the nail portions protrude outwardly from the tack strip through the sleeve windows, relative lengthwise slippage between the metal ribbon stock and the sleeve is prevented.
The present invention is directed specifically toward improvements to the upholstery tack strips of the type generally disclosed in our above-cited U.S. Pat. No. 6,537,646 B2. More specifically, according to the present invention upholstery tack strips include a metal ribbon and a thermoplastic sleeve covering at least a portion of the ribbon. The sleeve includes at least one lengthwise removed strip section so as to expose a corresponding lengthwise surface of the metal ribbon. Most preferably, at least one (and advantageously both) edges of the metal ribbon are knurled or serrated so as to present a roughened surface to the sleeve and thereby anchor the metal ribbon to the sleeve and thereby assist in maintaining the relative positioning of the sleeve and metal ribbon. An adhesive may optionally alternatively or additionally be applied to the metal ribbon so as to also assist in anchoring the thermoplastic sleeve thereto. The metal ribbon integrally includes nail sections which protrude outwardly from said tack strip.
These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Reference will hereinafter be made to the accompanying drawings, wherein like reference numerals throughout the various FIGURES denote like structural elements, and wherein;
FIG. 1 is a schematic view showing a possible manufacturing sequence in accordance with the present invention;
FIG. 2 is a top perspective view showing a representative length of an upholstery tack strip in accordance with the present invention; and
FIG. 3 is a bottom perspective view showing a representative length of an upholstery tack strip in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Accompanying FIG. 1 depicts one possible manufacturing sequence for making the upholstery tack strip of the present invention. In this regard, a roll of metal strip or ribbon stock 10 may be fed to and through the cross-head die 12 a associated with screw extruder 12 . Prior to being fed through the cross-head die 12 a , however, the ribbon 10 is preferably pulled through a knurling tool 12 b which may include, for example, a pair of opposed knurled rollers acting on at least one, and preferably both, of the lateral edges of the metal ribbon 10 so as to knurl the same as shown by reference numeral 10 a in FIGS. 2-3 below. In this manner, the knurled edges 10 a present a roughened surface to the thermoplastic sleeve applied via the cross-head die 12 a so as to assist in anchoring the ribbon 10 thereto. The ribbon 10 may optionally alternatively or additionally be pulled through an adhesive applicator 12 c which serves to apply an adhesive material onto the ribbon 10 and thereby assist in anchoring the thermoplastic sleeve thereto which will be applied via the cross-head die 12 a.
As is well known, thermoplastic pellets may be fed into the hopper (not shown) of the screw extruder 12 . The extruder 12 thus forms a molten stream of the thermoplastic material which is fed into the cross-head die 12 a and applies a coating over the entire surfaces of metal ribbon 10 . The coated ribbon (now designated by numeral 13 in FIG. 1 ) then enters a water quench bath 14 . Upon cooling, therefore, the thermoplastic material is thereby coated onto the metal ribbon stock 12 so as to form a composite strip preform 16 . Specifically, the preform 16 includes a core of the metal ribbon stock 10 which is embedded within, and thus coated entirely by, a sleeve formed of solidified thermoplastic material (i.e., the solidified residue of the thermoplastic material applied in its molten state by the cross-head die 12 a ).
Virtually any thermoplastic material may be employed in accordance with the present invention. Preferred thermoplastic materials include polyolefins (e.g., polyethylene and polypropylene), nylons, polyesters, polyvinyl chlorides and the like.
The composite strip preform 16 passes through an air dryer 18 which serves to remove water from the surface of the perform 16 prior to being directed to a cutter 20 a . The perform is pulled from the roll of stock 10 through the cross-head die 12 a , quench bath 14 air dryer 18 and cutter 20 a via an opposed set of pull rolls 22 - 1 , 22 - 2 . The cutter 20 a serves to cut a substantially centrally located longitudinally oriented strip section 16 a of the thermoplastic coating, which strip 16 a is then removed from the upper and lower surfaces, respectively, of the metal stock 10 via roller pairs 24 a . The removed thermoplastic strip 16 a is then collected in waste bin 26 a for recycling to the extruder 12 where it can be re-melted and combined with virgin thermoplastic material so as to coat the stock 10 in the cross-head die as was explained previously.
Optionally, a cutter 20 b , rollers 24 b and waste bin 26 b may be provided so as to remove a strip 16 b from the opposite surface of the composite strip 16 . If such a strip 16 b is removed, then a pair of longitudinally extending exposed surface regions of the metal ribbon 10 will result. That is, with removal of both strips 16 a , 16 b , only the side edge regions of the stock 10 will be covered with the thermoplastic material forming generally U-shaped edge protectors. Most preferably, however, as shown in FIGS. 2 and 3 , only the bottom strip 16 a is removed thereby exposing a lengthwise extending section 10 b of the lower surface of the metal strip 10 (see FIG. 3 ).
The edge-coated perform (now designated by reference numeral 16 - 1 in FIG. 1 ) may subsequently be formed into a roll 30 and then used as a feed for a coining/punching operation 32 as shown in FIG. 1 . Alternatively, the composite strip preform 16 may be fed continuously from the cross-head die 12 a , through the cutter 20 a and then to the coining/punching operation 32 .
During the coining/punching operation 32 , nail-forming punch dies are brought to bear directly against the upper and lower surfaces metal strip 10 . Thus, as with conventional tack strips, therefore, the coining/punching operation 32 serves to punch out generally triangularly shaped nails 10 - 1 from the metal ribbon 10 and bend them at substantially right angles thereto as shown in accompanying FIGS. 2 and 3 . The finished tack strip TS in accordance with the present invention may then be cut into desired lengths (e.g., from about 3 inches in length up to about 48 inches in length), packaged and shipped in operation 36 as shown in FIG. 1 .
As can be appreciated, removal of the strip 16 a will form a pair of opposed edge protectors 16 c , 16 d as an integral extruded member which covers the lateral edges of the metal ribbon stock 10 . That is, the removal of the strip 16 a to expose the lower surface of ribbon 10 will provide the generally U-shaped edge protectors 16 c , 16 d which are joined integrally one to another along the upper surface of the ribbon 10 . As such, the sleeve and the edge protectors 16 c , 16 d do not need to be installed during a separate operation. As noted previously, the knurled edges 10 a of the ribbon 10 present a roughed surface to the edge protectors 16 c , 16 d thereby anchoring the ribbon 10 thereto. However, if desired, an adhesive may be alternatively or additionally be applied to the edges 10 a of the ribbon stock 10 prior to being drawn through the cross-head die 12 a so that the resulting edge protectors 16 c , 16 d remain physically in place during handling. Also, in the embodiment depicted in FIGS. 2 and 3 wherein only strip 16 a is removed, there will also exist generally triangular sleeve remnants 16 - 2 integrally attached at their bases to the sleeve. Such remnants 16 - 2 will thus extend downwardly through the hole remaining in the ribbon 10 by virtue of the nails 10 - 1 being formed in the coining/punching operation 32 and thereby also assist to minimize lateral slippage of the sleeve relative to the ribbon 10 .
Thus, while the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | An upholstery tack strip includes a metal ribbon and a thermoplastic sleeve covering at least a portion of the ribbon. The sleeve includes at least one, and possibly a pair of, lengthwise removed strip section(s) so as to expose a corresponding lengthwise surface of the metal ribbon. The metal ribbon integrally includes nail sections which protrude outwardly from said tack strip. At least one, and preferably both, lateral edges of the metal ribbon are knurled or serrated so as to assist in anchoring the ribbon to the sleeve. | 8 |
FIELD OF ACTIVITY
[0001] Disclosed embodiments relate to an advanced cavity structure for optically sensitive devices in wafer level chip scale package and methods of manufacturing thereof.
BACKGROUND OF THE INVENTION
[0002] Optically sensitive devices such as image sensor and light detection integrated circuits play an important role in capturing color, image, and signal in optical electronic devices. These integrated circuits have been found in consumer electronics products and portable devices such as digital cameras, digital camcorders, and cellular phones.
[0003] One of the ways of packaging image sensor and light detection integrated circuits involves laminating silicon wafer between two glass substrates and completely encapsulating it with optical epoxy, whereby electrical contacts can be routed to the back of the silicon wafer, leaving the optically sensitive device exposed for light or image sensing applications via one of the glass substrates. The optical epoxy can, however, scatter and absorb the incident light, consequently leading to decayed and decreased optical sensitivity.
SUMMARY OF THE INVENTION
[0004] The present invention provides an advanced cavity structure for optically sensitive devices in wafer level chip scale packages. The optically sensitive devices comprise of image sensor or light detection integrated circuits formed on a substrate. In one embodiment, bleached cavity walls are formed about the image sensor or light detection integrated circuits. In this embodiment, the bleached cavity walls are substantially absorptive of incident light.
[0005] In yet a further embodiment, a transparent layer is formed on the bleached cavity walls and above the image sensor or light detection integrated circuits thereby defining open chambers between the transparent layer, the bleached cavity walls, and the image sensor or light detection integrated circuits. In this embodiment, the open chambers may be evacuated or gaseous thereby permitting the image sensor or light detection integrated circuits to receive or manipulate signals, whether image or light, via the transparent layer through the open chamber without decreasing or decaying the optical sensitivity of the incident light.
[0006] In yet another embodiment, at least one image sensor or light detection integrated circuit, at least one transparent layer, and at least one open chamber can be individually separated from at least one image sensor or light detection integrated circuits, at least one transparent layer, and at least one open chamber to comprise the wafer level chip scale package.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] (1) FIG. 1 is the cross-sectional view of a color filter integrated circuit on a substrate;
[0008] (2) FIGS. 2A-2C illustrate the steps of a conventional lithographic fabrication process with positive photoresist;
[0009] (3) FIGS. 3A-3C illustrate the steps of a conventional lithographic fabrication process with negative photoresist;
[0010] (4) FIG. 4 is an exemplary depiction of the color filter of FIG. 1 after the formation of cavity walls with bleached negative photoresist;
[0011] (5) FIG. 5A is an exemplary planar view of a color filter device before the formation of cavity walls with bleached negative photoresist;
[0012] (6) FIG. 5B is an exemplary planar view of a color filter device after the formation of cavity walls with bleached negative photoresist;
[0013] (7) FIG. 6 illustrates the wafer level chip scale packaging of integrated circuits with bleached cavity walls on substrate mounting onto transparent layer; and
[0014] (8) FIG. 7 is the cross-sectional view of a completed wafer level chip scale package.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0015] Initial reference is made to a schematic cross-sectional view of a color filter integrated circuit 102 on substrate 104 as illustrated in FIG. 1 . The color filters may comprise of primary colors such as red, blue, and green (R/G/B color filters) or complementary colors such as cyan, magenta, and yellow (C/M/Y color filters). In addition to color filters 102 , optically active complementary metal oxide semiconductor (CMOS) image sensors may also be formed on the substrate. Furthermore, although monocrystalline silicon of either N-type or P-type doping is typically the substrate of choice 104 , these integrated circuits may also be formed on, for example, gallium arsenide (GaAs) or indium phosphide (InP) substrates. A photoactive region 142 is formed on substrate 104 comprising at least in part of complementary P+ or N+ doping. The photoactive regions 142 comprise photosensitive photodiodes employed within devices including but not limited to charge coupled devices (CCD), charge injection devices (CID), and optically active CMOS devices. Other active semiconductor devices may also be used in place of the photodiodes 142 .
[0016] Subsequently, a patterned conductor pixel layer 144 is formed inside the color filter integrated circuit 102 . The conductor pixel layer 144 serves as the first directional charge collection array in receiving the incoming signal. These signals may consist of images or light photons. The conductor pixel layer 144 , consequently, stores the incoming signal by converting the images or light photons into electrical energy. Along with the conductor pixel layer 144 , bond pads 146 and scribe lines 148 are also formed for ease of packaging the die on a circuit board. Electrical signals are routed from the color filter integrated circuit 102 out to the bond pads 146 , while scribe lines 148 facilitate the separation of color filter integrated circuits 102 into individual devices. The first planarizing layer 150 , transparent to electromagnetic spectrum radiation, is then formed using known fabrication techniques. The planarizing layer 150 planarizes or smoothes the topography of the color filter integrated circuit, thereby making subsequent fabrication steps easier.
[0017] A layer of color filters 152 , separated by spacers 154 , are subsequently formed. The color filters 152 and spacers 154 are arranged in unique patterns to form color filter arrays 155 having desired sensitivity and performance characteristics. In addition to separating the color filters 152 , the spacers 154 also prevent scattering and reflections between neighboring color filter arrays 155 . Further to this isolation, each color filter 152 may be constructed such that a single color is assigned to each pixel and that each pixel responds to only one color wavelength. A second planarizing layer 156 , similar to the first planarizing layer, is subsequently formed, also serving to planarize the existing circuit topography and facilitate further processing of the circuits. Microlenses 158 are then formed on top of the color filters 152 employing methods and materials as are conventional in the art of integrated circuit fabrication to enhance optical sensitivity and provide optical flexibility as described in any of the following U.S. Pat. Nos. 6,531,266; 6,274,917; 6,242,277 and 6,171,885.
[0018] The formation of cavity walls for wafer level chip scale package is subsequently illustrated in FIGS. 2A-2C , FIGS. 3A-3C and FIG. 4 . As shown in FIG. 2A , the color filter integrated circuit 102 on substrate 104 is coated with a positive photoresist 170 . A photoresist is a light-sensitive chemical that is applied to the wafer utilizing a track coater spinning at high speeds. The spin speed determines the thickness of the photoresist with thicker films at low speeds and thinner films at high speeds. The positive designation indicates the tone of the photoresist and its sensitivity to light and susceptibility to being chemically washed away. The positive photoresist 170 coats about 8 to 30 microns using known integrated circuit fabrication techniques.
[0019] FIG. 2B illustrates the formation of a positive photoresist and its subsequent exposure to a light source 174 through a photomask 172 in order to harden the photoresist into a desired pattern. Typical exposures take place on a stepper or scanner and can last several seconds. The transparent parts of the photomask 172 are typically composed substantially of a quartz material that permits the light to pass through the photomask and onto the positive photoresist 170 while other areas of the photomask 172 comprise opaque chrome, which blocks the positive photoresist 170 from being exposed to the light source 174 . The portion of the positive photoresist 170 , which is not exposed to the light source 174 , exhibits no effect, while the area that is exposed to the light source 174 , subsequently undergoes a chemical reaction making it soluble in the presence of a tetra-methyl ammonium hydroxide (TMAH) base developer, a liquid chemical used for developing or dissolving photoresists.
[0020] FIG. 2C shows a cross-sectional view of the color filter integrated circuit 102 after developing or washing substrate 104 with TMAH base developer, whereby only the unexposed positive photoresist 176 remain while the area that was exposed to the light source 174 were developed or dissolved employing conventional integrated circuit fabrication techniques.
[0021] The positive photoresist pattern 176 creates a template for the subsequent formation of cavity walls as illustrated in FIGS. 3A-3C . As shown in FIG. 3A , the color filter integrated circuit 102 on substrate 104 with the remaining positive photoresist 176 is subsequently coated with a negative photoresist 190 . A negative photoresist is similar to a positive photoresist in all aspects with the exception that a negative photoresist will not be chemically washed away following an exposure to the light source. The negative photoresist 190 undergoes an exposure to a light source 194 through a photomask 192 as illustrated in FIG. 3B . Upon exposure to the light source 194 , a negative photoresist 190 will cross-link and harden, thereby preventing the exposed areas from being dissolved by the TMAH developer. Consequently, FIG. 3C shows a cross-sectional view of the color filter integrated circuit 102 after developing with TMAH developer. The negative photoresist 196 that was exposed to the light source 194 cross-linked and hardened, while the negative photoresist 196 that was not exposed to the light source 194 was developed or dissolved away with TMAH developer.
[0022] To produce the cavity walls 198 as illustrated in FIG. 4 , the substrate 104 with the remaining (positive and negative) photoresists as shown in FIG. 3C , is then subjected to a blanket or flood exposure with an external ultraviolet (UV) light source 199 . A blanket or flood exposure with an external UV light source 199 , also known as bleaching, exposes all of the color filter integrated circuits 102 on substrate 104 to the UV light source 199 . Upon exposure to the UV light source 199 , the remaining positive photoresist 176 undergoes a chemical reaction and becomes soluble to TMAH developer. The remaining negative photoresist 196 , however, exhibits the opposite trend and is further hardened or cross-linked by the exposure to the UV light source 199 . Consequently, FIG. 4 shows the cross-sectional view of the color filter integrated circuits 102 on substrate 104 along with the bleached negative photoresist cavity walls 198 after subsequent exposure and developing steps. Like with negative photoresist, however, other photo-sensitive polymeric materials such as positive photoresist and benzocyclobutene (BCB) may also be bleached to transform them into absorptive cavity walls 198 with low transmittance values. Furthermore, anti-reflective dielectric materials such as silicon nitride, silicon oxide, and silicon-oxynitride may also be tweaked into highly absorptive cavity walls 198 for the purposes of this invention.
[0023] FIG. 5A illustrates the planar view of a traditional color filter device prior to packaging where the arrays 155 of color filter integrated circuits 102 are clearly arranged by pixels along with spacers 154 , bond pads 146 , and scribe lines 148 . After the formation of the cavity walls 198 with the bleached negative photoresist 198 as shown in FIG. 5B , the spacers 154 and the bond pads 146 are no longer visible. The arrays 155 of color filter integrated circuits 102 on substrate 104 is subsequently surrounded and enclosed by the cavity walls 198 , thereby making the color filter device readily available for packaging onto a transparent layer 200 , such as glass-like materials including glass, sapphire, and quartz, as well as crystalline materials such as lithium niobate and lithium tantalate, as illustrated in FIG. 6 .
[0024] FIG. 7 illustrates a cross-sectional view of a wafer level chip scale package structure formed using the techniques described in this application. As shown in FIG. 7 , the image sensor or light detection integrated circuit 102 on substrate 104 can now be mounted to the transparent layer 200 via the bleached cavity walls 198 . As a result, an evacuated or gaseous chamber 202 is created between the substrate 104 and the transparent layer 200 . The chamber 202 , as formed and structured here, unlike when it passes through optical epoxy, will not decay or decrease the optical sensitivity of the image sensor or light detection integrated circuit 102 to the incident light 203 coming through the transparent layer 200 and onto the circuit 102 . Depending on the method and technique of packaging, the evacuated or gaseous chamber 202 may comprise of vacuum, oxygen gas, neon gas, argon gas, helium gas, nitrogen gas, air, or mixtures thereof.
[0025] Furthermore, any scattered incident light 203 will be absorbed 204 by the bleached cavity walls 198 , thereby further improving the sensitivity and performance of the device. In addition, the disclosed embodiments allow for wafer level testing of these optically sensitive devices, wafer level packaging, and can result in reduced cost and improved performance of producing wafer level chip scale packages as compared to conventional packaging techniques.
[0026] It will be appreciated by those of ordinary skill in the art that the invention can be embodied in other specific forms without departing from the spirit or essential character thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than the foregoing description, and all changes that come within the meaning and ranges of equivalents thereof are intended to be embraced therein.
[0027] Additionally, the section headings herein are provided for consistency with the suggestions under 37 C.F.R. § 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” the claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Summary of the Invention” to be considered as a characterization of the invention(s) set forth in the claims found herein. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty claimed in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims associated with this disclosure, and the claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of the specification, but should not be constrained by the headings set forth herein. | The present invention provides an advanced cavity structure for optically sensitive devices in wafer level chip scale package and methods of manufacturing thereof. Image sensor or light detection integrated circuits are formed on substrate. Substantially absorptive bleached cavity walls are formed about the image sensor or light detection integrated circuits. Upon attaching a transparent layer to the bleached cavity walls and above the image sensor or light detection integrated circuits, open chambers are formed thereby permitting the image sensor or light detection integrated circuits to receive and manipulate signals without decreasing or decaying the optical sensitivity of the incident light. Furthermore, individual image sensor or light detection integrated circuits may be separated from each other to comprise wafer level chip scale packages of at least one image sensor or light detection integrated circuits, at least one transparent layer, and at least one open chamber. | 7 |
BACKGROUND OF THE PRESENT INVENTION
This invention relates to methods and apparatus for making gloves. More particularly, it relates to a method of and apparatus for turning stitched leather gloves from their inside out condition in which they are stitched, to their finished condition, and for flattening the stitched seams of the gloves which are consequently disposed inside the fingers of the finished glove.
Gloves of leather and similar pre-formed materials are made by stitching together pre-cut pieces of the material. Since it is desirable that in the finished glove the stitched seams should be out of the way and not visible, for functional and/or aesthetic reasons, a leather glove is stitched together inside out, with the seams projecting outwardly, and then reversed so that the seams will be disposed inside the finished glove. In order that the glove may be worn comfortably, the seams inside the fingers of the gloves should not project inwardly to any great extent. It is therefore necessary to flatten the stitched seams. This is normally done after the glove is turned from its inside out condition, and is referred to in the art as blocking the glove.
Thus after a leather glove has been stitched together, there are the turning and blocking operations to be performed, before the glove is finished. Due to the relatively complex structure of a glove, with its finger, hand and cuff parts of different shapes, the turning and blocking operations do not readily lend themselves to performance by mechanical means in a simple, rapid and effective manner.
BRIEF DESCRIPTION OF THE PRIOR ART
It has previously been proposed to turn a stitched leather glove from inside out condition to right side out condition by mounting the inside out glove on an apparatus comprising tubular finger members which extend inside the glove fingers. Then rods or plungers are pushed down inside the tubes to reverse the fingers of the glove so that the fingers of the glove lie between the inside of the tubular finger members and the outside of the plungers, in their right side out condition. The cuff portion of the glove is gripped by hand or clamping means, and drawn upwardly over the tubular finger members so as to complete the turning of the glove. Examples of this type of glove turning apparatus are described in U.S. Pat. No. 3,738,547, Horton, U.S. Pat. No. 2,540,503, Becker, U.S. Pat. Nos. 2,286,057 and 2,286,058, Brownstein, U.S. Pat. No. 2,434,816, Suftko, U.S. Pat. No. 2,510,341, Keller and U.S. Pat. No. 978,434, Crosby.
In such glove turning processes and apparatus, however, considerable amounts of force have to be exerted to turn the fingers of the glove. This entails a substantial risk that the glove will be torn or otherwise damaged during the turning operation. Further, blocking of the glove is effected as a separate operation, either using separate apparatus, or using apparatus constituting a separate and distinct stage of a combined turning and blocking apparatus. Blocking of a leather glove is accomplished by applying heat to the seam in a forcibly flattened condition, substantially equivalent to ironing of textiles. Blocking is a time consuming process. In such prior art processes, the glove has to be held in the seam flattened condition at a temperature of about 300° F for a period of about 2 minutes, to accomplish the necessary blocking. This is a limitation in the production capacity of conventional leather glove making processes.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved process and apparatus for turning and blocking gloves of leather and the like materials.
A further object of the invention is to provide a glove finishing process in which turning and blocking of the glove is accomplished substantially simultaneously, as a single operation.
A further object of the invention is to provide a novel apparatus which will perform substantially simultaneous turning and blocking of leather and the like gloves.
Briefly stated, the objects of the present invention are accomplished by a process in which a stitched leather glove is initially mounted with at least one finger thereof, in an inside out condition, over a relatively small diameter finger mounting member, and then the glove finger is turned to right side out by rolling the glove finger onto the exterior surface of a relatively larger diameter finger receiving mandrel. Preferably there is substantially simultaneous application of heat to the glove finger, as it is turned. The turning of the glove by this process causes the necessary pressing under heat of the glove seams to effect blocking of the glove as it is turned.
Apparatus for turning and blocking gloves according to the present invention comprises:
at least one finger mounting member of relatively small diameter adapted to be received inside a finger of a stitched inside out glove mounted thereon;
at least one finger receiving mandrel of relatively larger diameter adapted to be arranged in substantial longitudinal alignment with said at least one finger mounting member;
means for engaging a glove mounted on said at least one finger mounting member and transferring said glove finger by rolling it onto the outer surface of said at least one finger receiving mandrel.
A preferred apparatus according to the present invention comprises four finger mounting members and four finger receiving mandrels adapted to be arranged in substantial alignment therewith, with means for heating each mandrel. Such an apparatus simultaneously turns and blocks the four fingers of a glove which can be arranged to extend substantially parallel to one another from the hand portion of the glove. A further apparatus according to the invention comprises a single finger mounting member and a single finger receiving mandrel adapted to be arranged in substantial alignment therewith. Such apparatus can be used to turn and block simultaneously the thumb or an individual finger of a glove.
It has been found that, when a glove is turned by the process or using the apparatus of the present invention, there is exerted sufficient stretching and pressing of the stitched seams to effect blocking of the glove as it is turned. The blocking is achieved by the stretching of the glove finger as it is rolled or turned onto a larger diameter mandrel, and by the application of heat while it is in its thus stretched condition. The heat is best supplied by heating the larger diameter finger receiving mandrel, with which the glove finger and its seams come into intimate contact in the stretched condition. It has been found that about 75% of the desired blocking can be accomplished by the actual turning of the glove in accordance with the process of the invention. The remainder of the blocking is accomplished by retaining the glove on the larger heated finger receiving mandrel, for a brief period.
The prior art arrangements are unable to achieve this simultaneous blocking and turning, since they turn a glove finger from the outside of a relatively larger diameter tube onto a relatively smaller diameter rod or plunger inserted down the inside of the tube. Such turning action is accompanied by a general compression of the glove finger, not a stretching, and such compression is incompatible with blocking the glove finger at the same time. The subsequent step of blocking the glove which is required is not only more time consuming because it is a separate stage of the entire process, but is a more time consuming operation in itself. The combined blocking and turning operation according to the present invention can be accomplished in about 10-15 seconds in practice, whereas conventional separate blocking operations normally take of the order of 2 minutes to complete.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The finger mounting members of smaller diameter are preferably rods, and the finger receiving mandrels are preferably hollow or tubular, and arranged to be movable so that the finger receiving mandrels will snugly surround the finger mounting members and the glove fingers mounted thereon. The means for engaging the glove is suitably an expandable and retractable wrist clamp, arranged to move longitudinally with respect to the finger receiving mandrels and to surround them. The wrist clamp is expanded to engage the inside of the cuff or wrist portion of the glove. It is then moved longitudinally of the finger receiving mandrels to draw the cuff and hand parts of the glove over the finger receiving mandrels and turn them right side out as it does so. As its travel continues, the wrist clamp turns the fingers of the glove by rolling them from their initial inside out engagement with the finger mounting members into their right side out engagement with the outside of the heated finger receiving mandrels. This rolling and turning of the fingers is accompanied by stretching as previously described. At the end of its travel, when the glove has been fully turned and is clear of the finger mounting members, the wrist clamp releases the glove.
It is preferred to provide a means for reducing the frictional forces experienced by the glove fingers during turning. If the turning is effected merely by the action of the moving wrist clamp pulling the finger portions of the glove against the edge of the finger receiving mandrels, large frictional forces will be experienced by the finger portions during turning. Particularly where the apparatus is operated at high speed, there is significant risk that these forces will be great enough to damage the gloves. Accordingly, the preferred apparatus of the invention includes means for reducing these frictional forces.
The preferred such means is a retractable member located inside the tubular finger receiving mandrel. The retractable member is urged outwardly, i.e. towards the finger mounting member. The retractable member is adapted to engage the end of the glove finger on the finger mounting member, when the finger receiving mandrel is moved to surround the glove finger. When the wrist clamp starts to turn the finger portions of the glove by pulling thereon, it is assisted by the outward thrust exerted by the retractable member on the end of the finger portion. This materially reduces the friction experienced by the finger portion as it turns around the end of the tubular mandrel. Further reductions in this friction are preferably accomplished, by providing the end portion of the tubular mandrel with a low friction surface (e.g. a TEFLON coating), and by arranging for a jet of air to be directed at the area of contact between the glove finger and the end of the tubular mandrel as turning of the finger proceeds.
The mandrels onto which the finger portions of the glove are turned determine in large part the size of the finished glove fingers. So that the apparatus may be used to produce gloves of different sizes, therefore, it is convenient to make the mandrels removable and replaceable with similar mandrels but of different sizes.
BRIEF DESCRIPTION OF THE DRAWINGS
A specific and preferred embodiment of an apparatus and process according to the present invention is illustrated in the accompanying drawings, in which:
FIG. 1 is a diagrammatic cross section of a finger of an unfinished leather glove, after it has been stitched together but before turning from the inside out to the right side out condition;
FIG. 2 is a diagrammatic cross section of the glove finger of FIG. 1, after turning but prior to blocking;
FIG. 3 is a diagrammatic cross section of the glove finger of FIG. 2 after blocking;
FIG. 4 is a somewhat diagrammatic front view of a glove turning and blocking apparatus according to the invention;
FIG. 5 is a longitudinal cross sectional view of a detail of the apparatus of FIG. 4;
FIG. 6 is a front view of a portion of the apparatus of FIG. 4, in a first position of the operating cycle;
FIG. 7 is a view similar to FIG. 6, with the apparatus in a second position of the operating cycle;
FIG. 8 is another view similar to FIG. 6, with the apparatus in a third position of the operating cycle;
FIG. 9 is another view similar to FIG. 6 with the apparatus in a fourth position of the operating cycle;
FIG. 10 is another view similar to FIG. 6 with the apparatus in a fifth position of the operating cycle;
FIG. 11 is a diagrammatic longitudinal cross sectional view similar to FIG. 5, showing parts of the apparatus in the operating position of FIG. 8;
FIG. 12 is a diagrammatic cross sectional view of a detail of the machine, along the line 12--12 of FIG. 11, turned through 90° to show other finger receiving mandrels, and with the wrist clamp expanded.
In the drawings, like reference numerals indicate like parts.
With reference to FIGS. 1-3, these illustrate the objective which the present invention sets out to achieve. The finger 1 of a leather glove is commonly made from two separate pieces of leather 2, 3 stitched together to form bulky seams 4, 5. The glove is stitched in its inside out position as shown in FIG. 1. When it is turned to the right side out position as shown in FIG. 2, the seams 4, 5, project inwardly a substantial distance. It is now necessary to flatten these seams, and generally press the inside of the finger, to make the inside thereof conform to the desired shape. After this operation, known as blocking, the finger assumes the general inside cross sectional shape shown in FIG. 3, in which the seams 4, 5 have been flattened and the interior cavity expanded and shaped to the desired configuration. The subsequent drawings, FIGS. 4 through 12, illustrate an apparatus and process by which this is accomplished.
With reference to FIG. 4, the apparatus comprises a fixed framework having vertical side members 10, 11 and a cross member 12. A bed 13 is pivotally mounted at 14, 15 in the vertical side members 10, 11 respectively, for limited pivotal movement about a generally horizontal axis. The bed 13 carries on its underside two vertically disposed cylinders 16, 17 containing slidable piston rods 18, 19 which pass upwardly through apertures in the bed 13. Cylinders 16, 17 are connected to a source of pneumatic power, which can raise and lower the piston rods 18, 19 therein. The bed 13 has affixed to its upper surface an upwardly extending stem 20, carrying at its upper end a skeletal hand 21 with finger mounting members in the form of rods 22, 23, 24 and 25 projecting upwardly therefrom
A movable table 26 is provided immediately above the bed 13. The table 26 is mounted on the upper ends of piston rods 18, 19 so that it can be raised and lowered in response to pneumatic pressure in cylinders 16, 17. The table 26 is provided, at each side, with vertically extending guide tubes 27, 28 fixed to the table 26 and passing through apertures in the bed 13, so that the guide tubes raise and lower with the table 26. The table 26 is also provided with a further aperture, near its center, to allow passage of hand stem 20 therethrough.
The table 26 is provided on its upper surface with a wrist clamp comprising a pair of interfitting metal channel members 29, 30, which are movable towards and away from each other, in a horizontal plane, relative to the table 26. Pneumatic cylinders 31, 33 with associated slidable piston rods 32, 34 are mounted on the upper surface of table 26. The piston rods 32, 34 are connected respectively to wrist clamp parts 29, 30, and can retract and expand the wrist clamp 29, 30 in response to pneumatic pressure in cylinders 31 and 33.
Vertical frame side member 10 is provided at its lower portion with an integral boss 35, to which is connected a pneumatic piston and cylinder arrangement 36, 37. The piston rod 37 connects via a crank arrangement 38 with the horizontal pivot 14 of the bed 13, so that the bed can be tilted by actuating cylinder 36.
A movable framework is provided, located generally above the bed 13, and movable in a vertical plane relative to the bed 13 and the fixed framework. The movable framework comprises an upper crosspiece 39 and a lower crosspiece 40. It also comprises vertical side rods 41, 42 secured to crosspieces 39, 40. Side rods 41, 42 pass through apertures in cross member 12 of the fixed framework, so that the lower portions of side rods 41, 42 are disposed inside but close to vertical side members 10, 11. The lower ends of side rods 41, 42 are vertically aligned with guide tubes 27, 28 respectively, associated with table 26, when the bed 13 and table 26 are in their normal, non-tilted position.
A pneumatic cylinder 43 is mounted on the upper surface of cross member 12 of the fixed framework, with its associated piston rod 44 extending vertically upward, and secured at its upper end to the middle of crosspiece 39 of the movable framework. This pneumatic cylinder 43 can be actuated to raise and lower the movable framework with respect to the fixed framework.
Compression springs 45, 46 are provided, seated in the upper surface of the cross member 12, and surrounding side rods 41, 42 respectively. The upper ends of the springs 45, 46 are adapted to be engaged by stop formations 47, 48 on respective side rods 41, 42 when the movable framework is lowered, to be compressed thereby when the movable framework is lowered to its full extent. The function and purpose of these springs 45, 46 is described hereinafter.
The lower crosspiece 40 of the movable framework carries on its upper surface an upstanding subsidiary frame with side walls 49, 50 and a head wall 51. Four tubular finger receiving mandrels 52, 53, 54, 55 extend downwardly through apertures in the crosspiece 40 in substantial longitudinal alignment with respective finger rods 22, 23, 24, 25 of the skeletal hand 21 associated with the fixed bed 13. The upper ends of tubular mandrels 52, 53, 54, 55 are received in the space defined by the subsidiary frame, and are secured to stop members 56, 57, 58, 59 respectively, which abut against the upper surface of crosspiece 40 and hence limit the downward protrusion of tubular mandrels 52, 53, 54, 55. The mandrels 52, 53, 54, 55 are slidable through the apertures in the crosspiece 40. Compression springs 60, 61, 62, 63 extend upwardly from stop members 56, 57, 58, 59 and are seated at their upper ends in the underside of head wall 51 of the subsidiary frame. The springs, 60, etc. urge their respective tubular mandrels 52, etc. downwardly, and hence urge stop members 56, etc. into abutment with crosspiece 40.
There are disposed within tubular mandrels 52, etc. respective retractable members in the form of slidable inner tubes 78 best shown in FIG. 5 the lower ends of which 64, 65, 66, 67 are bullet-like, and are visible in FIG. 4 protruding from the lower ends of the respective tubular mandrels 52, etc. The plungers extend upwardly within the tubular mandrels 52, etc. through associated stop members 56, etc. and associated compression springs 60, etc. and through apertures in the head wall 51, where they are received in respective stop members 68, 69, 70, 71 which abut against the upper surface of head wall 51. The retractable inner tubes 78 are also spring urged, by means shown in FIG. 5.
Now referring to FIG. 5, this illustrates in vertical cross section the tubular finger receiving mandrel 52 and associated parts, viewed from the side with respect to FIG. 4. It will be understood that the other mandrels 53, 54, 55 are essentially identical with the mandrel 52. At its upper end, the mandrel 52 extends through an aperture in lower crosspiece 40 of the movable framework. The upper end, above the crosspiece 40, is received in a stop member 56. The mandrel 52 is releasably secured to the stop member 56 by means of a screw 73 which is threadably received in a screw threaded aperture 74 in the side of the stop member 56 and extending into an aperture 75 in the side of the mandrel 52. The opposite side of the stop member 56 is provided with a horizontal bore 76 by means of which air pressure can be introduced to the interior of the mandrel 52. Compression spring 60 extends from the upper surface of the stop member 56 to the underside of the head wall 51 of the subsidiary frame of the movable framework, urging the stop member 56 and mandrel 52 in a downward direction. The lower part of the mandrel 52 is provided with a portion 77 of larger cross section.
Inside the mandrel 52 and extending longitudinally therethrough is the retractable inner tube 78 which terminates at its lower extremity in a removable bullet 64 extending below the end of the mandrel 52. The inner tube 78 and its associated parts are slidable within the mandrel 52. The tube 78 extends upwardly through an aperture in the stop member 56, within the coil spring 60, and through an aperture in head wall 51. At its upper end it is releasably received in stop member 68 by means of laterally extending screw 80 threadably received in a screw threaded aperture 81 and clamped against the side of the tube 78. A tension spring 82 extends from screw 80 to crosspiece 40 of the movable framework, thereby urging tube 78 and its associated parts downwardly relative to the movable framework. Downward movement is limited by abutment of stop member 68 against head wall 51.
Located within inner tube 78 near its bottom end is an electrical cartridge heater 83, the leads 84 from which pass upwardly inside the tube 78 and out of a lateral aperture 85 in the tube 78 and stop member 68, to a source of electrical heating power, not shown. The heater 83 is in contact with the tube 78, parts of which in turn contact mandrel 52 so that the entire lower portion of the mandrel assembly can be heated by means of cartridge heater 83.
The bullet 64 is of solid metal, namely aluminum, and is adapted to be removable from the tube 78. For this purpose, the bullet 64 is provided with a countersunk upwardly extending screw threaded bore 86. A closure plate 87 is provided near the bottom of the tube 78. The closure plate has a screw threaded aperture so that a screw 88 passing upwardly through the bore 86 of the bullet 64 attaches the bullet 64 releasably to the tube 78. It will be noted that, whilst the bullet 64 is of larger cross sectional area than the rest of the inner tube 78, there is still free space between the bullet 64 and the enlarged portion 77 of the mandrel. Thus a jet of air introduced through bore 76 has free communication with and exits from the bottom of the mandrel 52.
At its lower extremity, the tube 52 is provided on both its inner and outer surfaces and edge with a low friction coating 89 of TEFLON, to assist in the turning operations.
As noted, the glove fingers are received over the enlarged lower portion 77 of the mandrel 52 in operation, and according to the invention are stretched and blocked as they are received thereon. The mandrel 52 thus has an important role in determining the size of the finished glove. Tubular mandrel 52 is made removable from the apparatus, so that such mandrels of different sizes can be used, for use in turning different sized gloves. To remove mandrel 52, screw 86 is first unfastened and bullet 64 removed. Then screw 73 is unfastened, and tube 52 can then be removed downwardly from the assembly. An alternate tube is then inserted, screw 73 fastened and bullet 64 replaced.
With reference to FIG. 12, this shows in cross section the arrangement of the tubular mandrels 52, 53, 54, 55 at their enlarged lower portions. Their cross sectional shape is generally oval with straight longitudinal sides 90. Convenient and substantially constant spacing should be maintained between them, since they must align with the rods 22, 23, 24, 25 of the skeletal hand 21, and have sufficient spacing from one another to allow the turning of the fingers of the glove onto their exterior surfaces. Thus the curvature of the semicircular ends of the tubes 52, etc. is kept constant, to maintain constant width. The different sizes of tubes 52, etc. are arranged by providing tubes of different straight side 90 lengths. As shown in FIG. 12, for any given glove different sizes of tubes are used, and these are replaced with tubes of different straight side 90 lengths, for use with different glove sizes.
The operation of the machine as described herein will now be described, with reference to FIGS. 4 and 6 through 11.
Referring firstly to FIG. 4, at the start of the operating cycle the movable table 26 is at its lowermost position resting on the fixed bed 13. Pneumatic cylinder 36 is normally actuated to cause a forward tilting of the bed 13 and table 26 with associated parts including the skeletal hand 21. The extent of this tilt is limited by suitable stop means not shown. An inside out and unblocked glove 91 (seen in FIG. 6) is mounted on the skeletal hand 21. It will be noted that the finger rods 22, 23, 24 and 25 are of different lengths, to cooperate with the different lengths of the glove fingers, the pinky rod 25 being the shortest. The glove is mounted with the appropriate finger rods extending into the appropriate glove fingers, and with the cuff 92 of the glove 91 extending over the parts 29, 30 of the wrist clamp, which are at this stage in their retracted position. This forward tilted position of the skeletal hand 21 facilitates very greatly the operator's task in mounting the glove 91 thereon, and reduces risk of the operator's touching the heated mandrels 52, 53, 54, 55 during such loading. It also facilitates air blast-off removal, from the mandrels, of the glove turned and blocked during the previous machine cycle.
Next, the pneumatic pressure in cylinder 36 is switched, and the table 26 and bed 13 and associated parts tilt back to their vertical positions. Then cylinders 31 and 33 are actuated, to expand the wrist clamp 29, 30 inside the cuff 92 of the glove 91 so that the cuff 92 is firmly gripped. The apparatus is now in the position shown in FIG. 6.
The movable framework including the crosspiece 40 and tubular mandrels 52, 53, 54, 55 is now lowered with respect to the table 26 and bed 13 holding the skeletal hand. Tubular mandrels 52, 53, 54, 55 fit over the glove fingers mounted upon respective finger rods 22, 23, 24, 25. Proper vertical alignment is ensured by the cooperation of the lower ends of side rods 41,42 of the movable framework being received inside guide tubes 27,28 fixed to the table 26. If the alignment is incorrect, the rods 41,42 and the tubes 27,28 will abut and jam, preventing damaging engagement of the mandrels 52, 53, 54, 55 with the skeletal hand 21. The downward movement of the movable framework is set to a predetermined extent, defined by suitable limit switches, until the lower edge of the pinky tube mandrel 55 engages the bottom of the pinky finger of the glove. Since the pinky tube mandrel 55 has the longest distance of downward travel, there is extra motion of the other tubular mandrels 52, 53, 54 which is accommodated by compression of the respective springs 60, 61 and 62 associated with the other mandrels.
As the tubular mandrels 52 are pushed down over the glove fingers in this way, the bullets 64 engage the tops of the respective finger rods 22, 23, 24, 25 via the glove finger ends. They are retracted within the tubular mandrels 52 etc. against the urging of associated tension springs 82 (see FIG. 5) as the movable framework is moved downwardly. The upper ends of the inner tubes 78 bearing stop members 68 thus extend upwardly beyond the head wall 51 of the movable framework. The apparatus has now assumed the position shown in FIG. 7. During this downward travel of the movable framework including crosspiece 40 and tubular mandrels 52, 53, 54, 55 the stop formations 47 and 48 will engage springs 45 and 46. Compression of these springs together with elongation of the springs 82 will result in greatly reduced downward weight force of the movable frame, and hence reduce very substantially downward urging of tubular mandrels 52, 53, 54, 55.
Next, the downward force in cylinder 43 is stopped, and the table 26 moves upwardly relative to the bed 13 and skeletal hand 21. As it does so, it moves the wrist clamp 29, 30 upwardly in its expanded, glove engaging position. This causes turning to the right side out condition of the hand portion of the glove 91, about the top edge of the wrist clamp 29, 30 and the bottom edge of the tubular mandrels 52, 53, 54, 55.
Whilst this turning of the hand portion of the glove 91 is taking place, the tubular mandrels 52, 53, 54, 55, are effectively floating, being urged downwardly only by their associated respective springs 60, 61, 62, 63. The bullets 64, 65, 66, 67 press firmly on the tips of the glove finger being supported by the skeletal hand 21. The head wall 51 however, being part of the movable framework is at this point of the cycle just heavy enough to compress the springs 60, 61, 62, 63. The tubular mandrels 52 rest lightly at the bottom of the glove fingers. Turning of the hand portion of the glove 91 by upward movement of the wrist clamp 29,30 requires little force, and during such movement the tubular mandrels 52, 53, 54, 55 and bullets 64, 65, 66, 67 remain substantially stationary, maintained by their spring loadings. The hand portion turning is completed before turning of the finger portions commences. At this stage, the apparatus has assumed the positions shown in FIG. 8 and FIG. 11. The hand portion 93 of the glove is turned right side out and now lies inside the wrist clamp 29,30. The cuff 92 remains inside out, firmly gripped by and lying outside of the wrist clamp 29, 30. The finger 1 is inside out and has not started to turn. It rests on finger rod 22, and bullet 64 sits lightly thereon.
The force required to turn the finger 1 is considerably greater than the force required to turn hand portion 93. As wrist clamp 29,30 continues to move upwardly from its position shown in FIG. 8 and FIG. 11, and the finger 1 starts to turn, a jet of air is introduced through bore 76 into inner tube 78, from where the air passes out around the bottom of bullet 64 and around the bottom edge of tubular mandrel 52. This air jet combined with the TEFLON coated lower edge 89 of the tubular mandrel 52 reduces very substantially the frictional forces experienced by finger 1 during turning. The continued upward travel of wrist clamp 29,30 is against the light downward urging of the tubular mandrel 52 and the compression of the leather inside the mandrel 52, on account of slight upward travel of mandrel 52 and lack of movement of bullet 64. The compression springs 45 and 46 control the ease with which the tubular mandrel 52 will travel upwardly, controlling the compression of the leather between the bullet 64 and the edge of the tubular mandrel 52. The glove finger is consequently being turned due firstly to the compression forces exerted on the leather inside the tubular mandrel 52, aided by air pressure within the mandrel 52 which tends to urge the leather into contact with the rod 22, and due secondly to tension force on the leather outside the mandrel 52, over the bottom edge of mandrel 52 lubricated by the TEFLON coating 89 and the pressure of air. Glove finger 1 is thus being turned from a small diameter rod 22 to a larger diameter mandrel 52. Tubular mandrel 52 is heated as a result of the cartridge heater 83. This simultaneous stretching and heating as the glove finger is turned causes a substantial degree of blocking.
It will be appreciated that, in effect, turning of the glove is taking place in advance of the edge of the tube 52, due to the presence of the air jet previously described. The tube 52 is thus serving as a guide for the turning finger, and at this stage there is little if any contact between the edge of the tubular mandrel 52 and the glove finger being turned.
When the finger 1 has been turned for approximately three-fourths of its length, the air jet to bore 76 is cut off. Continued upward movement of the wrist clamp 29,30 causes the stop member 68 associated with the bullet 64 to come into abutment with frame cross member 12, whereupon it is positively held against further upward movement and can exert much greater downward force in response to upward movement of the wrist clamp 29,30. The bullet 64 now enters the end of the finger 1, contacting the leather thereof, as the end of the finger 1 is wholly removed from the rod 22 and transferred to the mandrel 52. Bullet 64 now extends below the end of tube 52, to receive the finger end and to block it. It will be noted that the end of bullet 64 is appropriately tapered to conform to the shape of the inside of the glove finger end. The apparatus is now in the position shown in FIG. 9.
A small degree of further upward travel of the wrist clamp 29,30, with the air exhausted on both sides of the cylinder 31 and 33 to relax the wrist clamp, completes the turning of the glove 91, by turning the cuff 92. Then the wrist clamp 29,30 on table 26 is withdrawn downwardly, leaving the glove 91 suspended on the mandrels 52, 53, 54, 55 where it is retained briefly so as to complete the blocking. This is the position of the apparatus illustrated in FIG. 10. Then the glove is removed from the machine, suitably by a blast of air from bore 76, and the machine is ready for a new cycle of operation.
The control means for the machine of the invention are not illustrated, but it will be appreciated that their design and operation are within the skill of the art. Thus a suitable interconnection of pneumatic pressure supplies and sequential operating controls is associated with pneumatic cylinders, 36, 16, 17, 31, 33 and 43 to arrange a cycle of operations as described herein. The apparatus cycles semi-automatically with the operator switching on the operating cycle after loading a glove onto skeletal hand 21 with the table 26 and bed 13 in their tilted forward position, whereupon the apparatus automatically completes a cycle and returns to this same position.
The apparatus can be operated at high speeds, with the entire cycle of automatic operation being completed in a period of from 10-30 seconds. To complete the blocking of the glove 91, it needs to remain in stretched contact with the heated tubular mandrels 52, 53, 54 and 55 only for a period of about 10 seconds. The mandrels 52 etc. can be heated to relatively high temperatures, such as 250°-500° F to accomplish the blocking, since the glove contacts them for only a brief interval.
Whilst the process and apparatus of the invention have been specifically described with reference to the making of leather gloves, it will be appreciated that it can be used with gloves of other, similar materials also. Gloves of a material which is preformed and requires parts to be stitched or otherwise secured together as seams, the material having the characteristic of stretching with a degree of resilience, can be made according to the invention.
The embodiments of the present invention described above are intended to be illustrative, preferred embodiments only, and the scope of the present invention is defined by the appended claims. | A process of simultaneously turning and blocking a leather glove is disclosed, in which the fingers of the glove are initially mounted upon elongated members of relatively small diameter, and are turned onto heated mandrels of relatively larger diameter. The stretching of the finger portions as they are turned in this manner, combined with the application of heat from the heated mandrels, causes simultaneous blocking of the glove fingers as they are turned. In an apparatus for carrying out this process, the finger receiving members of lesser diameter are rods, and the mandrels onto which the fingers are turned are tubular. A wrist clamp is provided, which grips the inside of the cuff portion of the glove, and draws the glove off the finger mounting members onto the heated mandrels by movement relative to the finger mounting members. The turning of the glove fingers is assisted by the provision of retractable inserts in the tubular mandrels, which push on the finger ends to assist the pulling forces exerted by the moving wrist clamp to effect the turning. | 3 |
BACKGROUND OF THE INVENTION
Trauma to the brain or spinal cord caused by physical forces acting on the skull or spinal column, by ischemic stroke, arrested breathing, cardiac arrest, Reye's syndrome, cerebral thrombosis, cerebral embolism, cerebral hemorrhage, encephalomyelitis, hydrocephalus, post-operative brain injury, cereal infections and various concussions results in edema and swelling of the affected tissues. This is followed by ischemia, hypoxia, necrosis, temporary or permanent brain and/or spinal cord injury and may result in death. The tissue mainly affected are classified as grey matter, more specifically astroglial cells. The specific therapy currently used for the treatment of the medical problems described include various kinds of diuretics (particularly osmotic diuretics), steroids (such as, 6-α-methylprednisolone succinate) and barbiturates. The usefulness of these agents is questionable and they are associated with a variety of untoward complications and side effects. Thus, the compounds of this invention comprise a novel and specific treatment of medical problems where no specific therapy is available.
A recent publication entitled "Agents for the Treatment of Brain Injury" 1. Aryloxyalkanoic Acids, Cragoe et al, J. Med. Chem., (1982) 25, 567-79, reports on recent experimental testing of agents for treatment of brain injury and reviews the current status of treatment of brain injury.
In addition, some compounds having structures related to the compounds of the present invention have been reported as being useful in the treatment and prevention of calcium oxalate kidney stone formation in U.S. Pat. No. 4,342,776 of Cragoe at al. There is, however, no suggestion in the patent that any of the compounds disclosed therein would be of use in the treatment of brain injury.
The compounds of the invention have the added advantage of being devoid of the pharmacodynamic, toxic or various side effects characteristic of the diuretics, steroids and barbiturates.
DESCRIPTION OF THE INVENTION
The compounds of the instant invention are best characterized by reference to the following structural formula (I). ##STR1## Wherein R is cycloalkyl (C 3 to C 6 ), cycloalkyllower alkyl (C 4 to C 7 total), aryl, such as phenyl, substituted aryl, such as phenyl with substituents, such as halo, methyl, methoxy, and hydroxy, heterocyclic, such as thienyl, aralkyl, such as benzyl and phenethyl, lower alkyl, branched or unbranched, lower alkenyl, branched or unbranched and lower alkynyl and the like. R 1 is lower alkyl, branched or unbranched, alkenyl or alkynyl and the like. X and Y are chloro or methyl and the like and A is a bond, --O--, or --O(CH 2 ) q , where q is 1 to 5 and Z is O or H and OH.
When the R and R 1 substituents are different, the 2-position carbon atom of the indane ring is asymmetric and these compounds of the invention are racemic. However, these compounds of their precursors can be resolved so that the pure enantiomers can be prepared, thus the invention includes the pure enantiomers. This is an important point since some of the racemates consist of one enantiomer which is much more active than the other one. Furthermore, the less active enantiomer generally possesses the same intrinsic toxicity as the more active enantiomer. In addition, it can be demonstrated that the less active enantiomer depresses the inhibitory action of the active enantiomer at the tissue level. Thus, for three reasons it is advantageous to use the pure, more active enantiomer rather than the racemate.
An example of this is seen with the compound of Example 1, which is (+)-3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione 1-methylpiperazine salt which is much more active than the (-)-enantiomer described in Example 23. Thus, by using the pure (+)-enantiomer, not only has the much less active component of the racemate been eliminated but its unwanted contribution to toxicity and side effects abolished and its detrimental effect on intrinsic activity has been eliminated.
With the compounds where Z is H and OH, i.e. those where there is a hydroxy group on the 1-position of the indane ring, a second asymmetric carbon atom (the 1-position of the indane ring) is established. Therefore, the compounds where Z is H and OH and R and R 1 are different consist of two diastereomers, each of which is a racemate. However, the diastereomers can be separated by fractional crystallization or chromatography. When intermediates which are preresolved at the 2-position of the indane ring, reduction of a 1-indanone to a 1-indanol produces two diastereomers, each consisting of a single enantiomer, which can be separated by fractional crystallization or chromatography. This type of compound is illustrated by Examples 32 and 33.
Since the products of the invention are acidic, the invention also includes the obvious pharmaceutically acceptable salts, such as the sodium, potassium, ammonium, trimethylammonium, piperazinium, 1-methylpiperazinium, guanidinium, bis-(2-hydroxyethyl)ammonium, N-methylglucosamonium and the like salts.
It is also to be noted that the compounds of Formula I, as well as their salts of Formula I-G, often form solvates with the solvents in which they are prepared or from whih they are recrystallized. These solvates may be used per se or they may be desolvated by heating (e.g. at 70° C.) in vacuo.
Although the invention primarily involves novel substituted-3-(2,3-dihydro-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-diones, and their salts, it also includes their derivatives, such as oximes, hydrazones and the like.
In accordance with one aspect of the present invention, there is included a novel group of compounds which are pure enantiomers of compounds of Formula I-A: ##STR2## wherein X, Y, R and R' are defined as hereinabove, provided that R and R' are not the same entities, and the pharmaceutically acceptable salts thereof, as well as pharmaceutical compositions in unit dosage form containing an effective amount of one of the compounds encompassed by the above formula and the method of treating brain injury using one of said pharmaceutical compositions.
Also included in this aspect of the invention are novel racemic compounds in which R is cycloalkyl, cycloalkyl-lower alkyl, aryl selected from phenyl, halophenyl, methoxyphenyl, hydroxyphenyl, heterocyclic, including thienyl, aralkyl selected from benzyl and phenethyl, lower alkyl, lower alkenyl, lower alkynyl; and R' is lower alkyl, lower alkenyl or lower alkynyl, provided that R is not cycloalkyl or alkyl when R' is lower alkyl and both X and Y are chloro, and the method of treating brain injury using said novel racemic compounds.
In accordance with a second aspect of the present invention, there is included a novel group of diastereomers and their enantiomers of compounds of Formula I-B: ##STR3## wherein X, Y, R and R' are as defined hereinabove, provided that R and R' are not the same entities, said diastereomers being derived by reduction of a pure enantiomer, particularly the pure (+)-enantiomer of the corresponding 1-oxo compound, as well as pharmaceutical compositions in unit dosage form containing an effective amount of one of the compounds encompassed by a diastereomer of the above formula. Also included are the corresponding racemic compounds wherein, X, Y, R and R' are defined as hereinabove provided that R is not cycloalkyl or alkyl when R' is lower alkyl and X and Y are both chloro.
In accordance with a third aspect of the present invention, there is included a novel group of compounds of Formula I-C: ##STR4## wherein X, Y, R and R' are as defined hereinabove including, when R and R' are different entities, the racemic compounds and the (+)-enantiomers of said racemic compounds and pharmaceutical compositions in unit dosage form containing an effective amount of one of the defined compounds or a (+)-enantiomer thereof.
In accordance with a fourth aspect of the present invention, there is included a novel group of diastereomers and their enantiomers of Formula I-D: ##STR5## said diastereomers being derived by reduction of the pure enantiomer, especially the pure (+)-enantiomer of the corresponding 1-oxo compound, as well as pharmaceutical compositions in unit dosage form containing an effective amount of one of the novel derived diastereomers. Also included are the corresponding racemic compounds wherein X, Y, R and R' are defined as hereinabove provided that R is not cycloalkyl or alkyl when R' is lower alkyl or cycloalkyl and X and Y are both chloro.
In accordance with a fifth aspect of the present invention, there is provided a novel group of compounds of Formula I-E: ##STR6## wherein Z, X, Y, R, R' and q are as defined hereinabove and the optical isomers thereof, wherein R and R' are different entities, and/or Z is H and OH, as well as pharmaceutical compositions in unit dosage form containing an effective amount of a compound of the above formula or a pure enantiomer, particularly the (+)-enantiomer or diastereoisomer derived therefrom by reduction of the corresponding 1-oxo compound.
PREFERRED EMBODIMENT OF THE INVENTION
The preferred embodiments of the instant invention are realized in structural Formula I-F wherein: ##STR7## R 2 is cyclopentyl, phenyl or benzyl Z is as defined before.
R 3 is lower alkyl, alkenyl and alkynyl, and A 1 is a bond, --O--, and O(CH 2 ) q- where q is 1 to 4.
Also included are the diastereomers and the enantiomers of each racemate.
Preferred compounds are (+)-3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its non-toxic salts.
Other preferred compounds are 3-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione, and its (+)-enantiomer and their pharmaceutically acceptable salts.
Other preferred compounds are 3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]4-hydroxy-1H-pyrrole-2,5-dione.
Other preferred compounds are 3-(6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione, its (-)-enantiomer and their pharmaceutically acceptable salts.
Other preferred compounds include 3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione, its (+)-α-diastereomer and the (+)-β-diastereomer (each of which are pure enantiomers) and their pharmaceutically acceptable salts.
Other preferred compounds include 3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione, its (+)-α-diastereomer, its (+)-β-diasterisomer (each of which are pure enantiomers) and their pharmaceutically acceptable salts.
Other preferred compounds include the (+)-α-diastereomer and (+)-β-diastereomer of 3-[2-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione, each of which consists of a single pure enantiomer.
Especially preferred are the pure enantiomers since, in most instances, one enantiomer is more active biologically than its antipode.
Included within the scope of this invention are the pharmaceutically acceptable salts of the parent 3-substituted-4-hydroxy-1H-pyrrole-2,5-diones since a major medical use of these compounds is solutions of their soluble salts which can be administered parenterally.
Thus, the acid addition salts can be prepared by the reaction of the 3-substituted-4-hydroxy-1H-pyrrole-2,5-diones of this invention with an appropriate amine, ammonium hydroxide, guanidine, alkali metal hydroxide, alkali metal carbonate, alkali metal bicarbonate, quaternary ammonium hydroxide and the like. The salts selected are derived from among the non-toxic, pharmaceutically acceptable bases.
The synthesis of the 3-substituted-4-hydroxy-1H-pyrrole-2,5-diones of Formula I are generally carried out by the reaction of the appropriate amide (Formula II) with diethyl oxalate in the presence of a base and a solvent. ##STR8## Advantageously, the base that is used can be potassium tert.-butoxide but other bases, such as sodium ethoxide or potassium methoxide can be used. The use of dimethylformamide is especially advantageous as a solvent but other polar, inert solvents such as 1-methyl-2-pyrrolidione can be used. The reaction is generally conducted at the ambient temperature but it can be conducted at temperatures as low as 10° C. and as high as 50° C. for periods of time of 6 to 24 hours, depending on the specific reactants.
The reaction can be conducted using amides of Formula II which are mixtures of diastereomers, pure diastereomers, racemates or pure enantiomers and, thus, obtain the corresponding 3-substituted-4-hydroxy-1H-pyrroline-2,5-diones of Formula I as mixtures of diastereomers, pure diastereomers, racemates or pure enantiomers.
Some 3-(2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-diones of the instant invention are advantageously prepared by the oxidation of the corresponding 3-(2,3-dihydro-1-hydroxy-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-diones. Advantageously this is carried out using an oxidizing agent, such as Jones reagent (CrO 3 in dilute sulfuric acid) using a solvent, such as acetone, 2-butanone, and the like. The reaction is generally conducted at ambient temperatures but temperatures in the range of 10° to 40° C. can be used.
The preparation of the intermediate amides of Formula II is carried out by any one of several methods involving the reaction of the appropriate ester Formula III, acid chloride of Formula IV or acylimidazole of Formula V with ammonia. ##STR9## The reaction of an ester of Formula III is generally carried out in a solvent such as dimethylformamide or 1-methyl-2-pyrrolidinone and then ammonia in a solvent, such as methanol or ethanol, is added. Ambient temperature is advantageously employed but temperatures as low as 10° C. or as high as 100° C. can be used; however, when higher temperatures are employed, it is necessary to use a sealed vessel to contain the ammonia. The reaction time varies, depending on the temperature and may require from twelve hours to four weeks.
When an acid chloride of Formula IV is used, the reaction is generally conducted in an inert solvent, such as methylene chloride or benzene and the ammonia added in a solvent like ether or a mixture of ether and methylene chloride. Usually it is also advantageous to introduce ammonia gas and finally aqueous ammonia. The reaction is generally conducted at temperatures in the range of 0° C. to 10° C. but, if a sealed reaction vessel is used, temperatures of 10° to 50° C. can be used. The reaction times are generally in the range of 10 minutes to two hours.
When an amide of Formula II is prepared from an acylimidazole of Formula V, a solvent, such as tetrahydrofuran or dioxane is employed since the acylimidazole is generated in that solvent. Then, the acylimidazole is treated with ammonia gas or aqueous ammonia. The reaction is generally carried out at ambient temperatures but temperatures as low as 10° C. or as high as 50° C. can be used.
The preparation of amides of Formula II-A, i.e. those in which Z=H+OH are best prepared by reduction of the corresponding compound of Formula II-B where Z=O. The reduction is advantageously conducted using sodium borohydride in a solvent like ethanol at room temperature for a period of 1 to 5 hours. ##STR10##
One method for the preparation of the intermediate esters of Formula III is carried out by esterification of the appropriate carboxylic acid of Formula VI. ##STR11##
The reaction is conducted using the appropriate alcohol (Alkyl-OH) such as methanol or ethanol, as a solvent and employing a small quantity of an acid catalyst, such as boron trifluoride etherate, sulfuric acid or p-toluenesulfonic acid. The reaction is generally carried out at the boiling point of the alcohol for a period of one to five hours. Another method of preparing esters of Formula III will be described later.
The intermediate acid chlorides of Formula IV are generally generated by methods well-known to those skilled in the art, such as by the reaction of the appropriate acid of Formula VI with a reagent, such as, thionyl chloride in a solvent, such as benzene or toluene at the boiling point of the solvent for a period of one to four hours. ##STR12##
The intermediate acylimidazoles can be prepared by the reaction of the appropriate carboxylic acid of Formula VI with 1,1'-carbonyldiimidazole in a solvent, such as tetrahydrofuran or dioxane at temperatures of -10° to 10° C. for periods of 15 minutes to 2 hours.
The carboxylic acid intermediates of Formula VI where A is O or O(CH 2 ) q' are designated by Formula VI-A. They are prepared by any one of several methods: ##STR13##
The first method involves heating the ester of Formula VII, where R 4 =alkyl, in a solution of acetic acid and an aqueous inorganic acid, such as hydrochloric acid, sulfuric acid and the like. The hydrolysis also can be effected in aqueous alcoholic base such as sodium hydroxide or potassium hydroxide in aqueous methanol or ethanol. The product is recovered by acidification with an acid, such as, hydrochloric acid. The reaction can be carried out at temperature of 30° C. to 100° C. for periods of about 20 minutes to 6 hours, depending on the specific ester used and the other reaction conditions. In the instances, where the ester is sensitive to strong base, it is advantageous to carry out the hydrolysis using a weak base, such as aqueous sodium bicarbonate. A solvent, such as aqueous ethanol, methanol or isopropyl alcohol is used and the mixture heated to 45° to 100° C. for periods of 15 minutes to 4 hours. Acidification of the reaction mixture with a strong aqueous acid, such as hydrochloric acid, hydrobromic acid or sulfuric acid produces the desired compound of Formula VI.
A second method for the preparation of compounds of the type illustrated by Formula VI involve the reaction of a haloalkanoic or halocycloalkanoic acid (W-A-COOH) with the appropriate phenol of Formula VIII.
Using a haloalkanoic or halocycloalkanoic acid W-A-COOH, where W=iodo, bromo or chloro and A is as defined above, for example, iodoacetic acid or bromofluoroacetic acid, as the etherification agent, the reaction is conducted in the presence of a base. The base is selected from among the alkaline earth or alkali metal bases such as sodium or potassium carbonate, calcium hydroxide and the like. The reaction is carried out in a liquid reaction milieu, the choice being based on the nature of the reactants; however, solvents which are reasonably inert to the reactants and are fairly good solvents for the compounds of Formula VIII and the W-A-COOH reagent, can be used. Highly preferably are dimethylformamide, ethanol, acetone, and N-methyl-2-pyrrolidinone and the like.
A third method for preparing compounds of Formula VI involves the pyrolysis of the corresponding tert.-butyl ester of Formula IX. This method involves heating a tert.-butyl ester of the type illustrated by Formula IX at from about 80° C. to 120° C. in a suitable nonaqueous solvent in the presence of catalytic amount of a strong acid. The solvents are generally selected from among the type benzene, toluene, xylene, etc. and the acid catalyst may be a strong organic or inorganic acid, such as p-toluenesulfonic acid, benzenesulfonic acid, methanesulfonic acid, sulfuric etc. The acid, being a catalyst, is generally used in relatively small quantities as compared to the tert.-butyl ester, IX. It is to be noted that this reaction is a pyrolysis and not a hydrolysis, since water is excluded from the reaction and the products are a carboxylic acid (Formula VI) and isobutylene and no alcohol is produced.
Another method of converting compounds of Type IX to those of Type VI is by heating compounds of Type IX with trifluoroacetic acid in a solvent like dichloromethane.
A fourth method is limited to the instances where A=O(CH 2 ) 2 , which produces compounds of Formula VI-A. In this method, a compound of Formula X is oxidized to a compound of Formula VI-A. ##STR14## The reaction is conducted in a solvent mixture of water and methylene chloride (or carbon tetrachloride) using an oxidizing agent, such as potassium permanganate and a phase transfer agent, such at "triton B" and the like.
The reaction is conducted conveniently at 10° C., but temperatures as low as 5° C. or as high as 35° C. can be used for periods of 30 minutes to 6 hours.
The product is conveniently isolated by reducing the excess potassium permanganate with sodium bisulfide and hydrochloric acid, extracting the organic phase with aqueous sodium hydroxide and acidifying the aqueous extract with an acid such as hydrochloric acid. If necessary, the product is purified by chromatography or recrystallization.
Compounds of formula X are prepared from the corresponding phenol of Formula VIII by reaction with 1-bromobutene or 1-iodobutene. The reaction (where Hal=bromo or iodo)
VIII+Hal-CH.sub.2 CH.sub.2 CH=CH.sub.2 →X
is conveniently conducted in a polar solvent, such as dimethylformamide, 1-methyl-pyrrolidone and the like. A base, such as potassium carbonate or sodium carbonate is employed to scavange the acid that is produced by the reaction. It is often beneficial to heat the base with the phenol (VIII) for a period of 10 minutes to an hour at 90° to 100° C. to generate the salt of the phenol before the 1-bromobutene or 1-iodobutene is added. The final reaction is generally conducted at temperatures of 50° to 100° C. for periods of 12 to 24 hours.
The esters of Formula VII or IX are conveniently prepared by the reaction of a phenol of Formula VIII with a haloalkanoic acid ester of Formula W(CH 2 ) q COOR 4 . When R 4 is tert.-butyl, compounds of Formula IX are produced.
VIII+W(CH.sub.2).sub.q COOR.sup.4 →VII or IX
If lower temperatures are employed or if the particular halo ester is not very reactive, the reaction time may be much longer.
In general, the reaction is conducted in the presence of a base, such as an alkali metal carbonate, hydroxide or alkoxide such as potassium carbonate, sodium carbonate, potassium hydroxide, sodium ethoxide and the like. Solvents which are essentially inert to the reactants and product and in which the reactants and product are reasonably soluble are usually employed. Dimethylformamide, ethanol and acetone, for example, have been found to be especially advantageous to use as solvents. The reaction may be conducted at a temperature in the range from about 25° C. to the boiling point temperature of the particular solvent employed. The reaction is generally complete in about 15 to 60 minutes; but, the reaction may require a longer period of time.
The phenols of Formula VIII are prepared by any one of several methods; but the following method is especially convenient. This procedure involves the ether cleavage of anisoles of Formula XI or oxyacetic acids of Formula VI-B. This ether cleavage ##STR15## accomplished by any one of many agents known to cleave ethers, especially useful are the hydrohalide salts of weak bases, such as pyridine hydrochloride or pyridine hydrobromide, but other agents, such as aqueous hydrobromic acid, aluminum bromide or sodium nitrite in dimethylformamide can be used. When pyridine hydrohalides are used, the temperatures above that which these substances melt are generally employed. This usually involves temperatures in the range of 150° to 215° C., but temperatures somewhat lower or higher can be used. The period of heating varies depending on the specific compound, but periods of from 15 minutes to 2 hours may be used.
The anisoles of Formula XI are prepared by any one of several methods known to those skilled in the art; however, a convenient method consists in the reaction of a compound of Formula XII with a compound of Formula W-R' where W is as defined previously (iodo, bromo or chloro). ##STR16##
The reaction is generally carried out by first treating the compound of Formula XII with a suitable base, for example, an alkali metal hydride, such as sodium hydride and the like, or an alkali metal alkoxide, for example potassium tert. butoxide and the like. The ion that is generated is then treated with the compound of Formula W-R' (an alkyl halide, alkenyl halide or alkynyl halide). Any solvent which is substantially inert to the reactants employed may be used. Suitable solvents include, for example, 1,2-dimethoxyethane, tert.-butyl alcohol, benzene, toluene, dimethylformamide and the like. The reaction is conducted at temperatures in the range of 25° C. to about 125° C. In general, the reaction is conducted in the range from about 15° to 50° C. It is beneficial to conduct the reaction is a dry, inert atmosphere, for example in dry nitrogen or dry argon.
The carboxylic acid intermediates of Formula VI where A is a bond and Z is O=(designated as VI-B) are prepared by the following sequence of three synthetic steps. ##STR17##
The 2,3-dihydro-1-oxo-1H-inden-yl trifluoromethanesulfonates of Formula XIV are prepared from the corresponding phenols of Formula VIII. The reaction is conducted in a polar solvent, such as dimethylformamide or 1-methyl-2-pyrrolidinone in the presence of a base, such as potassium carbonate or sodium carbonate. The reaction is generally carried out at temperatures in the range of -10° C. to 45° C. but temperatures somewhat higher or lower can be used. The reaction time varies from 30 minutes to 6 hours.
The diethyl (2,3-dihydro-1-oxo-1H-inden-yl)-malonates of Formula XV are prepared by the reaction of compounds of Formula XIV with a metal salt of diethylmalonate. The metal salt of diethyl malonate is conveniently prepared from diethyl malonate and sodium hydride in an inert atmosphere using a solvent, such as dimethylformamide of 1-methyl-2-pyrrolidinone. The metal salt of diethyl malonate in the solvent is then treated with a compound of Formula XIV in an inert organic solvent, for example benzene or toluene. The reaction is generally conducted at a temperature of -5° C. to 50° C. for a period of 6 to 24 hours.
Finally, the compounds of Formula VI-B are prepared by heating compounds of Formula XV with aqueous base. Bases, such as sodium hydroxide or potassium hydroxide are especially useful. To achieve adequate solubility during the reaction, an inert organic solvent is employed, such as ethanol or propanol along with the water. The reaction is generally conducted at temperatures in range of 50° C. to 100° C. for periods of 2 to 24 hours. The final product (VI-B) is generated by acidification of the reaction mixture.
As mentioned earlier, the compounds of this invention possess one and sometimes two asymmetric carbon atoms. In the instances where they possess two asymmetric carbon atoms, the reaction whereby these chiral centers are established can produce two diastereomers. These may be separated to obtain each pure diastereomer by methods well known to those skilled in the art, such as by fractional crystallization, column chromatography, high pressure liquid chromatography and the like.
Those compounds possessing only one asymmetric carbon atom, as well as each pure diastereomer from compounds possessing two asymmetric carbon atoms, consist of a racemate composed of two enantiomers. The resolution of the two enantiomers may by accomplished by forming a salt of the racemic mixture with an optically active base such as (+) or (-)amphetamine, (-)cinchonidine, dehydroabietylamine, (+) or (-)-α-methylbenzylamine, (+) or (-)(1-naphthyl)ethylamine. (+) cinchonine, brucine, or strychnine and the like in a suitable solvent such as methanol, ethanol, 2-propanol, benzene, acetonitrile, nitromethane, acetone and the like. There is formed in the solution, two diastereomeric salts, one of which is usually less soluble in the solvent than the other. Repetitive recrystallization of the crystalline salt generally affords a pure diastereomeric salt from which is obtained the desired pure enantiomer. The optically pure enantiomer of the compound of Formula I is obtained by acidification of the salt with a mineral acid, isolation by filtration and recrystallization of the optically pure antipode.
The other optically pure antipode may generally be obtained by using a different base to form the diastereomeric salt. It is of advantage to isolate the partially resolved acid from the filtrates of the purification of the first diastereomeric salt and to further purify this substance through the use of another optically active base. It is especially advantageous to use an optically active base for the isolation of the second enantiomer which is the antipode of the base used for the isolation of the first enantiomer. For example, if (+)-α-methylbenzylamine was used first, then (-)-α-methylbenzylamine is used for the isolation of the second (remaining) enantiomer.
A method which is especially useful in obtaining pure enantiomers involving asymmetry about the 2-carbon atom is to use pure enantiomers of the intermediate compounds. This is particularly advantageous in the instance of compounds of Formula VI, most particularly compound of Formula VI-B. These compounds are readily resolved by the methods described above and many have already been described in the scientific and patent literature. These resolved compounds can then be used per se in subsequent synthetic steps, such as conversion to compounds of the types illustrated by Formula III, IV, V or VII which ultimately lead to compounds of Formula I which are pure enantiomers.
When compounds of Formula I are prepared where both the 1-carbon atom and the 2-carbon atom of the indane ring are asymmetric, the two diastereomers that are produced may be separated by methods well-known to those that are skilled in the art. For example, methods such as fractional crystallization, column chromatography, high pressure liquid chromatography and the like may be used.
The instances where intermediate compounds are used which are preresolved to the pure enantiomers in regard to the 2-carbon atom prior to establishment of the asymmetry about the 1-carbon is established are especially advantageous. An example of this is the reduction of a compound of Formula II-B to one of Formula II-A. In this situation, two diastereomers are produced but each consists of a single enantiomer. Thus, by using one of the methods for separating diastereomers listed above, the two diastereomers can be separated to obtain two pure enantiomers.
Therefore, by starting with a pure enantiomer of Formula VI, two of the possible enantiomers can be obtained. They, by using the opposite enantiomer of Formula VI the other two enantiomers can be obtained. This provides a method of obtaining all four enantiomers of compounds of Formula I where both the 1-carbon and 2-carbon atoms are asymmetric.
The acid addition salts of Formula I-G (where B + represents a cation from a pharmaceutically acceptable base) are prepared by reacting a carboxylic acid of Formula I with an appropriate base of formula BH, for example, alkali metal or alkaline earth bicarbonate, carbonate or alkoxide, an amine, ammonia, an organic quaternary ammonium hydroxide, guanidine and the like. The reaction is illustrated below: ##STR18##
The reaction is generally conducted in water when alkali metal hydroxides are used, but when alkoxides and the organic bases are used, the reaction may be conducted in an organic solvent, such as ether, ethanol, dimethylformamide and the like.
The preferred salts are the sodium, ammonium, diethanolamine, 1-methylpiperazine, piperazine and the like salts.
It is to be recognized that compounds of Formula I are dibasic acids but it is generally intended to prepare only the salts derived from the more acidic center as shown by Formula I-G. Therefore, only bases of the appropriate base strength are used to produce the monobasic salts of Formula I-G or, alternatively, the bases are used only in amounts equivalent to the molar quantities of the acid. In the instance of diacidic bases, for example 1-methylpiperazine, molecular equivalent amounts of compounds of Formula I and BH are used.
Inasmuch as there are a variety of symptoms and severity associated with grey matter edema, particularly when it is caused by head trauma stoke, cerebral hemorrhage or embolism, post-operative brain surgery trauma, spinal cord injury, cerebral infections and various brain concussions, the precise treatment is left to the practioner. Therefore, it is left to the judgment of the practitioner to determine the patient's response to treatment and to vary the dosages accordingly. A recommended dosage range is from 1 microgram/kg to 20 mg/kg of body weight as a primary dose and a sustaining dose of half to equal the primary dose, every 4 to 24 hours.
The compounds of this invention can be administered by a variety of established methods, including intravenously, intramuscularly, subcutaneously, or orally. As with dosage, the precise mode of administration is left to the discretion of the practitioner. However, for the very ill and comatose patient, the parenteral route, particularly the intravenous route of administration is highly preferred. Another advantage of the intravenous route of administration is the speed with which therapeutic brain levels of the drug are achieved. It is of paramount importance in brain injury of the type described to initiate therapy as rapidly as possible and to maintain it through the critical time periods. For this purpose, the intravenous administration of drugs of the type Formula I in the form of their salts (Formula I-G) is superior.
One aspect of this invention is the treatment of persons with grey matter edema by concomitant administration of a compound of Formula I or I-G, a pharmaceutically acceptable salt, and an antiinflammatory steroid. These steroids are of some, albeit limited, use in control of white matter edema associated with ischemic stroke and head injury. Steroid therapy is given according to established practice as a supplement to the compound of Formula I or I-G as taught elsewhere herein.
Similarly, a barbiturate may be administered as a supplement to treatment with a compound of Formula I or I-G.
The compounds of Formula I or I-G are utilized by formulating them in a composition such as tablet, capsule or elixir for oral administration. Sterile solutions or suspensions can be used for parenteral administration. About 70 micrograms to 750 mg of a compound or mixture of compounds of Formula I or I-G, its a physiologically acceptable salt, is compounded with a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, flavor, etc. in a dosage form as called for by accepted pharmaceutical practice. The amount of active substance in the composition is such that dosage in the range indicated is obtained.
Illustrative of the adjuvants which may be incorporated in tablets, capsules and the like are the following: a binder such as gum tragacanth, acacia, corn starch or gelatin; an excipient such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; a sweetening agent such as sucrose, lactose, or saccharin; a flavoring agent such as peppermint, oil of wintergreen or cherry. When the dosage unit from is a capsule, it may contain in addition to materials of the above type a liquid carrier such as a fatty oil. Various other materials may be present as coatings or to otherwise enhance the pharmaceutical elegance of the preparation. For instance, tablets may be coated with shellac, sugar or the like. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propyl parabens as preservatives, a dye and a flavoring such as cherry or orange flavor.
Sterile compositions for injection can be formulated according to conventional pharmaceutical practice by dissolving or suspending the active substance in a conventional vehicle such as water by injection, a naturally occurring vegetable oil like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or a synthetic fatty vehicle like ethyl oleate or the like. Buffer, preservatives, antioxidants and the like can be incorporated as required.
The basic premise for the development of agents for the treatment of brain injury of the types described is based on the studies in experimental head injury by R. S. Bourke et. al. (R. S. Bourke, M. A. Daze and H. K. Kimelberg, Monograph of the International Glial Cell symposium, Leige, Bel. Aug. 29-31, 1977 and references cited therein) and experimental stroke by J. H. Garcia et. al. (J. H. Garcia, H. Kalimo, Y. Kamijyo and B. F. Trump, Virchows Archiv. [Zellopath.], 25, 191 (1977).
These and other studies have shown that the primary site of traumatic brain injury is in the grey matter where the process follows a pattern of insult, edema, ischemia, hypoxia, neuronal death and necrosis followed, in many instances, by irreversible coma or death. The discovery of a drug that specifically prevents the edema would obviate the sequalae.
Experimental head injury has been shown to produce a pathophysiological response primarily involving swelling or astroglia as a secondary, inhibitable process. At the molecular level, the sequence appears to be: trauma, elevation of extracellular K + and/or release of neurotransmitters, edema, hypoxia and necrosis. Astroglial swelling results directly from A K + -dependent, cation-coupled, chloride transport from the extracellular into the intracellular compartment with a concommitant movement of an osmotic equivalent of water. Thus, an agent that specifically blocks chloride transport in the astroglia is expected to block the edema caused by trauma and other insults to the brain. It is also important that such chloride transport inhibitors be free or relatively free of side effects, particularly those characteristics of many chloride transport inhibitors, such as diuretic properties. Compounds of the type illustrated by Formula I and I-G exhibit the desired effects on brain edema and are relative free of renal effects.
That this approach is valid has been demonstrated by the correlation of the in vitro astroglial edema inhibiting effects of chloride transport inhibitors with their ability to reduce the mortality of animals receiving experimental in vivo head injury. As a final proof, one compound (ethacrynic acid) which exhibited activity both in vitro and in vivo assays was effective in reducing mortality in clinical cases of head injury. These studies are described in the Journal of Medicinal Chemistry, Volume 18, page 567 (1982).
Three major biological assays can be used to demonstrate biological activity of the compounds. The (1) in vitro cat cerebrocortical tissue slice assay, (2) the in vitro primary rat astrocyte culture assay and (3) the in vivo cat head injury assay. The first assay, the in vitro cat cerebrocortical tissue slice assay has been described by Marshall, L. F.; Shapiro, H. M.; Smith, R. W. In "Seminars in Neurological Surgery: Neutral Trauma"; Popp. A. J.; Bourke, R. S.; Nelson, L. R.; Kimelberg, H. K,. Eds.; Raven Press: New York, 1979; p. 347, by Bourke, R. S.; Kimelberg, H, K.; Daze, M. A. in Brain Res. 1978, 154, 196, and by Bourke, R. S.; Kimelberg, H. K.; Nelson, L. R. in Brain Res. 1976, 105, 309. This method constitutes a rapid and accurate method of determining the intrinsic chloride inhibitory properties of the compounds of the invention in the target tissue.
The second assay method involves the in vitro primary rat astrocyte assay. The method has been described by Kimelberg, H. K.; Biddlecome, S.; Bourke, R. S. in Brain Res. 1979, 173, 111, by Kimelberg, H. K.; Bowman, c.; Biddlecome, S.; Bourke, R. S., in Brain Res. 1979, 177, 533, and by Kimelberg, H. K.; Hirata, H. in Soc. Neurosci. Abstr. 1981, 7, 698. This method is used to confirm the chloride transport inhibiting properties of the compounds in the pure target cells, the astrocytes.
The third assay method, the in vivo cat head injury assay has been described by Nelson, L. R.; Bourke, R. S.; Popp, A. J.; Cragoe, E. J. Jr.; Signorelli, A.; Foster, V. V.; Creel, in Marshall, L. F.; Shapiro, H. M.; Smith, R. W. In "Seminars in Neurological Surgery: Neural Trauma"; Propp, A. J.; Bourke, R. S.; Nelson, L. R.; Kimelberg, H. K., Eds.; Raven Press: New York, 1979; p. 297.
This assay consists of a highly relevant brain injury in cats which is achieved by the delivery of rapid repetitive acceleration-deceleration impulses to the animal's head followed by exposure of the animals to a period of hypoxia. The experimental conditions of the assay can be adjusted so that the mortality of the control animals falls in the range of about 25 to 75%. Then, the effect of the administration of compounds of this invention in reducing the mortality over that of the control animals in concurrent experiments can be demonstrated.
Using the assays described supra, compounds of this invention exhibit marked activity both in vitro and in vivo. For example, in the in vitro assays compounds of Formula I and I-G inhibit chloride transport by 50% at concentrations as low as 10 -9 to 10 -10 molar and lower. Likewise in the in vivo assay compound of Formula I or I-G reduce the mortality due to head injury by statistically significant values as compared to control animals.
The following examples are included to illustrate the preparation of representative compounds of Formula I and I-G and representative dosage forms of these compounds.
EXAMPLE 1
(+)3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: (+)3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl) Trifluoromethanesulfonate
A mixture of (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one (25.05 g, 0.0837 mole) and potassium carbonate (35.4 g. 0.256 mole) in dimethylformamide (100 ml.) is stirred at 25° C. for 1 hour, cooled to 0° C. then treated with trifluoromethanesulfonyl chloride (10.5 ml., 0.984 mole) over a 3 minute period. The reaction mixture is stirred at 25° C. for 1 hour, poured into ice water (700 ml.) extracted with ether, washed with water and brine and dried over MgSO 4 . The ether is evaporated at reduced pressure to give 34.2 g of (+) (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl) trifluoromethanesulfonate which melts at 104°-6° C. and is used in Step B without further purification.
Step B: (+)-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic Acid
Diethyl malonate (34.4 g., 0.215 mole) is added to a stirred suspension of sodium hydride (56% on mineral oil, 9.2 g., 0.215 mole) in dimethylformamide (130 ml.) at 10°-15° C. in an inert atmosphere during a 1 hour period. The reaction mixture is stirred at 25° C. for 1.5 hours, cooled to 5° C. and treated with (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl) trifluoromethanesulfonate 34.2 g., 0.0793 mole) in toluene (45 ml.) over a 1 hour period 5°-7° C. The reaction mixture is stirred at 25° C. for 18 hours, poured into a mixture of ice water (700 ml.) and concentrated hydrochloric acid (20 ml.), extracted with ether (3×125 ml.) and methylene chloride (125 ml.). The combined organic extracts are washed with water and brine and dried over MgSO 4 .
Evaporation of the organic solvents at reduced pressure gives crude (+)-diethyl (6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)malonate which is dissolved in ethanol (100 ml), treated with a solution of sodium hydroxide (40 g) in water (300 ml.) and heated at reflux for 4 hours. The reaction mixture is cooled, diluted with water (300 ml) and extracted with hexane (2×125 ml).
The aqueous layer is acidified with hydrochloric acid, extracted with ether (4×100 ml) then extracted into aqueous sodium bicarbonate (15×100 ml) which is acidified with hydrochloric acid and extracted with ether and methylene chloride. The combined organic extracts are washed with water and brine, dried over MgSO 4 and evaporated at reduced pressure to give 23 g. of (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid. A small sample is converted to its dicyclohexylamine salt, m.p., 163° C.
Analysis for C 17 H 18 Cl 2 O 3 .C 12 H 23 N; Calc. C, 66.66; H, 7.91; N, 2.68; Found: C, 66.15; H, 8.17; N, 2.71%.
Step C: (+)-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide
To a solution of (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid (21.8 g., 0.0623 mole) in chloroform (150 ml) and dimethylformamide (1 drop) is added thionyl chloride (25 ml). The reaction mixture is heated at reflux for 3 hours, cooled and concentrated at reduced pressure. The crude (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetyl chloride, thus obtained, is dissolved in methylene chloride (75 ml) and added over 0.5 hour to a mixture of ether (100) ml) and methylene chloride (75 ml) which has been saturated with ammonia.
The addition is conducted at 0°-10° C. Ammonia is passed into the solution for 15 minutes following the addition and then concentrated aqueous ammonia (25 ml) and water (150 ml) are added. The organic layer is washed with water, brine, dried over MgSO 4 and evaporated at reduced pressure leaving 19.8 g. of (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide as a foam which is used in Step D without further purification.
Step D: (+)3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine salt
In a nitrogen atmosphere, (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide (19.8 g., 0.0582 mole) and diethyl oxalate (9.14 g., 0.0626 mole) are dissolved in dimethylformamide (100 ml.) and stirred in an ice bath. Potassium tert. butoxide (15.2 g, 0.136 mole) is added in two portions at a 10 minute interval. The reaction mixture is stirred at 25° C. for 18 hours, poured into water (600 ml) acidified with hydrochloric acid, extracted with ether, washed with water and brine and dried over MgSO 4 . Evaporation of the ether at reduced pressure gives (+)3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione as the hemietherate in the form of a foam. Upon drying at reduced pressure, the analysis of the hemietherate is as follows:
Calc. for C 19 H 17 Cl 2 NO 4 .1/2C 4 H 10 O: C, 58.48; N, 5.14; N, 3.25; Found: C, 58.61; H, 4.91; N, 3.45%.
Further drying of the hemietherate at reduced pressure at about 70° C. gives the solvent free material.
The 1-methylpiperazine salt of the above described compound is prepared by dissolving the compound in ether and treating it with an equimolar quantity of 1-methylpiperazine which gives a precipitate which upon filtration and drying weighs 25.2 g. After recrystallization from 2-propanol this salt melts at 204°-206° C., [α] 25 D=+21.7° (C=1, CH 3 OH).
Analysis, calculated for C 19 H 17 Cl 2 NO 4 .C 5 H 12 N 2 ; C, 58.30; H, 5.91; N, 8.50; Found: C, 58.05; H, 5.98; N, 8.67%.
EXAMPLE 2
(+)3-(6,7-Dichloro-2-cyclopentyl-2-ethyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine salt
The preparation is conducted essentially as described in Example 1, Steps A through D except that an equimolar amount of 6,7-dichloro-2-cyclopentyl-2-ethyl-2,3-dihydro-5-hydroxy-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step so that 3-(6,7-dichloro-2-cyclopentyl-2-ethyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 3
3-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
By following substantially the procedure described in Example 1, Steps A to D, but substituting an equimolar amount of 2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A and using the product of each step in the subsequent step there are obtained 3-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt.
Analysis for C 22 H 23 Cl 2 NO 4 ; Calc. C, 60.55; H, 5.31; N, 3.23; Found: C, 60.56; H, 5.60; N, 3.10%.
EXAMPLE 4
3-(6,7-Dichloro-2,3-dihydro-2-methyl-2-(1-methylethyl)-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is conducted essentially as described in Example 1, Steps A through D except that an equimolecular amount of 6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-(1-methylethyl)-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then the product of Steps A, B and C are used in each subsequent step so that 3-(6,7-dichloro-2,3-dihydro-1-oxo-methyl-2-(1-methylethyl)-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 5
3-(6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
Step A: 6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-5-methoxy-2-methyl-1H-inden-1-one
6.7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-5-methoxy-1H-inden-1-one (56.7 g., 0.181 mole) dissolved in dry toluene (200 ml.) is added dropwise with stirring under nitrogen over 1 hour at room temperature to a suspension of sodium hydride (56% in mineral oil, 8.74 g. 0.204 mole) in toluene (50 ml) and dry dimethylformamide (220 ml.) The mixture is stirred at room temperature for 1.75 hours after completion of the addition, cooled to 0° C., and then methyl iodide (25 ml., 0.4 mole) is added at 0°-5° C. After stirring at 5° for 25 minutes and for one hour at room temperature, methanol (15 ml.) is slowly added followed by acetic acid (10 ml.). The mixture is poured into ice water (1500 ml.) the layers are separated and the aqueous phase extracted three times with toluene (150 ml.) and then with methylene chloride (150 ml.). The combined organic extracts are washed with water, dried over magnesium sulfate and concentrated under vacuum. The residue is triturated with a mixture of hexane and petroleum ether (1:1) are filtered. The solid (50 g.) is recrystallized from a mixture of methylcyclohexane (110 ml.) and hexane (55 ml.) to obtain 38 g. of product, m.p. 75°-77° C. The filtrates from the recrystallization are concentrated and the residue recrystallized from methylcyclohexane to obtain a second drop of 5.5 g. for a total yield of 73%.
Step B: 6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one
6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-5-methoxy-2-methyl-1H-inden-1-one (43.5 g., 0.1329 mole) is added to fused pyridine hydrochloride (440 g.) at 160° C. the mixture is heated with stirring under nitrogen at an internal temperature of 175°-185° C. for 80 minutes. The molten mixture is poured into ice and water (1500 ml.). The solid is extracted with methylene chloride and then ether. The combined organic extracts are washed with water, dried over magnesium sulfate and concentrated in vacuo. The filtrate is further concentrated to obtain an additional 7.0 g. of 6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one, m.p., 188°-90° for a total yield of 96%.
Step C: (6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl) Trifluoromethanesulfonate
Anhydrous potassium carbonate (17.7 g., 0.128 mole) is added to a solution of 6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one (13.35 g., 0.0426 mole) in dry dimethylformamide (60 ml.) The suspension is stirred for 1 hour at room temperature, cooled to 15° C. and then trifluoromethanesulfonyl chloride is added at 15°-18° C. After stirring for 1 hour at room temperature, the reaction mixture is poured into ice water (700 ml.). The oil that separates is extracted with ether (125 ml.). The combined organic extracts are washed with water, dried over magnesium sulfate and concentrated in vacuo to obtain the amber, oily product (18.8 g.), which is used in the next step without further purification.
Step D: (6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid
Diethyl malonate (18.3 g., 0.114 mole) is added with stirring under nitrogen at 10°-15° C. to a suspension of sodium hydride (56% in mineral oil, 4.89 g., 0.114 mole) in dry dimethylformamide (85 ml.). The reaction mixture is stirred for 1 hour at room temperature, cooled to 5° C. and then 6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl trifluoromethanesulfonate (18.8 g., 0.0426 mole dissolved in dry toluene (20 ml.) is added over 1 hour at 5°-7° C. After stirring at room temperature for 18 hours, the reaction mixture is poured into ice water (1000 ml.) and extracted with ether (4×150 ml.) and then with methylene chloride (2×50 ml.). The combined organic extracts are washed three times with water and concentrated under vacuum. The residual oil is dissolved in ethanol (150 ml.) and added to a solution of 20 g. of sodium hydroxide in water (150 ml.). The mixture is refluxed for 3 hours, cooled and the ethanol removed under vacuum. The residue is diluted with water, extracted with hexane and then acidified with hydrochloric acid. The gum that separates is extracted with ether. The combined etheral extracts are washed with water and then extracted repeatedly with dilute sodium bicarbonate. The combined aqueous extracts are acidified with hydrochloric acid and extracted with ether. The ether extracts are washed with brine, dried over magnesium sulfate an concentrated under vacuum to obtain the crude (6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid, 9.3 g., m.p. 145.5°-148° C., in 62% yield. Recrystallization from butyl chloride affords material which melts at 149°-151° C.
Calc. for C 18 H 20 Cl 2 O 3 : C, 60.85; H, 5.67; Found: C, 60.86; H, 6.02.
Step E: (6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-yl)acetamide
To (6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid (5.68 g., 0.016 mole) dissolved in chloroform (25 ml.) containing dimethylformamide (1 drop), thionyl chloride 92.4 ml., 0.33 mole) is added. The mixture is refluxed for 16 hours, cooled, concentrated under vacuum and the residual acid chloride dissolved in methylene chloride (25 ml.). The solution is added over 10 minutes with stirring and cooling in an ice bath to a solution of ether (200 ml.) which had been saturated with ammonia. The mixture is stirred an additional 10 minutes and then poured into ice water. The layers are separated and the aqueous phase extracted with ether and then with methylene chloride. The combined organic extracts are washed with brine, dried over magnesium sulfate and concentrated under vacuum to obtain the (6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide, 5.0 g., 88%, as an orange colored foam which is used in the next step without further purification.
Step F: 3-(6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
(6,7-Dichloro-2-cyclopentylmethyl)-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide (5 g., 0.0141 mole) and diethyl oxalate (2.19 g., 0.015 mole) are dissolved in dry dimethylformamide (30 ml.) and stirred in an ice bath under nitrogen for 20 minutes. Potassium t-butoxide (3.53 g., 0.0315 mole) is then added in two portions 15 minutes apart. The mixture is stirred while cooling in the ice bath for another 45 minutes, then stirred at room temperature for 18 hours and poured into ice water (500 ml.) The mixture is acidified with hydrochloric acid and extracted with ether (4×125 ml.). The combined organic extracts are washed with water and then repeatedly extracted with dilute sodium carbonate. The combined aqueous extracts are acidified with hydrochloric acid, extracted with methylene chloride and then with ether. The combined organic extracts are washed with water, dried over magnesium sulfate and concentrated under vacuum. The residue is chromatographed on silica (175 g.) with a mixture of toluene, dioxane and acetic acid (50:5:1). The appropriate product fractions are concentrated under vacuum and the residue is dissolved in ether and extracted with dilute sodium bicarbonate. The aqueous extracts are acidified with hydrochloric acid and extracted with methylene chloride and then with ether. The combined organic extracts are washed with water, dried over magnesium sulfate and concentrated under vacuum to obtain the 3-(6,7-Dichloro-2-cyclopentylmethyl-2,3-dihydro- 2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione as a foam which was then dried under high vacuum at 90° C. for 2 hours to give 3.6 g. (63%).
Calculated for C 20 H 10 Cl 2 NO 4 : C, 58.85; H, 4.69; N, 3.43; Found: C, 58.90; H, 4.98; N, 3.20.
EXAMPLE 6
3-(2-Allyl-6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out essentially as described in Example 1, Steps A through D, except that an equimolar amount of 2-allyl-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step so that 3-(2-allyl-6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt is obtained in Step D.
EXAMPLE 7
3-(6,7-dichloro-2,3-dihydro-1-oxo-phenyl-2-propargyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: 6,7-dichloro-2,3-dihydro-5-hydroxy-2-phenyl-2-propargyl-1H-inden-1-one
The preparation is conducted essentially as described in Example 5, Step B except that an equimolar amount of [(6,7-dichloro-2,3-dihydro-1-oxo-2-phenyl-2-propargyl-1H-inden-5-yl)oxy]acetic acid is used in place of the 6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-5-methoxy-2-methyl-1H-inden-1-one used in Example 5, Step B. There is thus obtained 6,7-dichloro-2,3-dihydro-5-hydroxy-2-phenyl-2-propargyl-1H-inden-1-one.
Steps B, C, D and E: 3-(6,7-dichloro-2,3-dihydro-1-oxo-2-phenyl-2-propargyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The synthesis was carried out essentially as described in Example 1, Steps A through D except that an equimolar amount of 6,7-dichloro-2,3-dihydro-5-hydroxy-2-phenyl-2-propargyl-1H-inden-1-one was used in place of the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then the products of Steps B, C and D are used in each subsequent step so that 3-(6,7-dichloro-2,3-dihydro-1-oxo-2-phenyl-2-propargyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione 1-methyl-piperazine salt is obtained in Step E.
EXAMPLE 8
3-(6,7-Dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione 1-Methylethanolate
The preparation is carried out by following substantially the procedures described in Example 1, Steps A through D, except that an equimolar amount of 6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-phenyl-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-indene-1-one used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step so that 3-(6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione 1-methylethanolate is obtained in Step D. This product melts at 140°-144° C. after recrystallization from 1-methylethanol.
Analysis Calculated for C 20 H 13 Cl 2 NO 4 .C 3 H 8 O: N, 3.03; H, 4.58; Cl, 15.34; Found: N, 3.02; H, 4.46, Cl, 15.26%.
EXAMPLE 9
3-(2-Benzyl-6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt Hemietherate
The preparation is carried out by following substantially the procedure described in Example 1, Steps A through D, except that an equimolar amount of 2-benzyl-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step so that 3-(2-benzyl-6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt hemietherate are obtained in Step D.
Analysis calculated for C 21 H 15 Cl 2 NO 4 .C 5 H 12 N 2 .1/2C 4 H 10 O: C, 60.76; H, 5.83; N, 7.59; Found: C, 60.54; H, 6.00; N. 7.56%.
EXAMPLE 10
3-(6,7-Dichloro-2-p-fluorophenyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine salt
The preparation is carried out by following substantially the procedures described in Example 1, Steps A through D, except that an equimolar amount of 6,7-dichloro-2-p-fluorophenyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one that is used in Example 1, and Step A. Then, the product of Steps A, B and C are used in each subsequent step so that 3-(6,7-dichloro-2-p-fluorophenyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 11
3-(6,7-Dichloro-2,3-dihydro-2-p-methoxyphenyl-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine salt
The preparation is carried out by following substantially the procedures described in Example 1, Steps A through D, except that an equimolar amount of (6,7-Dichloro-2,3-dihydro-2-p-methoxyphenyl-2-methyl-1-oxo-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one that is used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step (i.e. Steps B, C and D respectively) so that 3-(6,7-dichloro-2,3-dihydro-2-p-methoxyphenyl-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 12
3-[6,7-Dichloro-2,3-dihydro-1-oxo-2-methyl-2-(2-thienyl)-1H-inden-5-yl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out by following essentially the procedures described in Example 1, Steps a through D, except that an equimolar amount of 6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-(2-thienyl)-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one that is used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step (i.e. Steps B, C and D respectively) so that 3-[6,7-dichloro-2,3-dihydro-1-oxo-2-methyl-2-(2-thienyl)-1H-inden-5-yl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 13
3-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione Hemitoluene Solvate and Their (+)-Diastereomers
A stirred solution of a mixture of the diastereomeric racemates of 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione (2.55 g., 0.0062 mole) in acetone (75 ml.) is treated with a solution of Jones reagent (prepared from CrO 3 (0.91 g.) H 2 O (6.5 ml.) and H 2 SO 4 (0.8, SO 4 (0.8 ml.)) over a 10 minute period. The acetone solution is decanted from the precipitated salts, evaporated at reduced pressure, poured into water (100 ml.) and extracted with ether which, in turn, is washed with water, dried over MgSO 4 and evaporated at reduced pressure. The resultant oil is chromatographed on silica (75 g.) eluted with a mixture of methylene chloride, tetrahydrofuran and acetic acid (50:1:1). The pertinent fractions are evaporated at reduced pressure, the residue treated with toluene (100 ml.) and evaporated to azeotrope the residual acetic acid to provide 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione hemitoluene solvate which melts at 181°-3° C.
Analysis calculated for C 19 H 17 Cl 2 NO 5 .1/2C 7 H 8 ; N, 3.07; H, 4.64; Cl, 15.54; Found: N, 2.96; H, 4.78; Cl, 15.47%.
By starting with a mixture of the two (+)-diastereomers of 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione instead of the mixture of racemates described above there is obtained (+)3-[(6,7-dichloro-2-cyclopentyl)-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione.
EXAMPLE 14
3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxymethyl]-4-hydroxy-1H-pyrrole-2,5-dione 1-Methylpiperazine Salt
Step A: 4-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]-1-butene
2-Cyclopentyl-6,7-dichloro-2,3-dihydro-2-methyl-5-hydroxy-1H-inden-1-one (12 gm., 0.04 mole) is dissolved in dimethylformamide (30 m.) and treated with potassium carbonate (5.5 gm., 0.04 mole). The mixture is stirred and heated on a steam bath for 30 minutes and 4-bromo-1-butene (5.5 gm., 0.04 mole) is added and the mixture stirred and heated at 60° C. for 24 hours. The reaction mixture is poured into water (300 ml.) and, after standing, the product removed by filtration, dried and recrystallized from petroleum ether. The yield is 11.5 gm., m.p. 63°-65° C.
Analysis Calc. C 19 H 22 Cl 2 O 4 : C, 64.59; H, 6.28; Found: C, 64.72; H, 6.46%.
Step B: 4-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-oxy]propanoic acid
A mixture of 4-[(2-cyclopentyl-6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]-1-butene (8.8 gm., 0.025 mole), water (200 ml.), methylene chloride (100 ml.), potassium permanganate (9.9 gm, 0.062 mole) and "triton B" (300 mg.) is stirred at 10° C. for 2 hours. Sodium bisulfite and concentrated hydrochloric acid is added portionwise alternately until a clear solution results. The methylene chloride phase is separated, washed with water and then extracted with 5% sodium hydroxide solution. The aqueous extract is separated and acidified and then extracted with ether. The ether extract is dried over sodium sulfate and the solvent removed using a rotary evaporator. The oily product is chromatographed using a column of silica gel (300 gm.) using a mixture of methanol and toluene (1:4, Vol./Vol.). Evaporation of pooled cuts of uniform composition gives 2.1 gm. of an oil which solidifies upon trituration with petroleum ether. Recrystallization from a mixture of ether (30 ml.) and petroleum ether (60 ml.) gives pure product m.p. 140°-142° C.
Analysis Calc. for C 18 H 20 Cl 2 O 4 : C, 58.23; H, 5.43%: Found: C, 58.33; H, 5.60%.
Step C: 3-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]propanamide
The reaction is carried out as described in Example 1, Step C except that the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic is replaced by an equimolar amount of 3-[(6,7-dichloro-2-cyclopentyl-2-methyl-1-oxo-1H-inden-5-yl)oxy]propanoic acid. There is thus obtained first 3-[(6,7-dichloro-2-cyclopentyl-2-methyl-1-oxo-1H-inden-5-yl)oxy]propanoyl chloride and, finally, 3-[(6,7-dichloro-2-cyclopentyl-2-methyl-1-oxo-1H-inden-5-yl)oxy]propanamide.
Step D: 3-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxymethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The reaction is conducted as described in Example 1, Step D except that the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide is replaced by an equimolar amount of 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]propanamide. There is thus obtained 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxymethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt.
EXAMPLE 15
3-[2-((6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: 4-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide
A stirred solution of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyric acid (7 g.) and boron trifluorideetherate (5 ml.) in methanol (50 ml.) is heated at reflux for 1 hour. The methanol is evaporated at reduced pressure, the residue dissolved in ether, washed with water, dried over MgSO 4 and evaporated at reduced pressure. The crude methyl ester thus obtained is dissolved in dimethylformamide (25 ml.), treated with methanol saturated with ammonia and stirred at 25° C. for 2 weeks. The 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide is separated as white crystals melting at 138° C. and is used in Step B without further purification.
The 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide is also prepared by treating a solution of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyric acid (3.85 g., 0.01 mole) in dry tetrahydrofuran (100 ml.) with 1,1'-carbonyldiimidazole (1.62 g., 0.01 mole) in tetrahydrofuran (25 ml) at 0° C., stirring for one hour and then treating with 25% aqueous ammonia (25 ml), stirring for 4 hours at 35° C., and removing the solvent to obtain the product.
Step B: 3-[2-((6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
To a stirred solution of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide (1.83 g., 4.8 mmole) and diethyl oxalate (0.7 ml., 5.2 mmole) cooled in an ice bath and in a nitrogen atmosphere is added potassium tert. butoxide (1.24 g., 11.1 mmole) in several portions during a 10 minute period. The reaction mixture is stirred at 25° C. overnight, poured into cold aqueous hydrochloric acid, extracted into ether, extracted into 2% potassium hydroxide, acidified with aqueous hydrochloric acid, extracted into ether, washed with water, dried over MgSO 4 and evaporated at reduced pressure. The residue is chromatographed on silica (40 g.,) and eluted with a mixture of methylene chloride, tetrahydrofuran and acetic acid (50:1:1). The pertinent fractions are evaporated at reduced pressure, the residue treated with toluene (50 ml) and evaporated to azeotrope the residual acetic acid. The residual oil is dissolved in ether (10 ml.) and methanol (0.5 ml.) then treated with 1-methylpiperazine to give 3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione 1-methylpiperazine salt which melts at 191° C.
Analysis for C 21 H 21 Cl 2 NO 5 .C 5 H 12 N 2 : Calc: C, 57.99; H, 6.18; N, 7.80; Found: C, 58.44; H, 6.56; N, 7.73%.
EXAMPLE 16
3-[3-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)propyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: Methyl 5-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]pentanoate
2-Cyclopentyl-6,7-dichloro-2,3-dihydro-2-methyl-hydroxy-1H-inden-1-one (12 g., 0.04 mole) is dissolved in dimethylformamide (30 ml) and treated with potassium carbonate (5.5 g., 0.04 mole). Methyl 5-bromopentanoate (8.5 g., 0.04 mole) is added dropwise with good stirring over a period of 30 minutes. Then, the mixture is stirred and heated in a steam bath for two hours. The mixture is cooled and poured in to ice water (300 ml.). The product which solidifies upon standing is removed by filtration. The yield is 15.1 g., m.p. 83°-86° C. Upon recrystallization from petroleum ether the methyl 5-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]pentanoate melts at 85°-88° C.
Analysis: Calculated for C 21 H 26 Cl 2 O 4 : C, 61.02; H, 6.34; Found: C, 61.26; H, 6.64%.
Step B: 5-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]pentanoic acid
A mixture of methyl 5-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]pentanaoate (14 g., 0.0339 mole), acetic acid (100 ml) and 6N hydrochloric acid (50 ml) is stirred and refluxed for 6 hours. The mixture is poured into water (400 ml) and the product which solidifies upon standing is removed by filtration and dried. The product is recrystallized from a mixture of tetrahydrofuran, ether and petroleum ether (50/100/200 ml) to give 12.5 g. of 5-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]pentanoic acid, m.p. 106°-108° C. Analysis calculated for C 20 H 24 Cl 2 O 4 : C, 60.15; H, 6.06%: Found: C, 60.19; H, 6.23%.
Steps C and D
These steps are carried out by following essentially the procedures described in Example 1, Steps C and D except that an equimolar amount of 5-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]pentanoic acid is substituted for (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid that is used in Example 1, Step c. Thus, there is obtained in Step C 5-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]pentanamide and in Step D, 3-[3-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)propyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt.
EXAMPLE 17
3-[4-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)butyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: Ethyl 6[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5 -yl)oxy]hexanoate
6,7-Dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one (12 g., 0.04 mole) is dissolved in dimethylformamide (50 ml.), treated with potassium carbonate (5.5 g., 0.04 mole) and heated and stirred on a steam bath for 30 minutes. Ethyl 6-bromohexanoate (8.9 g., 0.04 mole) is added dropwise with good stirring over 15 minutes, then the mixture is heated and stirred in a steam bath for two hours. The reaction mixture is poured into water (400 ml.) and extracted with ether (2×150 ml.). The either extract is dried over sodium sulfate, filtered and the ether removed at reduced pressure. The residue, which crystallizes upon standing, is recrystallized from a mixture of ether and petroleum ether to give ethyl 6-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]hexanoate, 16 g., m.p. 69°-72° C.
Analysis, calculated for C 23 H 30 H 30 Cl 2 O 4 : C, 62.58; H, 6.85. Found: C, 62.8; H, 7.11%.
Step B: 6-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]hexanoic acid
A mixture of ethyl 6-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]hexanoate (16 g., 0.036 mole), acetic acid (100 ml.) and 6N hydrochloric acid (50 ml.) is stirred and refluxed for 6 hours. The mixture is poured into ice water (500 g.), extracted with ether, dried over Na 2 SO 4 , filtered and concentrated to a volume of 100 ml., and chilled. A total of 11.5 of 6-[6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]hexanoic acid separates, m.p. 127°-129° C.
Analysis, calculated for C 21 H 26 Cl 2 O 4 : C, 61.01; H, 6.34%; Found: C, 61.03; H, 6.54%.
Steps C and D
These steps are carried out by following essentially the procedures described in Example 1, Steps C and D except that an equimolar amount of 6-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]hexanoic acid is substituted for (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid that is used in Example 1, Step C. Thus, there is obtained in Step C 6-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]hexanamide and in Step D, 3-[4-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)butyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt.
EXAMPLE 18
3-[5-((6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)pentyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: Ethyl 7-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]heptanoate
6,7-Dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one (12 g., 0.04 mole) is dissolved in dimethylformamide (30 ml.), and potassium carbonate (5.5 g., 0.04 mole) is added and the mixture stirred and heated on a steam bath for 30 minutes. Ethyl 7-bromoheptanoate is added dropwise over 10 minutes with stirring and heating on a steam bath for two hours. The mixture is poured into a mixture of ice and water (300 g., total) and then extracted with ether. The ether extract is dried over Na 2 SO 4 , filtered and the ether removed at reduced pressure. The residue is dissolved in petroleum ether and cooled to -70° C. to obtain ethyl 7-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]heptanoate, 17.7 g., m.p. 47°-50° C.
Analysis, calculated for C 24 H 32 Cl 2 O 4 : C, 63.29; H, 7.08; Found: C, 63.42; H, 7.35%.
Step B: 7-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]heptanoic acid
A mixture of ethyl 7-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]heptanoate (16 g., 0.035 mole), acetic acid (100 ml.) and 6N hydrochloric acid (50 ml.) is stirred and refluxed for 6 hours. The mixture is poured into water (400 ml.) where upon the product slowly solidifies. The product is removed by filtration, dried and recrystallized from a mixture of tetrahydrofuran, ether and petroleum ether (50, 100 and 200 ml., respectively) to give 7-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]heptanoic acid, 12.1 g., m.p. 107°-110° C.
Analysis, calculated for C 22 H 28 Cl 2 O 4 : C, 61.83; H, 6.60; Found: C, 61.93; H, 6.90%.
Steps C and D
These steps are carried out by following essentially the procedures described in Example 1, Steps C and D except that an equimolar amount of 7-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]heptanoic acid, is substituted for the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid used in Step C. Thus, there is obtained in Step C, 7-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]heptanamide and in Step D, 3-[5-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)pentyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt.
EXAMPLE 19
3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: (6,7-Dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)acetamide
To a stirred solution of (6,7-dichloro-2-cyclopentyl)-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide (6.8 g., 0.02 mole) in ethanol (100 ml) is added sodium borohydride (760 mg. 0.02 mole). After one hour another portion of sodium borohydride (760 mg, 0.021 mole) is added and stirring continued for 3 hours. The reaction mixture is poured into ice water and extracted with ethyl acetate. The ethyl acetate extract is washed with water and dried over magnesium sulfate. The ethyl acetate is evaporated at reduced pressure to give (6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)acetamide consisting of a mixture of two diastereomer, each of which is a racemate.
Step B: 3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
In an atmosphere of dry nitrogen, (6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)acetamide (7.8 g., 0.02 mole) diethyl oxalate (3.14 g., 0.0214 mole) and dimethylformamide (40 ml.) is stirred while cooling in an ice bath. Potassium tert.-butoxide (5.2 g., 0.046 mole) is added in two portions at 10 minute intervals. The mixture is then stirred at 25° C. for 18 hours, poured into water, acidified with hydrochloric acid, extracted into ether and the ether extract dried over magnesium sulfate. Evaporation of the ether at reduced pressure gives 3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-yl)-4-hydroxy-1H-pyrrole-2,5-dione as a mixture of two diastereomers. The mixture of two diastereomers is converted to its 1-methylpiperazine salt, m.p. 226-8.
Analysis, calculated for C 19 H 19 Cl 2 O 4 .C 5 H 12 N 2 : C, 58.07; H, 6.29; N, 8.46; Found: C, 57.89; H, 6.40; N, 8.47; (which are separated by chromatography to two pure racemates designated as α-racemate and β-racemate).
EXAMPLE 20
3-[2-((6,7-Dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-b 2-methyl-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione
The preparation is carried out by following substantially the procedures described in Example 19, Steps A and B but substituting an equimolar amount of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1H-inden-5-yl)oxy]butyramide (Example 15, Step A) is substituted for the (6,7-dichoro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide used in Example 19, Step A. Then, the product of Step A is used in Step B to obtain 3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione as a mixture of two diastereomers each consisting of a racemate which are separated by chromatography to give the two pure racemates designated as α-racemate and β-racemate.
EXAMPLE 21
3-(7-Chloro-2-cyclopentyl-2,3-dihydro-2,6-dimethyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out by following substantially the procedures described in Example 1. Steps A and D except that an equimolar amount of 7-chloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2,6-dimethyl-1H-inden-1-one is substituted for the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step (i.e., Steps B, C and D respectively) so that 3-(7-chloro-2-cyclopentyl-2,3-dihydro-2,6-dimethyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 22
3-(2-Cyclopentyl-2,3-dihydro-2,6,7-trimethyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out by following essentially the procedures described in Example 1, Steps A and D except that an equimolar amount of 2-cyclopentyl-2,3-dihydro-5-hydroxy-2,6,7-trimethyl-1H-inden-1-one is substituted for the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step (i.e., Steps B, C and D respectively) so that 3-(2-cyclopentyl-2,3-dihydro-2,6,7-trimethyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 23
(-)-3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out by following substantially described in Example 1, Steps A and D substituting an equimolar amount of (-)6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the product of Steps A, B and C are used in each subsequent step so that (-)-3-(6,7-dichloro-2-cyclo-pentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D. The melting point of the 1-methylpiperazine salt is 203°-204° C.
Analysis, calculated for C 24 H 29 Cl 2 N 3 O 4 : C, 58.30; H, 5.91; N, 8.50%. Found: C, 58.37; H, 6.02; N, 8.61%.
EXAMPLE 24
(+)-[6,7-Dichloro-2,3-dihydro-2-methyl-2-(1-methyl-ethyl)-1-oxo-1H-inden-5-yl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: (+)6,7-Dichloro-2,3-dihydro-2-methyl-2-(1-methylethyl)-1-oxo-1H-inden-1-one
The preparation is conducted essentially as described in Example 5, Step B except that an equimolar amount of (+)(6,7-dichloro-2,3-dihydro-2-methyl-2-(1-methylethyl)-1-oxo-1H-inden-5-yl)-acetic acid is substituted for the 6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-5-methoxy-2-methyl-1H-inden-1-one that is used in Example 5, Step B. There is thus obtained in (+)-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-(1-methylethyl)-1H-inden-1-one.
Steps B, C, D and E
The synthesis is carried out essentially as described in Example 1, Steps A through D except that an equimolar amount of (+)-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-(1-methylethyl)-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one that is used in Example 1, Step A. Then, the products of Step B, C and D are used in each subsequent step (i.e., Steps C, D and E) so that (+)-6,7-dichloro-2,3-dihydro-2-methyl-2-(1-methylethyl)-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione-1methylpiperazine salt is obtained in Step E.
EXAMPLE 25
(-)[6,7-Dichloro 2,3-dihydro-2-methyl-2-(1-methylethyl)-1-oxo-1H-inden-5-yl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
Step A: (-)[6,7-Dichloro 2,3-dihydro-2-methyl-5-hydroxy-2-(1-methylethyl)-1H-inden-1-one
The preparation is carried out essentially as described in Example 5, Step B except that an equimolar amount of (-)[6,7-dichloro-2,3-dihydro-2-methyl-2-(1-methylethyl)-1-oxo-1H-inden-5-yl)oxy]acetic acid is substituted for the 6,7-dichloro-2-cyclopentylmethyl-2,3-dihydro-5-methoxy-2-methyl-1H-inden-1-one that is used in Example 5, Step B. There is thus obtained (-)-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-(1-methylethyl)-1H-inden-1-one.
Steps B, C, D
These synthetic steps are carried out essentially as described in Example 1, Steps A through D except that an equimolar amount of (-)-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-(1-methylethyl)-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the products of Step B, C and D are used in each subsequent step (i.e., Steps C and D) so that (-)-[6,7-dichloro-2,3-dihydro-2-methyl-2-(1-methylethyl)-1-oxo-1H-inden-5-yl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 26
(+)-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is conducted essentially as described in Example 1, Steps A through D except that (+)-2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the products of Step A, B and C are used in each subsequent step (i.e., Steps B, C and D) so that (+)-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 27
(-)-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is conducted essentially as described in Example 1, Steps A though D except that (-)-2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one used in Example 1, Step A. Then, the products of Step A, B and C are used in each subsequent step (i.e., Steps B, C and D) so that (-)-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 28
(+)-(6,7-Dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out substantially as described in Example 1, Steps A though D except that (+)-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-phenyl-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one that is used in Example 1, Step A. Then, the products of Step A, B and C are used in each subsequent step (i.e., Steps B, C and D) so that (+)-(6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 29
(-)-(6,7-Dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out substantially as described in Example 1, Steps A through D except that (-)-6,7-dichloro-2,3-dihydro-5-hydroxy-2-methyl-2-phenyl-1H-inden-1-one is substituted for the (+)-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-2-methyl-1H-inden-1-one that is used in Example 1, Step A. Then, the products of Step A, B and C are used in each subsequent step (i.e., Steps B, C and D) so that (-)-(6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt are obtained in Step D.
EXAMPLE 30
(+)-3-[2-((6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out substantially as described in Example 15, Steps A and B except that (+)-[(6,7-dichloro-2-cycopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyric acid is substituted for the corresponding racemic compound used in Example 15, Step A. There is obtained in Step A, (+)-4-[((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide which is then used in Step B in place of the corresponding racemic compound to obtain (+)3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt.
EXAMPLE 31
(-)3-[2((6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-Methylpiperazine Salt
The preparation is carried out substantially as described in Example 15, Steps A and B except that (-)-4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyric acid is substituted for the corresponding racemic compound used in Example 15, Step A. There is obtained in Step A, (-)-4[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide which is then used in Step B in place of the corresponding racemic compound to obtain (-)3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione and its 1-methylpiperazine salt.
EXAMPLE 32
(+)-Enantiomers of the two diastereomers of 3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
Step A: (+)-Enantiomers of the two diastereomers of (6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)acetamide
To a stirred solution of (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide (3.4 g, 0.01 mole) in ethanol (50 ml) is added sodium borohydride (380 mg, 0.01 mole). After one hour, another portion of sodium borohydride (380 mg, 0.01 mole) is added. The reaction is stirred for 3 hours, poured into ice water, extracted with ethyl acetate, washed with water and dried over magnesium sulfate. Evaporation of the ethyl acetate gives a mixture of the (+)-enantiomers of the two diastereomers of (6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)acetamide.
Step B: (+)-Enantiomers of the two diastereomers of 3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
In an atmosphere of dry nitrogen, a mixture of the (+)-enantiomers of the two diastereomers of (6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)acetamide (3.4 g, 0.01 mole) and diethyl oxalate (1.57 g, 0.0107 mole) are dissolved in dimethylformamide (20 ml) and stirred in an ice bath. Potassium tert. butoxide (2.6 g, 0.023 mole) is added in 2 portions at a 10 minute interval. The reaction mixture is stirred at 25° for 18 hours, poured into water, acidified with hydrochloric acid, extracted into ether, washed with water and dried over magnesium sulfate. Evaporation of the ether at reduced pressure gives a mixture of the two (+)-enantiomers of the two diastereomers of 3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione. Each of these two diastereomers consists of one enantiomer which are separated by chromatography to give the two pure diastereomers designated as the (+)-α-diastereomer and (+)-β-diastereomer.
EXAMPLE 33
(+)-Enantiomers of the two diastereomers of (+)-3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione
Step A: (+)-Enantiomers of the two diastereomers of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide
The preparation is carried out essentially as described in Example 15, Step A except that (+)-4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyric acid is substituted for the corresponding racemate used in Example 15, Step A. There is thus obtained (+)-enantiomers of the two diastereomer of 4-[(6,7-dichloro-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]butyramide.
Step B: (+)-Enantiomers of the two diastereomers of 4-[(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-1-methyl-1H-inden-5-yl)oxy]butyramide
The synthesis is conducted substantially as described in Example 19, Step A except that an equimolar amount of a mixture of the two (+)-enantiomers of the two diastereomers of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]-butyramide is substituted for the (6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-acetamide that is used in Example 19, Step A. There is thus obtained (+)-enantiomers of the two diastereomers of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-1-methyl-1H-inden-5-yl)oxy]butyramide.
Step C: (+)-Enantiomers of the two diastereomers of 3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)-oxy)ethyl]4-hydroxy-1H-pyrrole-2,5-dione
The preparation is conducted substantially as described in Example 1, Step D except theat an equimolar amount of the two (+)-enantiomers of the two diastereomers of 4-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]butylamide is substituted for the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide used in Example 1, Step D. There is thus obtained a mixture of the (+)-enantiomers of the two diastereomers of 3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy)-ethyl]-4-hydroxy-1H-pyrrole-2,5-dione. Each diastereomer consists of one pure enantiomer which are separated by chromatography to give the two pure diastereomers designated as (+)-α-diastereomer and (+)-β-diastereomer since they were derived from the (+)-enantiomer described in Step A.
EXAMPLE 34
(+)-Enantiomers of the diastereomers of 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione
Step A: (+)-Enantiomers of the diastereomers of [(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]acetamide
The preparation is carried out by following substantially the procedures described in Example 1, Step C except that an equimolar amount of (+)-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]acetic acid is substituted for the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetic acid used in Example 1, Step C. There is thus obtained first the (+)-enantiomers of the diastereomers of [(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]-acetyl chloride and then (+)-enantiomers of the diastereomers of [(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]acetamide.
Step B: (+)-Enantiomers of the diastereomers of [(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]acetamide
The preparation is carried out by following substantially the procedures described in Example 19, Step A, except that an equimolar amount of (+)-enantiomers of the diastereomers of [(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy]acetamide is substituted for the (6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide used in Example 19, Step A. There is thus obtained (+)-enantiomers of the (+)-diastereomers of [(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]acetamide.
Step C: (+)-Enantiomers of the diastereomers of 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione
The preparation is carried out by following substantially the procedures described in Example 1, Step D, except that an equimolar amount of (+)-enantiomers of the diastereomers of [(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]acetamide is substituted for the (+)-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)acetamide used in Example 1, Step D. There is thus obtained a mixture of the (+)-enantiomers of the diastereomers of 3-[(6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-hydroxy-2-methyl-1H-inden-5-yl)oxy]-4-hydroxy-1H-pyrrole-2,5-dione which consists of two diastereomers each of which are composed of a pure enantiomer. These diastereomers are separated by chromatography to give the pure diastereomers which are designated as (+)-α-diastereomer and the (+)-β-diastereomer since they are derived from the (+)-enantiomer described in Step A.
EXAMPLE 35
Parenteral Solution of the 1-Methylpiperazine Salt of (+)-3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
(+)-3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione 1-methylpiperazine salt (Example 1, Step D) (125.4 mg) is dissolved by stirring and warming with a sufficient volume of pyrogen-free water to give a final volume of 20 ml. The solution is then sterilized by filtration, the concentration of the active agent in the final solution is 0.5%.
EXAMPLE 36
Parenteral Solution of the Sodium Salt of (+)-3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
(+)-3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione (Example 1, Step D) (500 mg) is dissolved by stirring and warming with 0.25N sodium bicarbonate (5.4 ml). The solution is diluted to 10 ml and sterilized by filtration. All the water that is used in the preparation is pyrogen-free. The concentration of the active agent in the final solution is 5%.
EXAMPLE 37
Parenteral Solution of the Sodium Salt of (+)-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
(+)-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione (Example 26, Step D) (500 mg) is dissolved by stirring and warming with 0.25N sodium bicarbonate (5 ml). The solution is diluted to 10 ml and sterilized by filtration. All the water that is used in the preparation is pyrogen-free. The concentration of the active agent in the final solution is 5%.
EXAMPLE 38
Parenteral Solution of Sodium Salt of (+)-3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione
(+)-3-[2-((6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione (Example 30, Step B) (500 mg) is dissolved by stirring and warming with 0.05N sodium bicarbonate solution (4.9 ml). The solution is diluted to 10 ml and sterilized by filtration. All the water that is used in the preparation is pyrogen-free. The concentration of the active agent in the final solution is 5%.
EXAMPLE 39
Parenteral Solution of the Sodium Salt of (-)-(6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione
(-)-(6,7-Dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione (Example 29, Step D) (500 mg) is dissolved by stirring and warming with 0.25N sodium bicarbonate solution (5.4 ml). The solution is diluted to 10 ml and sterilized by filtration. All the water that is used in the preparation is pyrogen-free. The concentration of the active agent in the final solution is 5%.
Similar parenteral solutions can be prepared by replacing the active ingredient of the above example by any of the other 4-hydroxy-1H-pyrrole-2,5-dione compounds of this invention.
EXAMPLE 40
______________________________________Dry-Filled Capsules Containing 100 mg of ActiveIngredient Per Capsule Per Capsule______________________________________(+)-3-(6,7-Dichloro-2-cyclo- 100 mgpentyl-2,3-dihydro-2-methyl-1-oxo-1H--inden-5-yl)-4-hydroxy-1H--pyrrole-2,5-dioneLactose 99 mgMagnesium Stearate 1 mgCapsule (Size No. 1) 200 mg______________________________________
The (+)-3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione (Example 1, Step D) is reduced to a No. 60 powder and then the lactose and magnesium stearate are passed through a No. 60 bolting cloth onto the powder and the combined ingredients admixed for 10 minutes and then filled into a No. 1 dry gelatin capsule.
EXAMPLE 41
______________________________________Dry-Filled Capsules Containing 100 mg of ActiveIngredient Per Capsule Per Capsule______________________________________(+)-(2-Butyl-6,7-dichloro-2- 100 mgcyclopentyl-2,3-dihydro-1-oxo-1H--inden-5-yl)-4-hydroxy-1H--pyrrole-2,5-dioneLactose 99 mgMagnesium Stearate 1 mgCapsule (Size No. 1) 200 mg______________________________________
The (+)-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione (Example 26, Step D) is reduced to a No. 60 powder and then the lactose and magnesium stearate are passed through a No. 60 bolting cloth onto the powder and the combined ingredients admixed for 10 minutes and then filled into a No. 1 dry gelatin capsule.
EXAMPLE 42
______________________________________Dry-Filled Capsules Containing 100 mg of ActiveIngredient Per Capsule Per Capsule______________________________________(+)-3-[2-((6,7-dichloro-2-cyclo- 100 mgpentyl-2,3-dihydro-2-methyl-1-oxo-1H--inden-5-yl)oxy)ethyl]-4-hydroxy-1H--pyrrole-2,5-dioneLactose 99 mgMagnesium Stearate 1 mgCapsule (Size No. 1) 200 mg______________________________________
The (+)-3-[2-((6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)oxy)ethyl]-4-hydroxy-1H-pyrrole-2,5-dione (Example 30, Step B) is reduced to a No. 60 powder and then the lactose and magnesium stearate are passed through a No. 60 bolting cloth onto the powder and the combined ingredients admixed for 10 minutes and then filled into a No. 1 dry gelatin capsule.
EXAMPLE 43
______________________________________Dry-Filled Capsules Containing 100 mg of ActiveIngredient Per Capsule Per Capsule______________________________________(-)-(6,7-Dichloro-2,3-dihydro- 100 mg2-methyl-1-oxo-2-phenyl-1H--inden-5-yl)-4-hydroxy-1H--pyrrole-2,5-dioneLactose 99 mgMagnesium Stearate 1 mgCapsule (Size No. 1) 200 mg______________________________________
The (-)-(6,7-dichloro-2,3-dihydro-2-methyl-1-oxo-2-phenyl-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-dione (Example 29, Step D) is reduced to a No. 60 powder and then the lactose and magnesium stearate are passed through a No. 60 bolting cloth onto the powder and the combined ingredients admixed for 10 minutes and then filled into a No. 1 dry gelatin capsule.
Similar dry-filled capsules can be prepared by using any of the other compounds of this invention. | The invention relates to novel substituted-3-(2,3-dihydro-1H-inden-5-yl)-4-hydroxy-1H-pyrrole-2,5-diones, their analogs and their salts. These compounds are synthesized by methods selected from a number of synthetic routes depending on the particular structure, choice of intermediate or preferred reaction sequence. The compounds are useful for the treatment and prevention of injury to the brain and of edema due to head trauma, stroke (particularly ischemic), arrested breathing, cardiac arrest, Reye's syndrome, cerebral thrombosis, cerebral embolism, cerebral hemorrhage, cerebral tumors, encephalomyelitis, spinal cord injury, hydrocephalus, post-operative brain injury trauma, edema due to cerebral infections and various brain concussions. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates in general to ornamentation, and, more particularly, to a method of preparing works of art using wax.
There are a variety of methods for preparing original works of art, many of which have been the subjects of patents. Examples of such methods are disclosed in U.S. Pat. Nos. 1,815,589, 2,065,266, 2,811,800, 3,772,421 and 3,799,819.
Presented herein is a unique art form wherein the "paint" is wax and the "brush" is a hand-held tool which is warmed sufficiently to melt wax.
SUMMARY OF THE INVENTION
The method embodying the teachings of the present invention uses colored wax, such as crayons, or the like, to provide the "paint", and a hot hand-held tool, such as a travel iron, or the like, to "brush" the "paint" for developing a picture, design or the like.
The colored wax is first melted, then is transferred to a paper member to define a background. A hand-held tool is maintained at a temperature sufficient to melt the colored wax, and is used to define lines or other patterns in the background or to place other colors onto that background. The transfer of colored wax using the hand-held tool is accomplished by effecting contact between the hot tool and a crayon, or the like, to transfer colored wax to an appropriate location on the tool. The wax from the tool is then transferred to the background.
A finished picture is buffed, then a protective coat of varnish or other such material is placed on that picture.
OBJECTS OF THE INVENTION
A main object of the present invention is to provide a unique art form.
Another object of the present invention is to provide a new method for producing original works of art.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming part hereof, wherein like reference numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing one step in carrying out the process embodying the teachings of the present invention.
FIG. 2 is a perspective view showing another step in carrying out the process embodying the teachings of the present invention.
FIG. 3 is a perspective view showing another step in carrying out the process embodying the teachings of the present invention.
FIG. 4 is a view showing another step in carrying out the process embodying the teachings of the present invention.
FIG. 5 is a perspective view of another step in carrying out the process embodying the teachings of the present invention.
FIG. 6 is a perspective view of another step in carrying out the process embodying the teachings of the present invention.
FIG. 7 is a perspective view showing movements of a hand-held tool required to define pattern elements in the process embodying the teachings of the present invention.
FIG. 8a is a perspective view showing another step in carrying out the process embodying the teachings of the present invention.
FIG. 8b is a perspective view showing another step in carrying out the process embodying the teachings of the present invention.
FIG. 9 is a perspective view showing a kit used in carrying out the process embodying the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Shown in FIGS. 1-6, and FIGS. 8 and 9, are steps comprising a method of forming an original work of art. These steps embody the teachings of the present invention; however, certain variations can be effected without departing from the scope of this invention. Such steps, even though not specifically identified herein, are intended to be included.
A background is prepared for a picture P partially shown in FIGS. 5 and 6, using the steps indicated in FIGS. 1 and 2. A warming element 10, such as a food warming tray, or the like, is shown in FIG. 1. The element 10 has a planar upper surface 12 and preferably includes a temperature control 14 and is electrical, with a cord 16 connecting the heat producing means located beneath the planar surface 12 to a power source. The planar surface 12 is maintained at a temperature at which wax markers, such as crayons 20, will melt into a fluent mass 22, and remain liquid, but will not boil or otherwise break up. The fluent mass 22 remains viscous enough to be readily spread. Preferably, the wax will not be hot enough to bubble, but not be so cool as to smear when applied to a backing member such as a piece of paper 30 in the step described hereinafter. The paper can be white or colored as desired. Those skilled in the art will be able to select the temperature for surface 12 at which the crayon forms a liquid mass having a suitable and desirable viscosity. The mass 22 is formed by touching the hot surface 12 with a crayon tip or edge, with the tip being used in FIG. 1. Preferably, there should be just enough material in mass 22 to just cover one side of paper 30. The mass 22 can also be formed using several crayons to blend colors, or to produce streaks, or to produce highlights, or the like, as will occur to those skilled in the art. Masses can also be juxtaposed on the warming element to produce other effects.
The piece of paper 30 is then held at or adjacent one edge 32 thereof and smoothly and gently drawn through the mass 22 so that the crayon in mass 22 is transferred to face 34 of the paper. Preferably, the paper is drawn through the molten wax in one sweeping motion. The paper is moved through the mass 22 in a manner to produce a smooth and even background on the paper 30. It is noted that a blotchy background can be redone by rewaxing if done before the paper cools.
Other movements, such as rotary movements, spiral movements, or the like, can be used or combined with each other and/or with the above-discussed drawing movement to produce other effects, if so desired.
Preferably, the paper is a vintage gloss text paper having a glossy finish on face 34. The glossy finish of such paper prevents the paper from absorbing significant amounts of wax. Other similar papers can also be used without departing from the scope of this disclosure.
The background dries quickly, and appears as a smooth, even application of a layer of crayon to the paper 30.
A picture, design, or the like, is then placed on the paper. This step is shown in FIG. 3 wherein a picture P is produced.
A hand-held tool is used to produce the picture. A preferred hand-held tool is a travel iron 50 as shown in FIG. 3. Such a tool is really three tools in one, as will appear from the ensuing discussion, but other tools such as woodburning irons, heated needles, or the like can be used without departing from the scope of the present invention.
The travel iron 50 and the use thereof is best shown in FIG. 7, and attention is directed thereto. The iron 50 includes a planar bottom 52, a stern edge 54, a stem tip 56, a port side 58, a starboard side 60 and a top 62. A handgrip 64 is mounted on top 62. The iron 50 also contains heating elements (not shown), a power cord (not shown), as well as temperature regulating means (not shown). The iron 50 is maintained at a temperature sufficient to melt the wax material being used to form the picture. Considerations involved in temperature selection for the iron 50 are similar to those discussed above with regard to the warming element 10.
The tip 56 can be used to define lines 70 in the background by moving that tip over the background. The edges of the iron can also be used to define such lines. The wax of the background melts, thereby exposing some or all of the paper beneath the background. Varying amounts of pressure and/or angle between the iron and the paper can be used to define lines of various, and varying, widths, shapes, and the like.
Crayons can be melted onto the iron 50, either on the bottom 52, or on the tip 56, or on the sides 58 and/or 60, or even on the stem 54. A mass 74 of melted crayon is shown in FIG. 7. The melted wax is blotted onto and over the background to define leaves, grass, or the like. By varying the amounts of crayon in the mass 74, various effects can be produced. One or a plurality of colors can be used in the mass 74 to produce different effects.
Wax on the tip 56, as well as on edge 76, can be used to define colored lines. Varying pressure on the iron, or varying amounts of wax, or the like, can be used to vary the thickness of the lines thus defined. Wax on the tip or on the planar surface 52 can be blotted onto the background to define flowers, trees, or the like. Wax can be removed from the background using the tip as well.
The planar bottom adjacent the tip or the edges or the stem of the iron 50 can be stroked across the paper to produce a water effect. It is noted that the edges 78 and the tips 80 can also be used in carrying out the process. The strokes can be short, long, in any direction on the paper, even, varied, curved, or the like, as desired by the artist to produce sought effects.
It is also noted that while crayons have been specified, other means can also be used. A very acceptable media is produced by substituting TALLENS® for crayons. Even clear wax candles can be used. Other media will occur to those skilled in the art based on this disclosure, and will not be discussed; however, it is to be understood that such other media are also included in this invention.
A paintbrush 82 can also be used to complete the picture. A mass 22' of crayon is formed on the warming element, the brush dipped into that mass, and the molten crayon daubed, or otherwise applied to the picture as shown in FIG. 4. As also shown in FIG. 4, printed matter V can be included. The printed matter can be done free hand or in calligraphy. The process is as above-described, with the addition of Black Ink and Speed Ball calligraphy pens. The printed material is written before the art process begins.
A buffing step is shown in FIG. 5. After the wax on the paper is dry, a polishing cloth 90 is gently rubbed over the picture. The paper 30 is held against bending during this step. A facial tissue is suitable for use as polishing cloth 90. The buffing is carried out gently enough so the wax is not chipped.
A protective coating is applied to the buffed painting as shown in FIG. 6. The paper 30 is placed on a flat surface, and an applicator 100 is used to apply a protective coat, such as clear varnish 102 or the like, to the painting. The applicator preferably includes a spatula end 104 and a handle 106, with the spatula end being a soft material such as sponge rubber or the like. The varnish is brushed over the painting thinly and evenly with one or two strokes.
The painting is then set aside to dry.
The paper can then be inverted so the painting is face down, and adhesive, such as glue 112, or the like, applied to the rear surface 110 by an applicator 114, which may be similar to applicator 100, as shown in FIG. 8a. The adhesive is preferably placed on the back surface adjacent a top edge 116 of the paper 30.
The paper is then suitably placed on a mounting member, such as centering the paper on a greeting card material 118 as shown in FIG. 8b, or the like. The paper is then pressed onto the mounting member, and set aside to allow the adhesive to dry.
The finished product is an original work of art which is quickly and easily produced. Each picture will be slightly different from all other pictures, and thus each picture will be unique regardless of the skill of the artist.
It is also noted that the glossy side of a card can be used to form large prints. Such side is a chrome-coated enamel. For weight, such is known as "10 point". Such heavy paper prevents wrinkling.
A kit can include all of the materials necessary to produce pictures using the above-discussed process. A kit is shown in FIG. 9, and can include templates, stencils, forms, stamps, tracing means, brushes and crayons. The kit can also include heating elements as well as hand-held tools. The kits can also include backing members, greeting card materials, adhesive, and the like. The completeness of the kit need only be controlled by the price, and other considerations of a manufacturer. The kit can also include the protective coatings as well as applicators, and the like. The templates, stencils and the like are used as guides and the hand-held tool is guided thereby to define forms and pictures produced by the above-disclosed method. Thus, for example, a template can have shapes for trees, flowers, people, houses, or the like, and a user need only place the appropriate form over a background formed as above-discussed, and use the hand-held tool with that template to define the desired shape. The stamps can be used to stamp out selected patterns, and can be heated or heatable as desired, and can be used while the background is still molten to define shapes therein. Wax can also be placed on the stamps and then transferred to the background.
Such a kit can contain a large variety of forms, colors, and the like. Those skilled in the art will be able to envision such kits from the present discussion, and accordingly, greater detail will not be presented. However, such lack of detail is not intended to be limiting.
Such a kit can also include wax cutouts such as indicated by reference numeral 120 in FIG. 9. Each cutout is an add-on figure such as flower 122, bird 124, and the like, to be positioned on the backing paper after the background is defined, and is formed of crayon, or the like, and is cut out using scissors, knives, or the like, then placed on the background. Alternatively, adhesive can be used to attach the cut out figure to the background.
As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is, therefore, illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within the metes and bounds of the claims or that form their functional as well as conjointly cooperative equivalents are, therefore, intended to be embraced by those claims. | A process for preparing a work of art includes steps of melting crayon, transferring that molten crayon to a backing member to form a background and forming a design on that background. The design is formed using a hand-held heating element to melt portions of the background and/or to transfer further molten crayon to the background. A kit containing crayons and backing members is also disclosed. | 1 |
SUMMARY OF THE INVENTION
The invention is directed to an improved heat collector for solar systems. Specifically, it solves a problem associated with the so-called "greenhouse" type of collector wherein a solar absorber-heat exchanger is enclosed in a housing having a glazed surface for exposure of the absorber to solar rays. The invention permits the safe substitution of plastic absorber-exchangers for ones of copper or other metals currently costing many times that of the plastics employed herein. Use of plastic in greenhouse collectors has heretofore involved the danger of severe damage to the plastic by heat buildup within the closed structure housing the absorber-exchanger unless some means of removing excess heat resulting from a failure of the fluid circulation system is provided. The invention utilizes thermal expansion of the plastic absorber-exchanger to vent the collector interior to ambient air if a preselected temperature is exceeded, thus permitting the safe use of plastic arrays.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a greenhouse type collector incorporating the invention;
Fig. 2 is a partial vertical section taken along line 2--2 of FIG. 1;
FIG. 3 is a view of that portion of the device shown in FIG. 2 with the uppermost glazed cover element raised by expansion of a housed array by the suns rays; and
FIG. 4 shows an alternate embodiment of the device shown in FIGS. 1, 2 and 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a "greenhouse" type solar heat collector generically designated by reference numeral 10 and incorporating the invention. A housing 12, which may be of a suitable metal or plastic encloses an elongate solar abosorber-heat exchanger generically designated 14 and including a manifold 16 for fluid inlet from conduit 18 through flexible connector 20 to a plurality of tubular elements 22 connected in fluid flow relation thereto. A second manifold 24 is fixed to the opposite ends of elements 22, also in fluid flow relation thereto and leads through a rigid connector 26 to an outlet conduit 28. The opposite end of manifold 24, not shown, is suitably fixed to housing 12 to prevent movement of that end of the exchanger in respect to housing 12 in response to expansion or contraction of the entire assembly as the internal temperature of the collector varies as described below.
As shown in FIGS. 1 and 2, housing 12 may be of the configuration of a generally rectangular pan-line container with side walls 27, end walls 29 and bottom wall 30 as best shown in FIGS. 2 through 4. Housing 12 may be a stamping if of metal or molded or extruded if of a plastic of a type later described. The open face of housing 12 is positioned in use toward the sun and is normally closed by a planiform light transparent element or cover 33, glazed either with a suitable transparent plastic film or with glass. Exchanger 14 is supported within housing 12 on a plurality of bar-like elements 32 disposed in parallel spaced relation longitudinally of the exchanger. Elements 32 find their support on bottom wall 30 of housing 12 to extend transversely thereof as shown in FIG. 2, with tubular elements 22 resting upon but not attached to bar elements 32. Since the left hand end of the absorber-exchanger 14 (as shown in FIG. 1) is fixed to housing 12 and the right hand end is connected to housing 12 through flexible connector 20, the tubular array, slidably supported on bars 32 is free to expand or contract with heat changes within housing 12. As the temperature therein approaches a level which might cause damage to array 14, the non-fixed right hand end of the array has expanded slightly in the direction of the longitudinal arrow, FIG. 3.
The exchanger, particularly the tubular elements 22, may be of plastic such as acrylonitrile/butadiene/styrene (ABS) or polyvinyl chloride (PVC) and preferably loaded with carbon black or the like for optimum heat absorption. Such materials have a coefficient of expansion of from 6 to 13 × 10 -5 /° F. Housing 12 as above mentioned, may be fabricated of a glass filled plastic (fiberglass) or of steel or aluminum (thermal expansivity of from 0.4 to 1.3 × 10 -5 /° F.). A thermal insulation layer may be provided on the inner surfaces of the housing to reduce the passage of solar heat to the exterior. A temperature differential of 100° F. will cause array 14 (if fabricated 10 feet long) to expand approximately one inch relative to housing 12. Such differential motion is employed as below described to open and close cover 33 as shown in FIGS. 2, 3 and 4. As best shown in FIGS. 2 and 3 when the temperature within housing 12 is below a preselected critical level, housing cover 33 is drawn into snug marginal engagement with the open end housing by the combined weight of cover 33 and a pair of springs 36. Springs 36 are maintained in tension by the lever arms 38 of a pair of bellcranks generically designated 40. A shaft 42 fixed to and extending transversely of housing sidewalls 27 provides pivotal mounting for bellcranks 40. The vertical bellcrank arms 44 are pivotally attached to the outermost elements 22 of array 14 by pintle bolts 46. A pair of springs 48 are mounted in fixtures 50 on opposite side walls of housing 12 and are normally maintained under compression by the weight of cover 33 and the tension of springs 36 when bellcranks 40 are in their normal position as shown in FIG. 2.
As above mentioned, array 14 (of an assumed length of ten feet) will expand longitudinally some 1 inch in response to a temperature differential of 100° F. relative to the housing 12 when fabricated of certain materials above described. The device is designed normally to assume the FIG. 2 position until the internal housing temperature approaches a level considered likely to damage plastic exchanger 14. Such expansion moves the free end of the exchanger 14 in the horizontal arrow direction of FIG. 3 position. Arms 38 then rotate clockwise to relieve the tension on springs 36 sufficiently to allow compression springs 48 to raise cover 33 sufficiently to vent the interior of housing 12 with ambient air. As the internal temperature gradually drops with resultant contraction of the exchanger 14, bellcranks 40 are rotated counter-clockwise, increasing the tension of springs 36 sufficiently to compress springs 48 to the FIG. 2 position with resultant closure of cover 33.
An alternative embodiment of the device is shown in FIG. 4, wherein bellcranks 40 have their vertical lever arms mounted to lugs 52 to project outwardly of manifold 16 in the plane of exchanger 14. Bellcranks 40 are pivoted to housing 12 at 54, with arms 38 extending outwardly from the exchanger 14 and biased counter-clockwise by tension springs 56. As the exchanger 14 expands, the lever arms 38 are pivoted counter-clockwise to relieve the tension of springs 56 and cover 33 is raised by springs 48 in the manner above described. | An apparatus for collecting solar energy wherein a heat exchange array of plastic or the like is protected against damage by excessive heat buildup. The array is housed in a normally closed chamber having a portion transparent to solar rays and the chamber is periodically vented by means responsive to heat expansion of the enclosed array. The invention permits substantial cost reductions in solar heat exchanges; particularly of the type adapted to heat buildings, swimming pools and domestic water systems. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The following U.S. patent applications have subject matter related to this application: application Ser. No. 08/382,958, filed Feb. 2, 1995 now abandoned; Ser. No. 08/400,397, filed Mar. 7, 1995; Ser. No. 08/399,851 filed Mar. 7, 1995 now abandoned; Ser. No. 08/482,296, filed Jun. 7, 1995; Ser. No. 08/486,396, filed Jun. 7, 1995 now abandoned; Ser. No. 08/484,730, filed Jun. 7, 1995; Ser. No. 08/479,279, filed Jun. 7, 1995 now U.S. Pat. No. 5,805,914; Ser. No. 08/483,020, filed Jun. 7, 1995; Ser. No. 08/487,224, filed Jun. 7, 1995; Ser. No. 08/400,722, filed Mar. 7, 1995 now U.S. Pat. No. 5,596,517; Ser. No. 08/400,723, filed Mar. 7, 1995 now U.S. Pat. No. 5,594,678; Ser. No. 08/404,067, filed Mar. 14, 1995 now U.S. Pat. No. 5,590,067; Ser. No. 08/567,555, filed Dec. 5, 1995 now U.S. Pat. No. 5,617,458; Ser. No. 08/396,834, filed Mar. 1, 1995 now U.S. Pat. No. 5,677,648; Ser. No. 08/473,813, filed Jun. 7, 1995 now U.S. Pat. No. 5,821,885; Ser. No. 08/484,456, filed Jun. 7, 1995; Ser. No. 08/476,814, filed Jun. 7, 1995 now U.S. Pat. No. 5,798,719; Ser. No. 08/481,561, filed Jun. 7, 1995 now U.S. Pat. No. 5,801,973; Ser. No. 08/482,381, filed Jun. 7, 1995 now U.S. Pat. No. 5,828,907; Ser. No. 08/479,910, filed Jun. 7, 1995 now U.S. Pat. No. 5,768,629; Ser. No. 08/475,729, filed Jun. 7, 1995 now abandoned; Ser. No. 08/484,578, filed Jun. 7, 1995; Ser. No. 08/473,615, filed Jun. 7, 1995 now abandoned; Ser. No. 08/487,356, filed Jun. 7, 1995; Ser. No. 08/487,134, filed Jun. 7, 1995 now U.S. Pat. No. 5,835,792; Ser. No. 08/481,772, filed Jun. 7, 1995; Ser. No. 08/481,785, filed Jun. 7, 1995 now U.S. Pat. No. 5,703,793; Ser. No. 08/486,908, filed Jun. 7, 1995; Ser. No. 08/486,034, filed Jun. 7, 1995; Ser. No. 08/487,740, filed Jun. 7, 1995; Ser. No. 08/488,348, filed Jun. 7, 1995; Ser. No. 08/484,170, filed Jun. 7, 1995; Ser. No. 08/516,038, filed Aug. 17, 1995 now abandoned; Ser. No. 08/399,810, filed Mar. 7, 1995; Ser. No. 08/400,201, filed Mar. 7, 1995 (now U.S. Pat. No. 5,603,012); Ser. No. 08/400,215, filed Mar. 7, 1995 now abandoned; Ser. No. 08/400,072, filed Jun. 16, 1995 now U.S. Pat. No. 5,784,631; Ser. No. 08/402,602, filed Mar. 7, 1995; Ser. No. 08/400,206, filed Mar. 7, 1995 now abandoned; Ser. No. 08/400,151, filed Mar. 7, 1995; Ser. No. 08/400,202, filed Mar. 7, 1995; Ser. No. 08/400,398, filed Mar. 7, 1995 now abandoned; Ser. No. 08/400,161, filed Mar. 7, 1995; Ser. No. 08/400,141, filed Mar. 7, 1995; Ser. No. 08/400,211, filed Mar. 7, 1995 now U.S. Pat. No. 5,842,033; Ser. No. 08/400,331, filed Mar. 7, 1995; Ser. No. 08/400,207, filed Mar. 7, 1995 now abandoned; Ser. No. 08/399,898, filed Mar. 7, 1995; Ser. No. 08/399,665, filed Mar. 7, 1995 now abandoned; Ser. No. 08/400,058, filed Mar. 7, 1995 now abandoned; Ser. No. 08/399,800, filed Mar. 7, 1995; Ser. No. 08/399,801, filed Mar. 7, 1995; Ser. No. 08/399,799, filed Mar. 7, 1995 now abandoned; Ser. No. 08/474,222, filed Jun. 7, 1995; Ser. No. 08/486,481, filed Jun. 7, 1995 now abandoned; Ser. No. 08/474,231, filed Jun. 7, 1995; Ser. No. 08/474,830, filed Jun. 7, 1995 now abandoned; Ser. No. 08/474,220, filed Jun. 7, 1995 now U.S. Pat. No. 5,699,544; Ser. No. 08/473,868, filed Jun. 7, 1995; Ser. No. 08/474,603, filed Jun. 7, 1995; Ser. No. 08/485,242, filed Jun. 7, 1995 now U.S. Pat. No. 5,689,313; Ser. No. 08/477,048, filed Jun. 7, 1995 now abandoned; and Ser. No. 08/485,744, filed Jun. 7, 1995 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to video decompression. More particularly this invention relates to a video decoder, and to the management of memory being used to store decoded video frame pictures in an image formatter of a video decoder.
2. Description of the Related Art
Various compression standards for video data, i.e., JPEG, MPEG and H.261, are well known from U.S. Pat. No. 5,212,742. An important compression standard is the Moving Picture Experts Group Convention ("MPEG"), and more specifically MPEG-2 (ISO/IEC 13818). Circuitry used in decoders for MPEG-2 encoded video data is disclosed, for example, in European Patent Application No. 92306038.8, which is of common assignee herewith.
MPEG encoding involves three different picture types: Intra ("I"), Predicted ("P") and bidirectionally interpolated ("B"). B pictures are based on predictions from two pictures, one picture from the future and one from the past. I pictures require no further decoding by the Temporal Decoder, but must be stored in one of the two picture buffers for later use in decoding P and B pictures. The picture order is modified at the encoder so that I and P picture can be decoded from the coded date before they are required to decode B pictures. Decoding P pictures requires forming predictions from a previously decoded P or I picture. The decoded P picture is stored in picture buffers for use decoding P and B pictures.
B pictures can require predictions from the picture buffers. As with P pictures, half pixel motion vector resolution accuracy requires on chip interpolation of the picture information. B pictures are not stored in the buffers. They are merely transient.
In MPEG decoding a temporal and a spatial decoder are typically provided. The Spatial Decoder employed in the present invention performs all the required processing within a single picture, which reduces the redundancy within one picture. The Temporal Decoder reduces the redundancy between the subject picture and a picture which arrives prior to the arrival of the subject picture, as well as a picture which arrives after the arrival of the subject picture.
FIG. 1 illustrates how an I picture 2 is stored in a picture buffer 4, and then output. FIG. 2 shows how a P picture 6 is formed from a picture buffer 8, stored in a second picture buffer 10, and then output. FIG. 3 illustrates how a B picture 12 is constructed from information in two picture buffers 14, then output without being stored.
I and P pictures are usually not output from the temporal decoder as they are decoded. Instead, I and P pictures are written into one of the picture buffers, and are read out only when a subsequent I or P picture arrives for decoding. In other words, the temporal decoder relies on subsequent P or I pictures to flush previous pictures out of the two picture buffers. The spatial decoder can provide a dummy I or P picture at the end of a video sequence to flush out the last P or I picture. In turn, this dummy picture is flushed when a subsequent video sequence starts.
Peak memory bandwidth load occurs when decoding B pictures. In an example taken from the "worst case" scenario, the B frame may be formed from predictions from two picture buffers with all predictions being to half pixel accuracy. Table 1 presents performance data using a typical dynamic random access memory ("DRAM").
TABLE 1______________________________________ read or form prediction form predictionData bus width write 8 × 8 (half (integer pixel(bits) block pixel accuracy) accuracy)______________________________________ 8 3657 ns 4907 ns 3963 ns16 1880 ns 2907 ns 2185 ns32 991 ns 1907 ns 1741 ns______________________________________
From the data in Table 1, it can be seen that it will take the decoder's DRAM interface 3815 ns to read the data required for two accurate half pixel accurate predictions (via a 32 bit wide interface). The resolution that the Temporal Decoder can support is determined by the number of these predictions that can be performed within one picture time. In this example, the Temporal Decoder can process 8737 8×8 blocks in a single 33 ms picture period (e.g., for 30 Hz video).
If the required video format is 704×480, then each picture contains 7920 8×8 blocks (taking into consideration the 4:2:0 chroma sampling). It can be seen that this video format consumes approximately 91% of the available DRAM interface bandwidth (before any other factors such as DRAM refresh are taken into consideration). Accordingly, the Temporal Decoder can support this video format.
When MPEG picture re-ordering is employed the worst case scenario is encountered while P pictures are being decoded. During this time, there are 3 loads on the DRAM interface: (1) form predictions; (2) writing back the result; and (3) reading out the previous P or I picture.
Using the data from Table 1, the time for each of these tasks can be determined when a 32 bit wide interface is available. Forming the prediction takes 1907 ns/n while the read and the write each take 991 ns, a total of 3889 ns. This permits the Temporal Decoder to process 8485 8×8 blocks in a 33 ms period. Hence, processing 704×480 video will use approximately 93% of the available memory bandwidth (ignoring refresh).
A block diagram of a conventional decoder system 16 is presented in FIG. 4. Currently it is common to employ a synchronous DRAM as the DRAM 18 which is used in the video formatter 20. The spatial decoder 22, and the temporal decoder 24 utilize DRAMs 26, 28 respectively. During the MPEG decoding process up to three frame stores may be required to be stored in the DRAM 18. The DRAM interface 30 is particularly important in achieving acceptable performance. In the well known National Television System Committee ("NTSC") convention, this requirement amounts to 4 megabits/frame, for a total of 12 megabits. For the Phase Alternation Line ("PAL") convention, the frame size is approximately 5 megabits, so that 15 megabits of memory is needed in the DRAM 18. Commercial decoder systems have implemented the DRAM 18 as a 16 megabit random access memory ("RAM"), for reason of ready availability. However in the worst case, only 1 megabit of RAM remains for other processing functions of the video formatter 20, which is insufficient. Provision of an adequate amount of memory results in operation in a "4.3 frame store mode". Hence it has been necessary to provide another RAM (not shown), usually 4 megabits in size to accommodate the video formatter 20. The 4 megabit memory is larger than necessary, but is utilized because, as is the case of the 16 megabit RAM, it is an off-the-shelf component. In very large scare integrated circuit ("VLSI") realizations of an MPEG decoder, it is desirable to generally reduce the amount of memory for reasons of cost, power consumption, and space utilization.
The video formatter 20 processes data from the spatial decoder 22 and the temporal decoder 24. A digital video frame is treated as a grid of picture elements, or pixels. The pixels are grouped into 8×8 blocks, and the blocks are further grouped into 2×2 units, known as macroblocks. Thus a macroblock represents a grouping of 16×16 pixels, or a grouping of 2×2 blocks. A PAL picture constitutes 45×36 macroblocks, and an NTSC picture is 45×30 macroblocks. Referring to FIG. 5, each macroblock 32 comprises four luminance blocks 34 and two chrominance blocks 36, and contains the information for an original 16×16 grouping of pixels. Each of the four luminance blocks 34 and two chrominance blocks 36 is 8×8 pixels in size. The four luminance blocks 34 contain a 1 pixel to 1 pixel mapping of the luminance (Y) information from the original 16×16grouping of pixels. One chrominance block 36 contains a representation of the chrominance level of the blue color signal (Cu/b), and the other chrominance block 36 contains a representation of the chrominance level of the red color signal (Cv/r). Each chrominance level is subsampled such that each 8×8 chrominance block 36 contains the chrominance level of its color signal for the entire original 16×16 block of pixels.
More recently it has become possible to compress one of the noted three frame stores (the "B frame store"). When this is done the decoder is said to operate in "2.5 frame store mode". This is desirable because in the case of an NTSC signal, only 10 megabits of memory is required in the DRAM 18, and in the case of PAL, 12.5 megabits. A practical import is the ability to decode PAL pictures in a single 16 megabit memory. However memory management in the 2.5 frame store mode has presented considerable difficulties, because the MPEG algorithm may require the video formatter 20 to process an extensively intermingled sequence of I, P, and B pictures. Each type of picture undergoes distinct processing. Furthermore if the process of decoding a subsequent picture is delayed, it may be necessary to redisplay one or more fields of a current picture which places further demands on the decoder's memory management.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to improve the efficiency of memory management in the video formatter of an MPEG decoder.
It is another object of the invention to provide a memory manager for an MPEG decoder which allows rapid and efficient operation in 2.5 frame store mode.
It is yet another object of the invention to minimize the size, cost, and power consumption of memory units in an MPEG decoder.
These and other objects of the present invention are attained by an improved MPEG decoder operating in 2.5 frame store mode, and having an efficient memory management which allows a picture, particularly a B picture, to be stored and displayed, while simultaneously making use of a portion of the frame store memory. The video frame is treated as a grid, having rows of 8×8 pixel blocks referred to herein as "slices", or "block rows" of memory. The slices are manipulated in cross-coupled buffers which are each configured as a first-in first-out ("FIFO"), and cross-connected in a closed loop. Two processes operate on the memory so arranged: (1) a video reconstruction process which writes data into the memory ("write-back"), and (2) a display process, which accesses the memory and writes the video frame into another, external memory in a rastered format ("raster"). In the preferred embodiment there are three cross-coupled FIFOs, one designated for write-back, and the other two for reading 2:1 interlaced raster data. The two FIFOs utilized for the raster operation are allocated to the alternate lines of the picture.
According to the invention a video decoder includes a spatial decoder, a temporal decoder, a video formatter, and a data memory for storing the received data. The video formatter receives data from at least one of the temporal decoder and the spatial decoder. A memory manager for the video formatter uses a writeback memory, a first raster memory, and a second raster memory, wherein pointers to the data memory are stored in the writeback memory. The number of locations in the writeback memory is smaller than the sum of locations in the first raster memory and the second raster memory. A memory interface is coupled to the first raster memory, the second raster memory, the data source, the data memory, and the writeback memory. A writeback control circuit is provided for extracting pointers, preferably virtual memory pointers, from the writeback memory, wherein the extracted pointers are presented to the memory interface, and the received data is stored in locations of the data memory that are specified by the extracted pointers. The extracted pointers are transferred to the raster memory. A raster control circuit is provided for re-extracting the transferred pointers from the raster memory for presentation to the memory interface, wherein the received data is read from the data memory, and the re-extracted pointers are returned to the writeback memory.
Preferably the writeback memory, the first raster memory, and the second raster memory are FIFOs, which in one embodiment can be statically configured, and can be realized as a single RAM.
According to another aspect of the invention control circuitry is provided for dynamically configuring the FIFOs.
According to another aspect of the invention the writeback memory, the first raster memory, and the second raster memory are realized as a content addressable memory.
According to yet another aspect of the invention the writeback memory, the first raster memory, and the second raster memory are realized as a register file.
According to another aspect of the invention the data memory has a plurality of banks.
According to still another aspect of the invention the writeback memory, the first raster memory, and the second raster memory are cross-coupled FIFO memories for storage of pointers to the data memory. The FIFO memories each have a read pointer, a write pointer, and a status flag, and have control circuitry for initializing the read pointers, the write pointers, and the status flags of the FIFO memories, wherein the pointers are transferred between the writeback memory and the raster memories in a closed system.
According to an aspect of the invention there is a control circuit that asserts a lock signal when a decoded video field is required to be redisplayed by the video formatter causing the write pointer of a raster FIFO to be held stationary.
The invention provides a method of managing a memory holding decoded video data for display thereof. It is performed by decoding MPEG encoded video data in at least one of the spatial decoder and the temporal decoder, wherein the decoded data represents a picture to be displayed; storing the decoded video data in a data memory; storing pointers to locations of the data memory in a writeback memory; extracting the stored pointers from the writeback memory; writing the received video data into locations of the data memory that are specified by the extracted pointers; transferring the extracted pointers to at least one raster memory, wherein pointers stored in the first raster memory correspond to decoded video data of a first video display field, and pointers stored in the second raster memory correspond to decoded video data of a second video display field; reading data from locations of the data memory that are specified by the transferred pointers; outputting the read data for display thereof; and returning the transferred pointers to the writeback memory.
The steps of extracting the pointers and writing the received video data are performed while simultaneously transferring the extracted pointers, reading data, outputting the read data, and returning the extracted pointers.
BRIEF DESCRIPTION OF THE DRAWING
For a better understanding of these and other objects of the present invention, reference is made to the detailed description of the invention, by way of example, which is to be read in conjunction with the following drawings, wherein:
FIG. 1 is a diagram describing the storage of MPEG "I" pictures in the decoder according to the invention;
FIG. 2 is a diagram describing the storage of MPEG "P" pictures in the decoder according to the invention;
FIG. 3 is a diagram describing the storage of MPEG "B" pictures in the decoder according to the invention;
FIG. 4 is a block diagram of an MPEG decoder in accordance with the prior art;
FIG. 5 is a diagram of MPEG and JPEG macroblock structure in accordance with the prior art;
FIG. 6 is a block diagram of the memory manager in a video formatter of an MPEG decoder according to the invention;
FIG. 7 is an electrical schematic of the memory manager shown in FIG. 6;
FIG. 8 is an electrical schematic of control circuitry for interfacing with external memory in the memory manager shown in FIG. 7;
FIG. 9 is a detailed electrical schematic of the memory controller in the control circuitry illustrated in FIG. 8;
FIG. 10 is a more detailed electrical schematic of the readback FIFO controllers illustrated in the circuitry of FIG. 9;
FIG. 11 is a more detailed electrical schematic of the writeback FIFO controller illustrated in the circuitry of FIG. 9; and
FIG. 12 is a more detailed electrical schematic of a state machine in the circuitry of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 6, a video formatter 38 of a VLSI MPEG decoder, can receive a given picture on line 40, either as two deinterlaced field pictures, or as a single frame picture of interlaced data. The video formatter 38 is discussed with reference to PAL, since this is the largest picture size presently used; however it also operates with NTSC and can be adapted to other video conventions as well. A video frame is displayed in two segments, or fields, a top field and a bottom field. A PAL picture arrives on the line 40 as a sequential stream of macroblocks, and is stored in an external memory 42, where it is organized in two block rows for each row of macroblocks, for a total of 72 block rows. The data may arrive as one interlaced frame picture (i.e., 45×36 macroblocks), or as two sequential de-interlaced field pictures (i.e. 2×45×18 macroblocks). A frame macroblock contains data from each video display field, two blocks of data from the top field, and two blocks from the bottom field. A field picture macroblock contains 4 blocks of data, all from the same field. In order to manipulate the external memory 42 efficiently each field store is divided into slices of memory which correspond to rows of 8×8 blocks. Thus each slice is a row of 90 blocks, all from the same video field. The largest presently used picture size, 45×36 macroblocks, corresponds to 90×72 blocks. Thus each field store in the external memory 42 must accommodate 36 block rows of data.
According to the invention, the external memory 42 is managed by three cross-coupled FIFOs, connected as shown in FIG. 6. It should be noted that the external memory 42 is preferably virtual memory, but also could be physical memory in a particular application.
The external memory 42 has two banks, bank 0 44, and bank 1 46, which are accessed via a memory interface 48. Data from the top field is stored on bank 0 44, and the data from the bottom field is stored on bank 1 46. A first onchip FIFO, writeback FIFO 50 holds virtual pointers (hereinafter as simply "pointers") to free locations in the external memory 42. The free locations of the external memory 42 may thus have video data written into them. Each of the 36 rows of macroblocks stored in the external memory 42 is represented by a first pointer at location 52 addressing a first block row 54 in bank 0 44, and by a second pointer at location 56 addressing a second block row 58 in bank 1 46. There are thus (36×2) pointers, and thus the writeback FIFO 50 has a depth of 72. The use of the banked external memory 42 in combination with the memory interface 48 is desirable to maximize bandwidth during memory operations of the video formatter 38. It should be emphasized that the writeback FIFO 50 is programmable in length, under control of the microprocessor 60, so that reduced memory operations may be performed.
The other two FIFOs are the "raster" or "used memory" FIFOs, one for each video field. Raster FIFO 62 and raster FIFO 64 are allocated to the top video field and the bottom video field respectively. They hold pointers to slices of the external memory 42 where video data has been written. The raster FIFO 62 and raster FIFO 64 can each hold up to 54 pointers (1.5×36 block rows) for reasons which will become apparent.
In a cycle of operation, before any accesses to the external memory 42 take place, the writeback FIFO 50 is initialized or loaded with pointers to the free slices of the external memory 42. If all 72 slices are to be used for picture storage, the writeback FIFO 50 is loaded with 72 pointers. The raster FIFOs 62, 64 are cleared and are thus empty, indicating that no data has yet been written away for display.
A writeback process 66, which is implemented as a state machine, initially extracts two pointers 68, 70 from the writeback FIFO 50, and then presents a request to the memory interface 48 to store the first two block rows of the arriving picture into the external memory 42 at locations 72, 74, the locations pointed to by the pointers 68, 70. When both block rows have been stored, the writeback process 66 transfers the two pointers 68, 70 into one or both of the raster FIFOs 62, 64 as follows:
Case 1: The video data in the locations 72, 74 is an interlaced frame picture, and one block row consists of top field data, and the other block row consists of bottom field data. The writeback process 66 transfers the pointer 68 into location 76 of the top field raster FIFO 62, and transfers the pointer 70 into location 78 of the bottom field raster FIFO 64.
Case 2: The video data in the locations 72, 74 represents a field picture, and both blocks rows represent data for the same field. If the field was a top field, then both pointers are placed into the top field raster FIFO 62 at location 76 and location 80. A similar event would occur if the field were a bottom field, except that the bottom field raster FIFO 64 would be accessed.
In parallel with the execution of the writeback process 66, a raster process 82, implemented as a state machine, operates in a similar fashion. It extracts a pointer from the one of the raster FIFOs 62, 64. The raster process 82 operates on pointers corresponding to one video field at a time and continues to access data field until the entire field has been retrieved from the external memory 42. Assuming that a top field is desired to be displayed a pointer is extracted from location 84 in the raster FIFO 62. The extracted pointer is used to retrieve a block row from the external memory 42. After the block row is retrieved, the raster process 82 transfers the extracted pointer from location 84 into location 86 of the writeback FIFO 50. The raster process 82 then extracts the next pointer from location 88 of the raster FIFO 62 and proceeds in like manner until the entire top field has been retrieved from the external memory 42. The retrieved video data is accessed via the memory interface 48 and is output on line 90.
The writeback FIFO 50 and the raster FIFOs 62, 64 are cross coupled in that the output of one feeds the input of the other as described above. The system is closed, in that the sum total of the pointers in all three FIFOs at any one time is that number of pointers that was initialized into the writeback FIFO 50. The fact that the pointers are stored in FIFOs provides built-in rate control and anti-clash function. If the writeback FIFO 50 becomes empty, it is because all available memory slices are being used to hold data. The writeback process 66 is then unable to extract more pointers and stalls until pointers again become available from the writeback FIFO 50. Similarly the raster process 82 stalls when the raster FIFOs 62, 64 become depleted of pointers.
It is possible to implement the writeback FIFO 50 and the raster FIFOs 62, 64 on a single RAM and statically or dynamically configure them according to a particular video convention or combination of conventions being handled by the decoder. In the preferred embodiment a total of 180 locations must be provided in the writeback FIFO 50 and the raster FIFOs 62, 64, and they are implemented as a 192 position RAM for convenience. This is satisfactory, because the access of the external memory 42 requires a relatively long time, so that the bandwidth required for the writeback FIFO 50 and the raster FIFOs 62, 64 is relatively low. Dynamic configuration is accomplished by a control microprocessor 60.
The writeback FIFO 50 and the raster FIFOs 62, 64 are initialized at the start of every B picture sequence by adjusting the read and write pointers, and the read-not-written flag order to make the FIFOs appear empty. As the B pictures arrive, the FIFOs 50, 62, 64 are loaded and unloaded in a non-deterministic manner. When a sequence of B pictures has been completed, and the video formatter 38 moves on to process a P-picture, the FIFOs are frozen in their last state, and can resume loading and unloading when a next sequence of B pictures arrives. However in the preferred embodiment it was elected to reinitialize the writeback FIFO 50 and the raster FIFOs 62, 64 at the beginning of every sequence of B pictures in order to provide greater protection against unforeseen errors.
It may be necessary to display a field more than once, for example during frame rate conversion from motion picture film at 24 Hz to NTSC at 30 Hz (referred to herein as "3:2 pulldown operation"). The raster FIFOs 62, 64 are implemented with read and write pointers, and a copy of the FIFO read pointer may be stored at the start of the field retrieval. When the entire field has been retrieved from the external memory 42, the stored read pointer may be used to reset the FIFO read pointer back to the start of the field, so that the field may be accessed a second time. The raster process 82 must be aware that repetitive display is to occur so that the virtual pointers are not passed from the raster FIFOs 62, 64 to the writeback FIFO 50. Transfer of pointers to the writeback FIFO 50 only occurs when the field is accessed for the last time.
The FIFOs 62, 64 are configured for at least 7 bit data, the minimum number for encoding 72 block row pointers. In the preferred embodiment, an 8 bit RAM is employed for convenience.
If sequences of frame pictures alone or field pictures alone were being received by the video formatter 38, the raster FIFOs 62, 64 could be implemented with 36 locations each. However in practice an extra one half field store is required to avoid memory overflow or starvation of the writeback process 66. This is because, according to the MPEG convention, the video formatter 38 must cope with frame pictures irregularly mixed in with field pictures. Also, in practice the raster process 82 can stall, or lag the writeback process 66 by an interval required to store one field (one half frame of data), referred to herein as a "field time".
The case which results in the largest memory loading is the following sequence of B pictures: a preceding field picture and a current frame picture. In this situation, it is necessary to provide storage in each of the FIFOs 62, 64 for one of the fields in the current frame picture, as the writeback process 66 will not have completed its operation on the preceding field B-picture.
Assume that an entire video picture, either a frame picture or two field pictures, has been decoded and stored in the external memory 42 without any of the data having been retrieved for display. In this situation the writeback FIFO 50 is empty and each of the raster FIFOs 62, 64 contains 36 pointers. The system now remains locked until the raster process 82 is instructed to begin displaying a picture. Once the process of displaying a picture begins, memory slices in the raster FIFOs 62, 64 will be freed by the raster process 82 and pointers transferred to the writeback FIFO 50. Further assume that the raster process 82 is displaying the top field of a current field picture, using the top field raster FIFO 62, and that the next picture to be written away is a frame picture. Retrieval of the top field of the current picture frees up 36 block rows for the writeback process 66 to use. The writeback process 66 and the raster process 82 operate at about the same rate, so they are effectively coupled together. Thus, in the time it takes to store an entire picture, both fields may be displayed. However because a frame picture is being stored in parallel with the retrieval of a field picture, 18 block rows will be required for the top field of the following frame picture, and 18 for the bottom field. Because the top field raster FIFO 62 is being emptied by the raster process 82, there is room for the writeback process 66 to place re-used pointers relating to the top field of the following frame picture back into the raster FIFO 62. However the bottom field raster FIFO 64 has not been accessed, and already contains 36 pointers for the bottom field of the current field picture. Therefore enough room must be provided in the raster FIFO 64 to store the additional 18 pointers that will arrive under control of the writeback process 66 as it decodes the following frame picture. Otherwise the writeback process 66 would stall and eventually the entire MPEG decoder would lock up. Hence, to provide for all combinations of the worst cases, the FIFOs 62, 64 must be able to store 54 pointers (54=36+18).
The raster process 82 is driven by a video timing generator (not shown) at a standard display rate of 27 megahertz. The writeback process 66 operates at about the same rate, and effectively couples itself to the raster process 82, so that pointers are being written into the writeback FIFO 50 and the FIFOs 62, 64 as fast as they are being displayed. Provision for the worst case described above implies that in aggregate, the writeback FIFO 50 is never more than 2/3 full at any time.
Referring now to FIGS. 7, 8, and 9, a schematic of a preferred embodiment of the invention is shown, implemented in an integrated circuit. The three cross-coupled FIFOs discussed above are configured in a 192×8 bit RAM 94. Block 96 contains the control logic for accessing the RAM 94, and is shown in greater detail in FIG. 8. Memory controller 98 accesses locations within the FIFOs in the RAM 94. Block 100 and the block 102 are state machines for the writeback process and the raster process discussed above, respectively.
The structure of the memory controller 98 is shown in still further detail in FIG. 9. Decoding logical network 104 receives its inputs from the state machines 100, 102 and further decodes the input information. Circuitry 106 comprises a two bit counter 108 which produces a four state output 110, which is the state machine for the RAM controller, and is used to arbitrate among access requests by the writeback and raster processes. The memory controller 98 thus enables reading and writing by the writeback process, and reading and writing by the raster process according to the state of the output 110. Actual memory access by the writeback or raster process must thus await the appropriate state of the output 110. Addresses representing instances of pointers for the three individual FIFOs are provided by FIFO controller 112 for the writeback FIFO, and in two identical circuits, FIFO controllers 114, 116 for the top and bottom field raster FIFOs. A 7-bit bus is connected to FIFO controller 112, as it is necessary to provide for 72 addresses. In the case of FIFO controllers 114, 116, bus 118 and bus 120 connected thereto each have 6 bits, as it is only necessary to address 54 locations in the raster FIFOs. Multiplex circuitry 122 decodes the state of the memory controller 98, and what type of memory access is being requested. The relevant pointers from one of the FIFO controllers 112,114, 116 is then used to access the RAM 94 (FIG. 7).
The structure of the readback FIFO controllers 114,116 is illustrated in FIG. 10. Two 6-bit registers 124,126 generate the write and read pointers respectively. The logic associated with the register 126 includes an incrementer 128, a counter 130, and a nand gate 132 for clearing the register 126 when the read pointer reaches its last value. The logic associated with the register 124 is similar and in the interest of brevity the details will not be repeated. The counters 134,130 are used to configure the size of and control access to one of the raster FIFOs 62, 64 (FIG. 6).
An additional register 136 is used to capture and retain the value of the register 126 under certain circumstances, which will be described shortly. Two comparators 138, 140 are present in the circuit in order to compare the values contained in the registers 124, 126, 136. Comparator 138 is used to compare the outputs of the two counter registers 124,126. Comparator 140 compares the outputs of the FIFO write pointer generated by register 124 with the captured or retained value of the read pointer held in register 136. The output of the comparator 138 is used in conjunction with a read-not-written flag, which is implemented as a single flip-flop 142. Using gates 144,146 two status signals 148,150 are generated, indicating whether the FIFO is full or empty. These status signals are used by the logical network 104 to control how the FIFO is accessed and to prevent write operations when it is full, and to prevent read operations when it is empty.
The output of the comparator 140 is used to generate a "lock" signal NLOCK 152. The signal NLOCK 152 is utilized to control accesses to the raster FIFOs when the display of a field picture is being repeated. This event can occur when the decoder is performing in 3:2 pulldown operation or frame rate conversion, when it is necessary to effectively mark time by displaying an extra field. Instead of displaying both fields of a video picture just once, the first field is redisplayed or repeated after both fields have been displayed. For example first the top field is displayed, then the bottom field, and then the top field is displayed again. Under this circumstance it is desirable to preserve the contents of external memory for redisplaying one of the video fields. In order that the data in external memory is not freed up and overwritten once it has been displayed, the lock signal NLOCK 152 causes the write pointer of the raster FIFO to freeze, so that the read pointer can be reloaded for redisplay. When it is time to redisplay the first field, the value captured in the register 136 is loaded into the register 126, which has the effect of resetting the read pointer back to the start of the first field, so that it may be accessed a second time. The logical network 104 interprets the signal NLOCK 152 as an indication that the write pointer held in the register 124 is the same as the read pointer captured in the register 136, and that if the field is to be redisplayed, then additional FIFO write operations should be blocked in order to prevent the first data field from being overwritten. The first field data is thus preserved in external memory until it has been redisplayed a second time.
Referring again to FIGS. 6, 8 and 9, a signal NWSINK 154 operates in combination with the signal NLOCK 152. The signal NWSINK 154 is active during 3:2 pulldown or frame rate conversion and is asserted during the display of the first field if that field is to be redisplayed. The signal NWSINK 154 inhibits write instructions to the writeback FIFO controller 112 which originate from the raster process state machine 102. This is necessary because when the first picture field is displayed, the data slices in external memory must not be freed up and placed back into the writeback FIFO 50. During the display of the second field, or the redisplay of the first field, the signal NWSINK 154 is inactive, thus allowing the state machine 102 to cause writes to the writeback FIFO 50 so that the pointers to the free memory slices are placed therein.
FIG. 11 illustrates the structure of the writeback FIFO controller 112, which is very similar to that of the readback FIFO controllers, except that there is no additional register to capture the read pointer value for field redisplays. A control flip-flop 156 simplifies the writeback operation when the writeback FIFO is first accessed for a first B-type picture of a sequence. The flip-flop 156 is set and its output is active during the display of the very first B-picture in a sequence of B-pictures. This forces the state machine logical network 104 (FIG. 9) to reference the actual address of the FIFO rather than the contents of the external memory held at that address. This has the effect of causing the memory controller 98 to preload the external memory with the picture slice sequence. Setting the flip-flop 156 results in a control signal 132, which avoids the need for having a state machine that would clear the external RAM, and then preload it with the initial virtual pointers for the picture slice sequence. The flip-flop 156 is reset after the first B-picture has been displayed and is only set again at the start of a new B-picture sequence. Another control flip-flop 158 develops a control signal RASENB 160 which is used by the writeback process to synchronize the raster process. The flip-flop 158 is set before the B-picture sequence starts, and is reset when the writeback FIFO 50 (FIG. 6) is emptied for the first time. The output of the flip-flop 158, control signal FIRSTB 162 indicates to the raster state machine 102 when it should begin to start displaying the B-pictures. It is asserted when it is desired that the raster process lag the writeback by one field time (or one half frame store). This lag is optimal for smooth operation of the system.
FIG. 12 illustrates the state machine 164 which controls access into the RAM 94 (FIG. 7). It consists of flip-flops 166, 168,170, 172, and associated logic. Signal 174, signal 176, and signal 178 enable read requests and write request by the raster process, and the writeback process.
FIFO memories work quite well in a VLSI implementation for managing the pointers, as disclosed above. However it is possible to realize the three cross-coupled memories using memory management arrangements other than the FIFO without departing from the spirit of the invention. For example the pointers could be written into and extracted from the three cross-coupled memories using hash tables, linked lists of memory locations, caches, and many other forms of indirect addressing, as are known to the art. Alternate pointer memory schemes may rely on the fact that it is not essential for the raster process to extract pointers in the same order they were written into the raster memories by the writeback process, so long as a closed system of pointers is maintained.
Referring again to FIG. 6, the writeback FIFO 50, and the raster FIFOs 62, 64 are preferably implemented as a single port static RAM array for circuit power considerations, and because it requires a small silicon area. A register file would also be suitable, and a content addressable memory could also be used for the three FIFOs.
While this invention has been explained with reference to the structure disclosed herein, it is not confined to the details set forth and this application is intended to cover any modifications and changes as may come within the scope of the following claims: | An MPEG decoder operates in 2.5 frame store mode, and has an efficient memory management which allows a B picture to be stored and displayed while simultaneously making use of a portion of the frame store memory. The video frame is treated as a grid, having rows of 8×8 pixel blocks. The pixel blocks are manipulated in three FIFOs which are cross-connected in a closed loop. Two processes operate on the memory so arranged: (1) a video reconstruction process which writes data into the memory, and (2) a display process, which accesses the memory and writes the video frame into another, external memory in a rastered format. One of the three cross-coupled FIFOs is designated for write-back, and the other two for reading 2:1 interlaced raster data. The two FIFOs utilized for the raster operation are allocated to the alternate lines of the picture. | 7 |
FIELD OF THE INVENTION
This invention concerns ionomers comprising a substantially fluorinated, but not perfluorinated, polyethylene backbone having pendant groups of fluoroalkoxy sulfonic acids and the metal salts thereof, and with the uses of said ionomers in electrochemical applications such as batteries, fuel cells, electrolysis cells, ion exchange membranes, sensors, electrochemical capacitors, and modified electrodes.
BACKGROUND OF THE INVENTION
Copolymers of vinylidene fluoride (VDF) with vinyl alkoxy sulfonyl halides are known in the art.
The disclosures in Ezzell et al. (U.S. Pat. No. 4,940,525) encompass copolymers of VDF with vinyl ethoxy sulfonyl fluorides containing one ether linkage. Disclosed is a process for emulsion polymerization of tetrafluoroethylene (TFE) with the vinyl ethoxy comonomer.
Banerjee et al. (U.S. Pat. No. 5,672,438) disclose copolymers of VDF with vinyl alkoxy sulfonyl fluorides containing more than one ether linkage.
Connolly et al. (U.S. Pat. No. 3,282,875) disclose the terpolymer of VDF with perfluorosulfonyl fluoride ethoxy propyl vinyl ether (PSEPVE) and hexafluoropropylene (HFP). They broadly teach an emulsion polymerization process said to be applicable to copolymerization of vinyl ethers with any ethylenically unsaturated comonomer, with greatest applicability to fluorinated monomers.
Barnes et al. (U.S. Pat. No. 5,595,676) disclose "substantially fluorinated" copolymers of a vinyl ether cation exchange group-containing monomer with a "substantially fluorinated" alkene. The copolymer is produced by controlled addition of the alkene in emulsion polymerization, followed by hydrolysis in NaOH. PSEPVE/TFE copolymers are exemplified.
Hietala et al., J. Mater. Chem. Volume 7 pages 721-726, 1997, disclose a porous poly(vinylidene fluoride) on to which styrene is grafted by exposing the PVDF to irradiation. The styrene functionality is subsequently functionalized to sulfonic acid by exposure of the polymer to chlorosulfonic acid. The resultant acid polymer, in combination with water, provides a proton-conducting membrane.
Formation of ionomers and acid copolymers by hydrolysis of the sulfonyl fluoride functionality in copolymers of TFE and fluoro alkoxy sulfonyl fluorides is well known in the art. The art teaches exposure of the copolymer to strongly basic conditions.
See for example, Ezzell et al. U.S. Pat. No. 4,940,525, wherein is used 25 wt % NaOH(aq) for 16 hours at 80-90° C.; Banerjee et al. U.S. Pat. No. 5,672,438, wherein is used 25 wt % NaOH for 16 hours at 90° C., or, in the alternative, an aqueous solution of 6-20% alkali metal hydroxide and 5-40% polar organic liquid (e.g., DMSO) for 5 minutes at 50-100° C.; Ezzell et al. U.S. Pat. No. 4,358,545 wherein is used 0.05N NaOH for 30 minutes for 50° C.; Ezzell et al. U.S. Pat. No. 4,330,654, wherein is used 95% boiling ethanol for 30 minutes followed by addition of equal volume of 30% NaOH (aq) with heating continued for 1 hour; Marshall et al. EP 0345964 A1, wherein is used 32 wt % NaOH (aq) and methanol for 16 hours at 70° C., or, in the alternative, an aqueous solution of 11 wt % KOH and 30 wt % DMSO for 1 hour at 90° C.; and, Barnes et al. U.S. Pat. No. 5,595,676, wherein is used 20 wt % NaOH (aq) for 17 hours at 90° C.
Because of its high dielectric constant, high electrochemical stability, and desirable swelling properties, poly(vinylidene fluoride) is known in the art of lithium batteries as a highly desirable material for use as a membrane separator, For example Gozdz et al. (U.S. Pat. No. 5,418,091) disclose porous PVDF homopolymer and copolymer containing solutions of lithium salts in aprotic solvents useful as separators in lithium batteries.
Porous membranes of the type described by Gozdz, however, conduct both the cation and the anion back and forth across the separator, and are thus subject to concentration polarization during use, which degrades the performance of the battery in which it is used. So-called single ion conducting polymeric membranes, wherein the ionic salt is attached to the polymer backbone, thereby immobilizing either the cation or the anion, offer a solution to the concentration polarization problem, and are known in the art. One particularly well-known such single ion conducting polymer is Nafion® Perfluoroionomer Resin and Membranes available from DuPont, Wilmington, Del. Nafion is a copolymer of TFE and perfluoro(3,6-dioxa-4-methyl-7-octenesulfonyl fluoride) which has been hydrolyzed by treatment with an alkali metal hydroxide according to the teachings of the art as hereinabove described.
It is further known in the art, and hereinbelow shown, that PVDF homopolymers and copolymers are subject to attack by strong bases such as the alkali metal hydroxides taught in the art hereinabove cited. Of particular importance is that the attack of basic nucleophiles on a copolymer of VDF and perfluorovinyl ethers results in the removal of the vinyl ether moiety from the polymer, see W. W. Schmiegel in Die Angewandte Makromolekulare Chemie, 76/77 pp 39ff, 1979. Since the highly preferred monomer species taught in the art, and exemplified by DuPont's Nafion and similar products, for imparting ionomeric character to various polymers is a vinyl ether terminated by a sulfonyl halide functionality, the sensitivity to base attack of the VDF copolymer formed therewith has prevented the development of a single-ion conducting ionomer based upon VDF. There simply is no means taught in the art for making the ionomer.
SUMMARY OF THE INVENTION
The present invention solves this long-standing problem. This invention provides for an ionomer comprising monomer units of VDF and a perfluoro-alkenyl monomer having an ionic pendant group represented by the formula:
--(O--CF.sub.2 CFR).sub.a O--CF.sub.2 (CFR').sub.b SO.sub.3.sup.- M.sup.+
wherein R and R' are independently selected from F, Cl or a perfluorinated alkyl group having 1 to 10 carbon atoms, a=0, 1 or 2, b=0 to 6, and M is H or a univalent metal.
The present invention further provides for a functionalized olefin of the formula
CF.sub.2 ═CF--(O--CF.sub.2 CFR).sub.a O--CF.sub.2 (CFR').sub.b SO.sub.3.sup.- M.sup.+
where R and R' are independently selected from F, Cl or a perfluorinated alkyl group having 1 to 10 carbon atoms, a=0, 1 or 2, b=0 to 6 and M is a univalent metal.
The present invention further provides for a process for forming an ionomer, the process comprising
contacting a polymer comprising
monomer units of VDF and a perfluoroalkenyl monomer
having a pendant group of the formula
--(O--CF.sub.2 CFR).sub.a O--CF.sub.2 (CFR').sub.b SO.sub.2 F
wherein R and R' are independently selected from F, Cl or a perfluorinated alkyl group having 1 to 10 carbon atoms, a=0, 1 or 2, b=0 to 6,
with a suspension or solution of an alkali metal salt for a period of time sufficient to obtain the degree of conversion desired to the alkali metal sulfonate form of the polymer.
The present invention further provides for an ionically conductive composition comprising the polymer of the invention and a liquid imbibed therewithin.
The present invention further provides for an electrode comprising at least one electrode active material, the ionomeric polymer of the present invention mixed therewith, and a liquid imbibed therewithin.
The present invention further comprises an electrochemical cell comprising a positive electrode, a negative electrode, a separator disposed between the positive and negative electrodes, and a means for connecting the cell to an outside load or source wherein at least one of the group consisting of the separator, the cathode, and the anode, comprises the conductive composition of the invention.
DETAILED DESCRIPTION OF THE INVENTION
For the purposes of description in the present invention, the generic term "ionomer" will be taken to encompass the metal sulfonate and the sulfonic acid forms of the polymer of the invention.
In a surprising aspect of the present invention, a non-destructive method has been discovered for hydrolyzing the sulfonyl fluoride in a polymer comprising monomer units of VDF and a perfluoroalkenyl monomer having a pendant group of the formula
--(O--CF.sub.2 CFR).sub.a O--CF.sub.2 (CFR').sub.b SO.sub.2 F
to form the ionomer of the invention the ionomer being a polymer comprising monomer units of VDF and an ionic perfluoroalkenyl monomer having a pendant group of the formula
--(O--CF.sub.2 CFR).sub.a O--CF.sub.2 (CFR').sub.b SO.sub.3.sup.- M.sup.+
where R and R' are independently selected from F, Cl or a perfluorinated alkyl group having 1 to 10 carbon atoms, a=0, 1 or 2, b=0 to 6, and M is H or a univalent metal. Preferably, R is trifluoromethyl, R' is F, a=0 or 1, b=1, and M is H or an alkali metal. Most preferably, a=1 and M is Li.
In a further surprising aspect of the present invention, the same non-destructive method is applicable to hydrolyzing a functionalized olefin of the formula
CF.sub.2 ═CF--(O--CF.sub.2 CFR).sub.a O--CF.sub.2 (CFR').sub.b SO.sub.2 F (I)
to form the ionic olefin of the present invention, the ionic olefin having the formula
CF.sub.2 ═CF--(O--CF.sub.2 CFR).sub.a O--CF.sub.2 (CFR').sub.b SO.sub.3.sup.- M.sup.+ (II)
where R and R' are independently selected from F, Cl or a fluorinated, preferably perfluorinated, alkyl group having 1 to 10 carbon atoms, a=0, 1 or 2, b=0 to 6. Preferably R is trifluoromethyl, R' is F, a=1 and b=1, and M is a univalent metal.
The ionomer of the invention can be formed by first copolymerizing a non-ionic monomer (I) with VDF followed by hydrolysis to form the ionomer of the invention, or, alternatively, by first hydrolyzing monomer (I) to form the ionic monomer of the invention (II), followed by polymerization with VDF to form the ionomer of the invention. The process of first polymerizing followed by hydrolysis is preferred for operational simplicity.
A preferred hydrolysis process of the invention comprises contacting the sulfonyl fluoride-containing monomer or polymer with a mixture of alkali metal carbonate and methanol (optionally containing another solvent such as dimethyl carbonate), in the range of ca. 0-85° C., preferably room temperature to 65° C. for a sufficient length of time to convert the desired percentage of sulfonyl fluorides to the related metal sulfonate. The alkali metal carbonate is selected to provide the cation desired for the intended application. Suitable alkali metal carbonates include Li 2 CO 3 , Na 2 CO 3 , and K 2 CO 3 , with Li 2 CO 3 most preferred.
Generally preferred are the mildest hydrolysis conditions possible consistent with timely conversion of the sulfonyl fluoride into the ionic form desired. The severe hydrolysis conditions taught in the art for hydrolyzing sulfonyl fluoride to sulfonate cause degradation of the VDF-containing copolymer. The degree of conversion can be conveniently monitored by the disappearance of the characteristic infrared absorption band for the sulfonyl fluoride group at about 1470 cm -1 . Alternatively, 19 F NMR spectroscopy may be used as described in the examples.
The ionomers of the invention include copolymer compositions in which the ionic monomer unit is present in the ionomer of the invention at concentrations ranging from 1 to 50 mol %, preferably 2-20 mol %. The preferred ionomers comprise 80-98 mol % of monomer units of VDF and 2-20 mol % of perfluoro(3,6-dioxa-4-methyl-7-octene lithium sulfonate).
Other cationic forms of the ion-exchange membrane can be achieved using ion-exchange procedures commonly known in the art (see for example Ion Exchange by F. Helfferich, McGraw Hill, N.Y. 1962). For example, the protonic form of the membrane is preferably obtained by immersing the alkali metal-ionomer into an aqueous acid.
Silver and copper sulfonate ionomers can be made by ion exchange with the alkali metal sulfonate form of the polymer. For example, repeated treatment of the lithium sulfonate ionomer with an aqueous solution of a silver salt such as silver fluoride or silver perchlorate would produce at least a partially cation exchanged silver sulfonate ionomer. In a similar fashion, the cuprous sulfonate ionomer can be produced by repeated treatment of the alkali metal sulfonate ionomer with an aqueous acidic solution of a copper salt such as cuprous chloride.
In many applications, the ionomer is preferably formed into a film or sheet. Films of the ionomer may be formed according to processes known in the art. In one embodiment, the thermoplastic sulfonyl fluoride precursor is extrusion melt cast onto a cooled surface such as a rotating drum or roll, whence it is subject to hydrolysis according to the process hereinabove described. In a second embodiment, the sulfonyl fluoride precursor is dissolved in a solvent, the solution cast onto a smooth surface such as a glass plate using a doctor knife or other device known in the art to assist in depositing films on a substrate, and the resultant film subject to hydrolysis. In a third embodiment, the sulfonyl fluoride copolymer resin is subject to hydrolysis by dissolution or suspension in a hydrolyzing medium, followed by optional addition of cosolvent, and filtration or centrifugation of the resulting mixture, and finally solvent casting of the ionomer solution onto a substrate using a doctor knife or other device known in the art to assist in depositing films on a substrate. In a fourth embodiment, the ionic comonomer (II) and VDF are copolymerized as hereinbelow described, preferably in water, and the resultant polymer deposited upon a substrate using a doctor knife or other device known in the art.
It is found in the practice of the present invention that a thin film of the sulfonyl-fluoride-containing copolymer exhibits a tendency to dissolve during hydrolysis when the concentration of the sulfonyl fluoride moiety exceeds about 5 mol-%. Thus for the purpose of achieving better control over the film forming process, it is found preferable to suspend the non-ionic sulfonyl fluoride-containing precursor polymer in a solvent or combination of solvents such as, methanol, dimethyl carbonate, or mixtures thereof, also containing the hydrolyzing agent, preferably Li 2 CO 3 thereby hydrolyzing the polymer in solution. The thus hydrolyzed polymer is then cast as a film from solution.
The ionomer of the present invention, however formed, exhibits a low level of ionic conductivity in the dry state, at room temperature, typically ca. 10 -6 S/cm. It may be combined with a liquid to achieve higher levels of ionic conductivity. Depending upon the requirements of the application, the ionomer will be in the acid form or the metal salt form, the particular metal being determined by the application as well. The liquid employed therewith will likewise be dictated by the application. In general terms, it has been found in the practice of the invention that conductivity of the liquid-containing ionomer increases with increasing % weight uptake, increasing dielectric constant, and increasing lewis basicity of the liquid, while conductivity has been observed to decrease with increasing viscosity and increasing molecular size of the liquid employed. Of course, other considerations come into play as well. For example, excessive solubility of the ionomer in the liquid may be undesirable. Or, the liquid may be electrochemically unstable in the intended use.
One particularly preferred embodiment comprises the lithium ionomer combined with aprotic solvents, preferably organic carbonates, which are useful in lithium batteries. It is in lithium batteries that the particularly useful attributes of the ionomer of the invention are particularly noteworthy. High solvent uptake characteristic of VDF polymers results in desirably high ionic conductivity in the solvent-swollen membrane. Furthermore the VDF imparts highly desirable electrochemical stability in the lithium battery environment.
It is found in the practice of the invention that an ionomer of the invention containing at least 50% VDF, more preferably at least 80% VDF, may become excessively plasticized by the solvents imbibed within it, with concomitant loss of the physical integrity of the membrane. In some applications, it may be desirable to enhance the properties of the solvent-swollen membrane. Means available for improving the mechanical properties include: 1) Incorporation into the polymer by means known in the art, and following the synthetic pathway hereinbelow described, a non-ionic third monomer that is less solvent sensitive; 2) formation by known means of a polymer blend with a non-ionic polymer that is less solvent sensitive; 3) blending by known means of the ionomer of the invention with an inert filler; 4) blending different compositions of ionic copolymers; and 5) cross-linking.
Suitable third monomers include tetrafluoroethylene, chlorotrifluoro-ethylene, ethylene, hexafluoropropylene, trifluoroethylene, vinyl fluoride, vinyl chloride, vinylidene chloride, perfluoroalkylvinyl ethers of the formula CF 2 ═CFOR f where R f ═CF 3 , C 2 F 5 or C 3 F 6 . Preferred termonomers include tetrafluoroethylene, hexafluoropropylene, ethylene and the perfluoroalkylvinyl ethers. Termonomers are preferably present in the polymer at a concentration of up to 30 mol %.
Polymers suitable for blending with ionomers of the invention include poly(tetrafluoroethylene) and copolymers thereof with hexafluoropropylene or perfluoroalkyl vinyl ethers, poly vinylidene fluoride homopolymer and a copolymer thereof with hexafluoropropylene, polymethylmethacrylate, polyethylene oxide, and poly(vinyl chloride). A preferred composition comprises 25 to 50 weight % PVDF homopolymer blended with the VDF ionomer of the present invention. These materials are easily blended together by means common in the art such as dissolution and mixing in a common solvent such as acetone and then casting a membrane.
Suitable inert fillers include SiO 2 , Al 2 O 3 , TiO 2 , or CaF 2 . Small and high surface area particles less than 1.0 micron in diameter are desired, such as are available for the preferred grade of SiO 2 under the trade name Cab-o-sil® TS-530 silica. Loadings of up to 50 weight % filler are preferred.
The relatively high solubility of the ionomers of the present invention and their sulfonyl fluoride precursors provides a benefit in ease of processing during fabrication of the components of a battery but may be problematical during final assembly of the desired battery product. In a preferred embodiment of the battery of the present invention, a battery is formed from one or more electrochemical cells formed by laminating together in film form the anode, cathode, and separator compositions of the present invention, all of which have been rigorously dried prior to addition of a liquid selected from the group of organic carbonates and mixtures thereof, a mixture of ethylene carbonate and dimethyl carbonate being most preferred. Organic carbonates will not only swell the ionomeric polymer, but may also dissolve the polymer depending on the composition thereof, the primary determining factor being the degree of crystallinity, which in turn is related to the concentration of ionic comonomer in the polymer. The challenge is to swell the ionomer with solvent while minimizing dissolution of the polymer.
One way to achieve the necessary balance is to use the methods hereinabove described for improving the physical integrity of the solvent-containing ionomer. Another approach comprises dissolution of the ionomer into the preferred organic carbonate solvents, followed by introduction of the resulting solution into the pores of an inert porous polymer support such as Celgard® porous polypropylene, available from Hoechst-Celanese, or Gore-Tex microporous PTFE, available from W.L. Gore Associates, Newark, Del.
The preferred electrode of the invention comprises a mixture of one or more electrode active materials in particulate form, the ionomer of the invention, at least one electron conductive additive, and at least one organic carbonate. Examples of useful anode active materials include, but are not limited to, carbon (graphitic, coke-type, mesocarbons, polyacenes, and the like) and lithium-intercalated carbon, lithium metal nitrides such as Li 2 .6 Co 0 .4 N, tin oxides, lithium metal, and lithium alloys, such as alloys of lithium with aluminum, tin, magnesium, mercury, manganese, iron, and zinc. Lithium intercalation anodes employing carbon are preferred. Useful cathode active materials include, but are not limited to, transition metal oxides and sulfides, lithiated transition metal oxides and sulfides, and organosulfur compounds. Examples of such are cobalt oxides, manganese oxides, molybdenum oxides, vanadium oxides, sulfides of titanium, molybdenum and niobium, lithiated oxides such as spinel lithium manganese oxides Li 1+x Mn 2-x O 4 , chromium-doped spinel lithium manganese oxides Li x Cr y Mn z O 4 , LiCoO 2 , LiNiO 2 , LiNi x Co 1-x O 2 where x is 0<x<1, with a preferred range of 0.5<x<0.95, LiCoVO 4 , and mixtures thereof LiNi x Co 1-x O 2 is preferred. A highly preferred electron conductive aid is carbon black, preferably Super P carbon black, available from the MMM S.A. Carbon, Brussels, Belgium, in the concentration range of 1-10%. Preferably, the volume fraction of the lithium ionomer in the finished electrode is between 4 and 40%.
The electrode of the invention may conveniently be made by dissolution of all polymeric components into a common solvent and mixing together with the carbon black particles and electrode active particles. For cathodes the preferred electrode active material is LiNi x Co 1-x O 2 wherein 0<x<1, while for anodes the preferred electrode active material is graphitized mesocarbon microbeads. For example, a preferred lithium battery electrode of the invention can be fabricated by dissolving ionomer of the invention in a mixture of acetone and dimethyl-formamide, followed by addition of particles of electrode active material and carbon black, followed by deposition of a film on a substrate and drying. The resultant preferred electrode will comprise electrode active material, conductive carbon black, and ionomer of the invention, where, preferably, the weight ratio of ionomer to electrode active material is between 0.05 and 0.8 and the weight ratio of carbon black to electrode active material is between 0.01 and 0.2. Most preferably the weight ratio of ionomer to electrode active material is between 0.1 and 0.25 and the weight ratio of carbon black to electrode active material is between 0.02 and 0.1. This electrode can then be cast from solution onto a suitable support such as a glass plate or current collector metal foil, and formed into a film using techniques well-known in the art. The electrode film thus produced can then be incorporated into a multi-layer electrochemical cell structure by lamination, as hereinbelow described.
It may be desirable to incorporate into the electrode composition of the invention additional polymers or solvents for such purposes as improving the binding of the components thereof, or providing improved structural integrity of an article fabricated therefrom. One particularly preferred additional material is PVDF homopolymer, which may be incorporated simply by dissolving the polymer into the same solution from which the electrode is being formed, as hereinabove described.
In an alternative process, the dispersion of electrode-active material and optional carbon black and other adjuvants can first be cast onto a surface followed by addition of the ionomer of the invention in organic carbonate solution.
The invention is further described in the following specific embodiments.
EXAMPLES
For the purposes of this invention, the term "conductivity" used herein refers specifically to ionic conductivity as determined using the so-called four-point probe technique described in an article entitled "Proton Conductivity of Nafion® 117 As Measured by a Four-Electrode AC Impedance Method" by Y. Sone et al., J. Electrochem. Soc., 143, 1254 (1996). The method as described applies to aqueous electrolyte membranes. The method was modified for purposes of obtaining the measurements reported herein for non-aqueous solvents by placing the apparatus described in a sealed glove box purged with dry nitrogen in order to minimize any exposure to water. The method was also modified by substituting parallel linear probes traversing the full width of the test specimen for the point probes employed in the published method.
A 1.0 cm by 1.5 cm film was blotted dry and positioned into the conductivity cell. Cell impedance was determined over the range of 10 Hz to 100,000 Hz, and the value with zero phase angle in the higher frequency range (usually 500-5000 Hz) was ascribed to the bulk sample resistance in Ohms. The raw resistance value was then converted to conductivity, in S/cm, using the cell constant and film thickness.
Solvent uptake was determined from the equation
% uptake=(W.sub.w -W.sub.d)/W.sub.d
where W d was the weight of the membrane prior to solvent contact and W w was the weight of the membrane after solvent contact determined after first removing membrane from solvent and then blotting it dry using a paper towel to remove excess surface solvent.
All chemicals were used as received unless stated otherwise.
Differential scanning calorimetry (DSC) was performed according to ASTM D4591, in a nitrogen atmosphere and at a heating rate of 20° C./minute, using a TA Instruments Model 2910. Thermogravimetric analysis was performed using a TA Instruments Model 2950 at a heating rate of 10° C./min in air except where otherwise noted.
19 F NMR spectra were recorded using a Bruker AVANCE DRX 400 spectrometer. 1 H NMR spectra were recorded using a Bruker AVANCE DRX 500 spectrometer.
Intrinsic viscosity was determined at 25° C. in 1,2-dimethoxyethane.
Example 1
A 1-liter vertical stirred autoclave was charged with 500 ml of an aqueous solution of ammonium perfluorooctanoate (7 g), available from the 3M Company, Minneapolis, Minn., and PSEPVE (50.0 g, 0.112 mol). PSEPVE was prepared in the manner described in D. J. Connally and W. F. Gresham, U.S. Pat. No. 3,282,875 (1966). The vessel was closed, twice pressured to 100 psi nitrogen and vented, cooled to about 5° C. and evacuated. Vinylidene fluoride (50.0 g, 0.78 mol) was added, and the stirred (750 rpm) contents were heated to 60° C. A solution of 0.40 g potassium persulfate in 20 ml distilled water was added over a 20 minute interval. Pressure decreased from 400 psi to 5 psi within 2 hours. The polymer was isolated by freeze/thaw coagulation. After washing with distilled water several times, the polymer sponge was cut in several pieces, frozen in liquid nitrogen, added to a blender to produce a polymer crumb which was washed with additional portions of water. There was obtained 95.5 g of white polymer after drying at 25° C. under a vacuum of 10 millitorr. DSC showed T g =-23° C. and maximum of a broad melting transition at 125° C. (8.7 J/g). TGA, performed under nitrogen showed the onset of weight loss at ca. 250° C., with ca. 1% loss up to ca. 370° C. Intrinsic viscosity was 0.72 dl/g. The composition was found to be 87 mol % VDF and 13 mol % PSEPVE, as determined by a combination of 1 H and 19 F NMR. The NMR results were 1 H NMR (THF-d8): 3.3-2.9 (lower field shoulders), 2.9-2.7 (major multiplet), 2.6 and 2.3 (minor multiplets). 19 F NMR (THF-d8) featured signals at +45.4 (FSO 2 ), -78 to -80 (m's, OCF 2 and CF 3 ), -90 to -95 (m, CH 2 CF 2 ), -110 to -123 (series of m, for minor CH 2 CF 2 and CF 2 S), -144 (CF).
An 8.9 g sample of PSEPVE/VF2 copolymer (ca. 10 m equivalents of pendant sulfonyl fluoride) was suspended in methanol (50 mL), treated with lithium carbonate (0.81 g, 11 m equivalents CO 3 ), and stirred at 25° C. After 3 hr, another 50 ml methanol was added and the mixture was stirred for an additional 18 hr. The mixture was filtered under pressure through glass fiber paper. A portion of the methanol solution was used to cast films for conductivity testing and the remainder was evaporated to dryness under reduced pressure. 19 F NMR (THF-d8) showed only a trace signal for residual FSO 2 moieties (>99% conversion), major signals at -76 to -82, -90.6, -93.1 and -95.3, -108 to -112 and series of m's at -113.6, -115.9, -117.5, -122 to -124, and -144 to -145 with integration in accord with 13 mol % incorporated lithium sulfonate form of PSEPVE. I.V.=0.73 dl/g.
Example 2
A film ca. 80 micrometers in thickness was cast from the methanol solution of Example 1, by spreading a ca. 3 mL aliquot of the solution on a glass plate at 25° C. After slow evaporation of solvent, the resulting film was then dried for a period of time in a vacuum oven.
The dried membrane was transferred to a sealed container and conveyed to a glove box having a positive pressure of dry nitrogen applied thereto, wherein the membrane was removed from the sealed container and allowed to come to room temperature. The membrane was then cut into several sections 1.0 cm by 1.5 cm in size.
Using a micropipette, 20 microliters of propylene carbonate (99%, Aldrich Chemical Co., Inc., Milwaukee, Wis.) was deposited onto the surface of the membrane sample while at room temperature. Conductivity, measured after 10 minutes of solvent exposure, was 3.74×10 -4 S/cm.
Example 3
A further 1.0 cm by 1.5 cm sample of the dried membrane of Example 2 was treated according to the method therein described except that the solvent was a 1:1 by volume mixture of ethylene carbonate (98%, Aldrich Chemical Co., Inc., Milwaukee, Wis.) and dimethyl carbonate (99%, Alfa Aesar, Ward Hill, Ma.). The conductivity was found to be 6.87×10 -4 S/cm.
Example 4
A 1.0 cm by 1.5 cm sample of the dried membrane of Example 2 was treated according to the method therein described except that the solvent was distilled and deionized water. The conductivity was equal to 2.156×10 -2 S/cm.
Example 5
A mixture of 1 g of the Li ionomer of Example 1 and 1 g of poly(vinylidene fluoride) homopolymer, prepared by aqueous dispersion polymerization, was placed in a closed glass jar containing 60 ml acetone. Mild heat was applied while the contents were shaken to speed dissolution. Once both polymers were dissolved, solution aliquots were deposited on a glass surface in order to form films by slow solvent evaporation. The resulting films were dried for 18 hr at 50° C. in a vacuum oven.
The dried membrane was transferred to a sealed container and conveyed to a glove box having a positive pressure of dry nitrogen applied thereto, wherein the membrane was removed from the sealed container and allowed to come to room temperature.
A 1.0 cm by 1.5 cm membrane sample was immersed fully into an excess of propylene carbonate solvent in a sealed glass vial. After 1 hour, the membrane was removed from the solvent, blotted dry, and the weight uptake and conductivity measured. The weight uptake was 267% and the conductivity was 4.95×10 -4 S/cm.
Example 6
A 1.0 cm by 1.5 cm sample of the membrane of Example 5 was treated according to the method therein described except that the solvent was a 1:1 by volume mixture of ethylene carbonate and dimethyl carbonate. After one hour, the weight uptake was 150% and the conductivity was 6.60×10 -4 S/cm.
COMPARATIVE EXAMPLE 1
A 9.0 g sample of a non-ionic copolymer was synthesized in a manner similar to that employed to synthesize the polymer of Example 1 except that the initiator was a solution of 0.08 g potassium persulfate in 20 ml water. NMR indicated a composition of 86.8 mol % VDF and 13.2 mol % PSEPVE. A 9.0 g sample of the polymer so-synthesized was placed in a flask with 100 ml of methanol and 0.9 g of lithium carbonate. The slurry was stirred at room temperature under argon for 48 hours. 500 ml of THF was then added and the solution was filtered through a fritted funnel. The filtered solution was then placed in dialysis tubing (Spectra/Por(R) Dialysis Membrane, MWCO=3500) and dialyzed against deionized water for 11 days. The dialysis tubing contents were emptied into a flask and the water removed under vacuum. The collected polymer was then dried under vacuum at 50° C. The composition of the polymer was found to be 86.8 mol % VDF and 13.2 mol % PSEPVE by a combination of 1 H and 19 F NMR.
Films were cast by dissolving 0.58 g of polymer in a minimum amount of acetone and pouring the solution into round PFA petri dishes. The solvent was allowed to evaporate slowly to yield a film that was dried further in a recirculating nitrogen oven (Electric Hotpack Company, Inc., Model 633, Philadelphia, Pa.) at T=100° C. for 48 hours. Following the drying, the membrane was immersed into an excess of 1.0 M nitric acid (Reagent grade, EM Science, Gibbstown, N.J.) and heated to T=80° C. for one hour. Following this procedure, the membrane was rinsed with deionized water for several hours. The membrane was clear and intact after this procedure.
A 1.0 cm by 1.5 cm section of this membrane sample was fully immersed into an excess of LiOH (98%, EM Science, Gibbstown, N.J.), 1.0 molar in 1:1 by volume mixture of water and DMSO (HPLC grade, Burdick & Jackson, Muskegon, Mich.) mixture at T=70° C. for 1 hour. Upon reaching temperature, this membrane sample was visibly blackened and rapidly decomposed by the hydrolysis bath. After one hour, the membrane sample had fractured into several smaller pieces and was completely blackened.
Example 7
A 1-liter vertical stirred autoclave was charged with 500 ml of an aqueous solution of ammonium perfluorooctanoate (7 g) and PSEPVE (25.0 g, 0.056 mol). The vessel was closed, twice pressured to 100 psi nitrogen and vented, cooled to about 5° C. and evacuated. Vinylidene fluoride (50.0 g, 0.78 mol) was added, and the stirred (750 rpm) contents were heated to 60° C. A solution of potassium persulfate (0.08 g in 20 ml) was added over a 10 minute interval. Pressure decreased from 400 psi to 5 psi within 3 hours. The polymer was isolated by freeze/thaw coagulation and washed thoroughly with distilled water. There was obtained 69.4 g of white polymer after drying. DSC exhibited Tg=-23° C. and maximum of a broad melting transition at 120° C. (14.9 J/g). TGA showed the onset of weight loss at ca. 370° C. The composition was found to be 91.6 mol % VDF and 8.4 mol % PSEPVE, as determined by a combination of 1 H and 19 F NMR. The NMR results were 1 H NMR (acetone-d6): 3.6-2.6 (m), 2.4 (minor multiplet). 19 F NMR (acetone-d6): +45.57 (s), -78.0 to -80.0 (m's s, a=2.968), -90.0 to -95.0 (m's, a=8.646), -108 to -116 (series of m, a=2.721), -121 to -127 (m's, a=1.004), -143 to -144.0 (m, a=0.499); integration using internal CF signal and the combined CF 3 +CF 2 O signals to fix response for PSEPVE indicated 0.462/F for PSEPVE, 5.03/F for VDF.
30 g (26.2 milliequivalents) of the copolymer so produced was suspended in 300 ml methanol and treated with 2.13 g Li 2 CO 3 . The resulting mixture was stirred for 42 hours. An aliquot analyzed by 19 F NMR showed >99% conversion of sulfonyl fluoride groups to lithium sulfonate moieties.
A 50 ml portion of the methanol slurry was treated with ca. 120 ml acetone, and the resulting polymer solution was filtered under pressure. The filtered solution was used to prepared several film samples for further testing after standard drying procedures. 19 F NMR (acetone-d6): +45.6 (trace signal, a=below detection limits), -77.0 to -83.0 (m's, a=13.68), -88.0 to -100.0 (m's, a=38.9), -108 to -118 (series of m, a=10.78), -122 to -128 (m's, a=4.86), -144 to -145.5 (m, a=2.12); consistent with 91.6 mol % VDF, 8.4 mol % Li-PSEPVE.
TGA showed a gradual 3% weight loss to ca. 250°, followed by onset of polymer weight loss at 275° C. DSC featured a maximum of a broad melting transition at 126° C.
Comparative Example 2
A 3" by 3" sample of Nafion® 117 perfluorinated ionomeric membrane available from the DuPont Company, Wilmington Del., was exposed to an excess of LiOH (98%, EM Science, Gibbstown, N.J.), 1.0 molar in 1:1 by volume mixture of water and DMSO (HPLC grade, Burdick & Jackson, Muskegon, Mich.) mixture at T=60° C. for 2 hours, after which the membrane was washed in distilled water for 2 hours at T=80° C., and dried in a recirculating nitrogen oven (Electric Hotpack Company, Inc., Model 633, Philadelphia, Pa.) at 100° C. for 96 hours.
The dried membrane was transferred to a sealed container while still warm and conveyed to a glove box having a positive pressure of dry nitrogen applied thereto, wherein the membrane was removed from the sealed container and allowed to come to room temperature. The membrane was then cut into several sections 1.0 cm by 1.5 cm in size.
A cooled 1.0 cm by 1.5 cm membrane sample was then soaked in an excess propylene carbonate (99%, Aldrich Chemical Co., Inc., Milwaukee, Wis.) in a sealed glass vial for 2 hours at room temperature. The membrane was removed from the propylene carbonate bath, blotted with a paper towel to remove excess solvent. The conductivity was determined to be 2.16×10 -5 S/cm.
Example 9
0.5 g of Li 2 CO 3 -hydrolyzed ionomer prepared in the manner of Comparative Example 1 was dissolved in 15-20 ml of THF in a vial equipped with a stirring bar. 0.1 g of Cab-o-sil® TS-530 silica was added to the solution and dispersed by stirring. Films were cast into round PFA petri dishes (50 mm diameter). The solvent was allowed to evaporate slowly to yield a film that was dried further under vacuum for 48 hours at 100° C. in a vacuum oven. The resulting film was tough and easily separated from the substrate. The film was hydrolyzed to the lithium ionomer form by the method described herein. Conductivity, determined after soaking in distilled water, was 7.02×10 -3 S/cm.
Example 10
A 500 mL 3-neck round-bottom flask equipped with a magnetic stirring bar, 2 septa, and a water condenser further attached to a nitrogen source was charged with PSEPVE (98 g, 0.22 mol) and methanol (200 mL). The solution was stirred and lithium carbonate (16.2 g, 0.22 mol) was added in 3 portions. No exotherm was observed. The mixture was stirred 3 days at room temperature. The reaction mixture was centrifuged, then the supernatant was decanted and concentrated by vacuum distillation. Rigorous drying of the salt was accomplished by placing in a tray in a heated (80° C.) tube with a N 2 flow. Methanol content was 1.2 mol % (determined by 1 H NMR in D 2 O with CH 3 COOH internal integration standard). Another sample dried in a packed tube contained 0.6% methanol. Analytical data were consistent with the structure, LiO 3 SCF 2 CF 2 OCF(CF 3 )CF 2 OCF═CF 2 . 19 F NMR (D 2 O) δ-81.1 (m, 2F), -8.15 (m, 3F), -86.3 (m, 2F), -116.0 (dd, 86.1, 65.4 Hz, 1F), -119.0 (d, 7.6 Hz, 2F), -123.8 (ddm, 112.3, 86.1 Hz, 1F), -137.8 (ddm, 112.3, 65.4 Hz, 1F), -146.4 (m, 1F); FTIR (NaCl) 1780.6 (m), 1383.3 (w), 1309.0 (vs), 1168.2 (m).
Example 11
A 1-liter vertical stirred autoclave was charged with 500 mL of an aqueous solution of the ionic olefin of Example 10 (25.0 g, 0.056 mol). The vessel was closed, twice pressured to 100 psi nitrogen and vented, cooled to about 5° C. and evacuated. Vinylidene fluoride (50.0 g, 0.78 mol) was added, and the stirred (750 rpm) contents were heated to 60° C. A solution of potassium persulfate (0.08 g in 20 mL) was added over a 10 minute interval. Pressure decreased from 400 psi to 5 psi within 8 hours. Evaporation of water from the solution of copolymer resulted in 54 g of white solid. DSC (10°/min, N 2 ) exhibited maximum of a broad melting transition at 157° C. (10.7 J/g). TGA (10°/min, N 2 ) showed a ca. 5% weight loss (40-150° C. attributed to loosely bound water) and the onset of polymer weight loss at ca. 260° C. 1 H NMR (acetone-d6): 3.6-2.6 (m), 2.4 (minor multiplet). 19 F NMR (acetone-d6): -78.0 to -80.0 (m's, a=84.9), -90.0 to -95.0 (m's, a=236.9), -108 to -116 (series of m) and -121 to -127 (m's , combined a=112.5), -144 to -145.0 (m, a=15.1); integration using internal CF signal and the combined CF 3 +CF 2 O signals to fix response for Li-PSEPVE indicated 13.6/F for PSEPVE, 140.7/F for VDF. Thus, mol % VDF=91.2%; mol % Li-PSEPVE=8.8% and wt % VDF=57.4%; wt % Li-PSEPVE=42.6%.
Example 12
Separator and Cell Utilizing p(VdF-PSEPVE)
Below is a description of a separator and an electrochemical cell which used an ionomer of the invention in the electrolyte. Both the separator and the electrode may be considered porous structures imbibed with a liquid electrolyte, the electrolyte being a mixture of the ionomer dissolved in carbonate-based liquid solvents.
The following lithiation/dialysis procedure was used for the silica-filled film example. A 9.0 g sample of the polymer of Example 1, an 87 mol % VF 2 /13 mol % PSEPVE copolymer, was placed in a flask with 100 ml of methanol and 0.9 g of lithium carbonate. The slurry was allowed to stir at room temperature under argon for 48 hours. THF (500 ml) was added and the solution was filtered through a fritted funnel. The solution was then placed in dialysis tubing (Spectra/Por® Dialysis Membrane, MWCO=3500 from VWR) and dialyzed against deionized water for 11 days. The dialysis tubing contents were emptied into a flask and the water removed under vacuum. The collected ionomer was then dried under vacuum at 50° C.
In an argon-filled dry box, an electrolyte solution was prepared using 200 mg of the ionomer (in lithium form) dissolved in 2 ml of a 50:50 wt:wt mixture of ethylene carbonate and dimethyl carbonate. A microporous polyolefin separator (Celgard® 3501, Hoechst Celanese) was soaked in the electrolyte for 2 hours and gained 65% in weight. Its ionic conductivity, measured using a 4-point probe, was 10 -3 S/cm.
A cathode film was prepared by making a slurry containing 4 g of Li 1 .05 Mn 2 O 4 (50 m particle size), 0.215 g of SP carbon black, 2.5 ml of 4% EPDM in cyclohexane (a solution containing 4 g of DuPont Nordel® 3681 EPDM rubber dissolved in 96 g of cyclohexane), and an additional 2.5 ml of cyclohexane. The ingredients were shaken together in a glass vial with glass beads for 15 minutes, and then the slurry was cast onto FEP film using a doctor blade with a 10 mil gate height. The solvent was allowed to evaporate at ambient temperature, giving film with a coating weight of 21 mg/cm 2 . The cathode film was removed from the FEP base film, placed between 5-mil Kapton® sheets, and these in turn were placed between 5-mil brass foil sheets. This cathode package was then compressed between steel rollers heated to 110° C. and with a force of 2.8 lb. per inch of nip width by using a laminator (Western Magnum XRL-14, El Segundo, Calif.). Cathodes 13.6 mm dia. were punched out from the film, and these were dried in vacuum at 80° C. for 30 min.
A cathode (31.2 mg, 13.6 mm diameter) and a microporous polyolefin separator were soaked in the electrolyte solution from above for two hours. They were assembled with a 320 um thick lithium foil anode into a size 2325 coin cell. The cell was charged with constant current at 0.5 mA to a voltage of 4.3 V, at which point the voltage was held constant until the current dropped below 0.05 mA. The capacity on first charge was 3.81 mAh, which represents 131 mAh per g of lithium manganese oxide cathode material. The cell was discharged at a 0.5 mA rate to 3.7 V, and then the voltage was held constant at 3.7 V until the discharge current dropped below 0.05 mA. The discharge capacity was 3.15 mAh. The cell was repeatedly charged and discharged in a manner similar to above, with the 7 th discharge capacity being 2.96 mAh. The AC impedance of the cell was measured to be 98 ohm at a frequency of 0.01 Hz. | This invention concerns substantially fluorinated, but not perfluorinated, ionomers consisting of a polyethylene backbone having pendant groups of fluoroalkoxy sulfonic acids and metal salts thereof. Such ionomers are useful for electrochemical applications. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to the field of keyboard switch mechanisms. More particularly, this invention relates to a new and improved snap action or tactile keyboard switch mechanism in which the possibility of inadvertent key actuation is significantly reduced.
Snap action keyboard switch mechanisms of the general type of the present invention have found wide applicability as an operational input switch for various electric and electronic apparatus. Snap action switches are particularly effective because of a clicking action occurring during the switching operation. The clicking action enables the keyboard operator to confirm the input through variation in pressure felt in the finger known as tactile feel.
While conventional prior art tactile type keyboard switch structures have performed adequately, they have suffered from certain structural and operational problems. One such common deficiency occurs in the area located between the operational regions or keys. If the keyboard operator inadvertently presses a spot within this area, for example when a key is actuated off center, during the operation of the keyboard switch, one of the keys located adjacent to the pressed spot may erroneously be actuated. Consequently, this inadvertent actuation and input results in poor efficiency and frustration to the keyboard operator as well as misinformation and/or miscalculation in the supporting electric or electronic instruments.
SUMMARY OF THE INVENTION
The above-discussed and other deficiencies of the prior art are overcome or significantly reduced by the keyboard switch mechanism of the present invention. In accordance with the present invention, the area located between the operational regions or keys has a novel structural support. This support is accomplished by means of protrusions located on the switch sheet of the snap action keyboard. The protrusions are disposed beneath the non-operational regions, for example, between key locations. These protrusions act to alleviate the above-mentioned problems associated with inadvertent input caused by actuating the areas between the keys. The protrusions may be either formed in or mounted on the switch sheet. The protrusion height may vary depending on the distance between the operational regions in order to maintain optimum tactility.
The above-discussed and other advantages of the present invention will be apparent to and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, wherein like elements are numbered alike in the several figures:
FIG. 1 is a cross-sectional elevation view of a conventional snap action keyboard in accordance with the prior art.
FIG. 2 is a cross-sectional elevation view of a snap action keyboard in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a snap action keyboard switch in accordance with the prior art is shown. A resilient and flexible circuit sheet 2 having a desired fixed upper circuit contact patterns 1 formed thereon is shown. A resilient and flexible switch sheet 6 having a movable lower circuit contact patterns 5 formed thereon and corresponding to the upper contact patterns 1 is disposed beneath circuit sheet 2 across switch cavities 3. Circuit sheet 2 and switch sheet 6 are separated by an insulating spacer 4 having openings which define switch cavities 3. Adhesive layers 9, one of which is indicated, bond the circuit layers together. A pair of contacts 1 and 5 constitutes a key site. The space 7 between key sites contribute to the snap action effect. The keyboard structure is completed by a rigid base sheet 8 which accommodates and supports switch sheet 6.
In a known prior art embodiment, the individual switch elements formed in switch sheet 6, a semispherical, flat-topped shape is positioned below contact elements 1 and is suitable for initiating the desired snap or click action. These switch elements in switch sheet 6 invert upon actuation of cover sheet 2 by application of a downward force at the location of a circuit pattern 1 of a key site. Upon inversion of the switch elements, tactile snap action is translated to the keyboard operator while simultaneously the upper contact pattern 1 comes into electrical and mechanical contact with the lower contact pattern 5 thus closing a switch.
The non-conductive keyboard parts are typically made from an insulating synthetic material while the electrically conductive circuit patterns may be formed by any conventional printed circuit or similar technique.
As discussed earlier, the above described prior art device suffers from certain deficiencies. In particular, the area between the individual snap action elements corresponding to the portion of cover sheet 2 located above space 7 is susceptible to erroneous input by inadvertent application of actuating force. Thus, when a keyboard operator accidently presses this area suring operation, one of the adjoining key elements may snap through causing unintended input.
The keyboard switch of the present invention as shown in FIG. 2 eliminates the above-described problem. The keyboard of the present invention has a structure similar to that already described in FIG. 1. It includes a cover sheet 11 with a fixed upper circuit contact patterns 14 formed thereon. A switch sheet 13 with both snap action switch elements and support protrusions 17 formed therein is disposed beneath cover sheet 11. The switch elements are shaped similarly to the switch elements in FIG. 1 and have movable lower circuit contact patterns 14A formed thereon and corresponding to the upper contact patterns 14. Lastly, an insulating spacer sheet 12, base sheet 15 and bonding layers 18 (only one of which is shown) complete the component parts of the present invention. The keyboard shown in FIG. 2 operates in a henerally similar manner to the prior art keyboard shown in FIG. 1 in that the semispherical, flat-topped switch elements in switch sheet 13 invert upon actuation of cover sheet 11 by application of actuating force downwardly at a switch site. Similarly, upon inversion, a tactile snap action is translated to the operator as the upper contact pattern 14 comes into mechanical and electrical contact with the lower contact pattern 14A thus closing a switch.
Unlike the prior art switch, the switch sheet 13 is provided with structural supports in the form of support protrusions 17. The protrusions 17 may be either integrally formed into or attached onto the switch sheet 13. The protrusions 17 are disposed beneath the cover sheet 11 between the operational regions or keys, thereby supporting the switch sheet against accidental actuation when pressure is inadvertently applied to this non-operational area by the keyboard operator. Thus, the keyboard of the present invention reduces the likelihood of input error from inadvertent key actuation.
Experimentation has shown that if the distance between the keys or operating regions is short and if the height of the protrusions 17 are equal to the depth of the individual switch elements of the switch sheet 13, then the actuating force, for example, force needed by operator to fully depress the key, and the snap action return force are increased. Actually, the increase in return force is relatively greater than the corresponding increase in actuating force. The "click ratio" which is a measure of the degree of tactility and which is represented by: ##EQU1## is therefore reduced with the relatively increased return force. Since tactile feel is highly desired and a lower click ratio indicates less tactile feel, then the above hypothetical dimensional relationship should be avoided. This is easily accomplished by making the height of the protrusion 17 shorter than the depth of the individual switch elements. Thus, a satisfactory click ratio is obtained while maintaining the desired effect of the support protrusions 17. Also, tactile feel of a switch can be adjusted or varied in the design stage by the proportioning of the height of protrusions 17 and the depth of switch elements.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A snap action keyboard switch mechanism is presented wherein protrusions located on the switch sheet between adjoining snap action elements act to support the switch sheet and avoid inadvertent input. If a key is actuated off center, the support protrusions will prevent erroneous actuation of an adjoining key. The protrusion height varies depending upon the desired optimum tactility. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-007994, filed Jan. 16, 2001, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a portable information equipment and, more particularly, to a personal computer for reproducing CD/DVD data recorded on CD/DVD media and MP3 data recorded on a memory card and HDD etc.
2. Description of the Related Art
Upon reproducing digital audio/video data stored in a computer, switching data to be reproduced, and fastforwarding/rewinding data, a method of making an instruction using a mouse or inputting via a keyboard is used.
However, a portable notebook type computer does not always have high operability, since such conventional input interface requires delicate operations. For this reason, some personal computers simplify operations by making a choice from those displayed on a menu using a jog dial.
However, since the jog dial generates an event by dial operation, it can generate only two different events, i.e., an event indicating dialing in one direction, and an event indicating dialing in the other direction. Hence, if there are many choices, jog dial operations are complicated.
More specifically, if there are 20 choices, when the user wants to select the 20th choice while the cursor used to select an item is located at the first choice, he or she must turn the jog dial 20 times to move the cursor, resulting in troublesome operations.
BRIEF SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above situation, and has as its object to provide a portable information equipment which can easily select a plurality of processes by operating a jog switch.
Therefore, in order to achieve the above object, the first invention of the present invention is a computer system comprising: a switch for generating different events in correspondence with flip direction and flip times; and means for executing a process corresponding to a type of event generated by the switch.
According to this computer system, since different processes are executed in correspondence with the types of events generated by the jog switch, a plurality of processes can be selected by simple operations using the switch.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a front view of a computer with its display unit being opened;
FIG. 2 is a front view of the computer with its display unit being closed;
FIG. 3 is a side view from the direction of an arrow (S) in FIG. 1 with the display unit being closed;
FIG. 4 is a top view of operation buttons 14 and jog switch 15 ;
FIG. 5 is a side view of the jog switch 15 ;
FIG. 6 is a view for explaining the relationship between the operations of the jog switch 15 and events;
FIG. 7 is a schematic block diagram showing the arrangement of a notebook type personal computer according to an embodiment of the present invention;
FIG. 8 is a flow chart for explaining the operation of the notebook type personal computer of the embodiment when the system is OFF;
FIG. 9 is a flow chart for explaining the operation of the notebook type personal computer of the embodiment when the system is OFF;
FIG. 10 is a flow chart for explaining the operation of the notebook type personal computer of the embodiment when the system is active;
FIG. 11 is a flow chart for explaining the operation of the notebook type personal computer of the embodiment when the system is active;
FIG. 12 is a flow chart for explaining the operation of the notebook type personal computer of the embodiment when a player is running;
FIG. 13 is a flow chart for explaining the operation of the notebook type personal computer of the embodiment when the player is running;
FIG. 14 shows a tray icon in a CD/DVD mode;
FIG. 15 shows a tray icon in a digital audio mode;
FIG. 16 shows a display example upon switching a play list;
FIG. 17 shows a display screen used to select an object to be started by the system;
FIG. 18 is a diagram for explaining an informing method of the operation button and jog switch; and
FIG. 19 is a diagram for explaining switching of play lists.
DETAILED DESCRIPTION OF THE INVENTION
A notebook type personal computer according to an embodiment of the present invention will be described below with reference to the accompanying drawings. In this embodiment, data to be reproduced is limited to sound (audio) data, and a description of digital video data will be omitted.
The basic structure of the notebook type personal computer according to the embodiment of the present invention will be described first with reference to FIGS. 1 and 2 .
FIG. 1 is a front view of the computer with its display unit being opened, FIG. 2 is a front view of the computer with its display unit being closed, and FIG. 3 is a side view from the direction of an arrow (S) in FIG. 1 with the display unit being closed.
This computer comprises a computer main body 11 and display unit (panel) 12 .
The display unit 12 has a built-in display screen 12 comprising an LCD. The display unit 12 is attached to the computer main body 11 to be pivotal between the open and close positions.
The computer main body 11 has a low-profile box-shaped housing, and a keyboard, pointing stick, and the like are arranged on its upper surface.
A system indicator 13 , operation buttons 14 , and jog switch 15 are provided to the upper surface of the computer main body 11 . The system indicator 13 , operation buttons 14 , and jog switch 15 are externally exposed even when the display panel 12 is closed, as shown in FIG. 2 . In this embodiment, a notch is formed between the right and left hinges of the lower portion of the display panel 12 , so that a back (rear) side region of the upper surface of the computer main body is externally exposed even when the display panel 12 is closed.
The system indicator 13 includes a plurality of LED lamps, which indicate various kinds of status such as ON/OFF of a power supply, access to an HDD, connection/disconnection of an AC adapter, and the like by their ON/OFF states.
FIG. 4 is a top view of the operation buttons 14 and jog switch 15 , and FIG. 5 is a side view of the jog switch 15 . As shown in FIGS. 4 and 5 , the jog switch 15 has a knob 31 , which can be flipped to the right or left. When the user flips the knob 31 of the jog switch 15 to the right or left and then releases it, the knob 31 automatically returns to a neutral (central) state.
The operation buttons 14 are used to operate an object to be operated, which is switched by a program. For example, the object to be operated may be a CD/DVD medium or a digital audio medium.
As shown in FIG. 4 , the operation buttons 14 include a rewind button 14 a , play/pause button 14 b , stop button 14 c , and fastforward button 14 d.
The rewind button 14 a is used to rewind a tune to reproduce to the immediately preceding tune. The play/pause button 14 b is used to reproduce a tune, and to pause reproduce of a tune if it is pressed during reproduce. The stop button 14 c is used to stop reproduce of a tune when it is pressed during reproduce. The fastforward button 14 d is used to fastforward a tune to be reproduce to the next tune.
FIG. 6 is a view for explaining the relationship between the operations of the jog switch 15 and events. Note that a right event generated when the knob 31 of the jog switch 15 is flipped to the right will be explained below. Also, when the knob 31 is flipped to the left, a left event is generated.
As shown in FIG. 6 , when the jog switch 15 is flipped to the right (left) side, a right (left) event is generated. When the jog switch 15 is kept flipped to the right (left) for a predetermined period of time (e.g., 1 sec), a right (left) continue event is generated.
On the other hand, when the user releases the jog switch 15 immediately after a right (left) event was generated, and the jog switch 15 returns to a neutral state, a return event is generated. Likewise, when the jog switch 15 returns to a neutral state after a right (left) continue event was generated, a return event is generated.
A disk drive 21 is provided to the right side surface of the computer main body 11 . The disk drive 21 receives a disk medium 20 such as a CD-ROM or DVD-ROM that records audio data, a CD-ROM or DVD-ROM that records audio and video data, or the like as an object to be reproduced.
FIG. 7 shows a schematic arrangement of the notebook type personal computer according to this embodiment.
Referring to FIG. 7 , a CPU 41 controls the overall system, and executes programs stored in a main memory 42 .
The main memory 42 stores a program for implementing processes of the flow charts to be explained later in this embodiment, a CD/DVD reproduce application program used to reproduce CD/DVD media, a digital audio application program used to reproduce digital audio data such as MP3 data, and the like.
A CD/DVD player 43 is used to reproduce CD/DVD media.
A ROM (Read Only Memory) 44 stores a BIOS (Basic Input Output System), and has a program for detecting events from a jog witch 45 and console 48 .
The jog switch 45 generates different events depending on its flip direction and time, and also a return event when it returns to a neutral state, as shown in FIG. 6 .
A storage device 46 is a memory card that stores digital audio data (for example, MP3 data). A display unit 47 is a display device such as a TFT, CRT, or the like.
The console 48 has the operation buttons 14 shown in FIG. 4 , which include the buttons 14 a to 14 d.
The operation of the notebook type personal computer according to this embodiment will be described below. Note that the operation to be described below is implemented by the BIOS program stored in the ROM 44 and the program stored in the main memory 42 . The relationship between the BIOS program stored in the ROM 44 and the program stored in the memory 42 will be described later.
1) When system is OFF
The operation of the notebook type personal computer of this embodiment while the system is OFF will be explained below with reference to the flow charts of FIGS. 8 and 9 .
While the system is OFF (hibernation or standby state), when the user flips the jog switch 15 to the CD/DVD side (A side in FIG. 4 ) or audio data side (B side in FIG. 4 ), the system is started (resumed) (S 1 ), and it is checked if the jog switch 15 has been flipped to the CD/DVD side or audio data side (S 2 ).
If it is determined in step S 2 that the jog switch 15 has been flipped to the CD/DVD side, the object to be operated by the operation buttons 14 is switched to a CD/DVD medium (S 3 ). And then, a tray icon is switched to that which can identify a CD/DVD mode, e.g., an icon 47 shown in FIG. 14 (S 4 ), and it is then checked if a medium loaded in the CD/DVD player 43 is a CD (S 5 ).
If it is determined in step S 5 that the medium loaded in the CD/DVD player 43 is a CD, a CD reproduce application program is started (S 6 ) to reproduce the CD (S 7 ). If it is determined in step S 5 that the medium loaded is not a CD, a DVD reproduce application program is started (S 8 ) to reproduce a DVD (S 9 ).
On the other hand, if it is determined in step S 2 that the jog switch 15 has been flipped to the audio data side, the object to be operated by the operation buttons 14 is switched to a digital audio media (S 10 ). And then, a tray icon is switched to that which can identify a digital audio mode, e.g., an icon 50 shown in FIG. 15 (S 11 ), and the digital audio application program is started (S 12 ) to reproduce digital audio data (S 13 ).
In this manner, even when the system is OFF, CD/DVD media and digital audio data can be reproduced by flipping the jog switch.
2) When system is active
The operation of the notebook type personal computer of this embodiment while the system is active will be explained below with reference to the flow charts of FIGS. 10 and 11 .
When the user flips the jog switch 15 while the system is active, it is checked if the jog switch 15 has been flipped to the CD/DVD side or audio data side (S 21 ).
If it is determined in step S 21 that the jog switch 15 has been flipped to the CD/DVD side, the object to be operated by the operation buttons 14 is switched to a CD/DVD medium (S 22 ). The tray icon is then switched to that which can identify the CD/DVD mode, e.g., the icon shown in FIG. 14 (S 23 ), and it is then checked if a medium loaded in the CD/DVD player 43 is a CD (S 24 ).
If it is determined in step S 24 that the medium loaded in the CD/DVD player 43 is a CD, the CD reproduce application program is started (S 25 ) to reproduce the CD (S 26 ). If it is determined in step S 24 that the medium loaded is not a CD, the DVD reproduce application program is started (S 27 ) to reproduce a DVD (S 28 ).
On the other hand, if it is determined in step S 21 that the jog switch 15 has been flipped to the audio data side, the object to be operated by the operation buttons 14 is switched to a digital audio media (S 30 ). And then, the tray icon is switched to that which can identify the digital audio mode, e.g., the icon shown in FIG. 15 (S 31 ), and the digital audio application program is started (S 32 ) to reproduce digital audio data (S 33 ).
In this way, by only flipping the jog switch 15 while the system is active, CD/DVD media and digital audio data can be reproduced.
3) When player is running
The operation of the notebook type personal computer of this embodiment while the MP3 audio player or digital audio player reproduces the digital audio data will be explained below with reference to the flow charts of FIGS. 12 and 13 .
In this case, a case will be explained below wherein the digital audio player reproduces digital audio data.
As shown in FIG. 12 , it is checked if the jog switch 15 has generated a return event of a right event (S 41 ). Note that the return event of the right event generated by the jog switch 15 is an event generated when the jog switch 15 is flipped to the right to generate a right event and then returns to a neutral state. On the other hand, a return event of a right continue event is an event generated when the jog switch 15 is kept flipped to the right for a predetermined period of time to generate a right event and right continue event, and then returns to a neutral state.
Likewise, a return event of a left event is an event generated when the jog switch 15 is flipped to the left to generate a left event and then returns to a neutral state. On the other hand, a return event of a left continue event is an event generated when the jog switch 15 is kept flipped to the left for a predetermined period of time to generate a left event and left continue event, and then returns to a neutral state.
If it is determined in step S 41 that a return event of a right event has been generated, a next play list is selected (S 42 ), and the flow advances to step S 43 . On the other hand, if it is determined in step S 41 that a return event of a right event has not been generated, the flow advances to step S 43 . Note that the play list means a list of a group of some tunes, and contains information of a reproducing order of tunes included in the play list. In this embodiment, assume that there are a plurality of play lists as groups of tunes.
It is then checked in step S 43 if a return event of a left event has been generated. If it is determined in step S 43 that a return event of a left event has been generated, a previous play list is selected (S 44 ), and the flow advances to step S 45 . On the other hand, if it is determined in step S 43 that a return event of a left event has not been generated, the flow also advances to step S 45 .
FIG. 19 is a diagram for explaining switching of play lists.
As shown in FIG. 19 , a plurality of play lists are assigned to reproduce order. Pointer 51 indicates an activated list. In this case, the pointer 51 indicates a play list C assigned to reproduce order 3 , thus the lay list C is activated.
If the return event of the right event is generated, the pointer 51 moves to a position indicating a play list B assigned to reproduce order 2 . And then, the play list B is activated. Namely, if the return event of the right event is generated, the activated play list is switched to a previous play list.
If the return event of the left event is generated, the pointer 51 moves to a position indicating a play list D assigned to reproduce order 4 . And then, the play list D is activated. Namely, if the return event of the left event is generated, the activated play list is switched to a next play list.
The plurality of play lists are stored a memory of the personal computer and the play lists can be inserted/added by a user.
It is checked in step S 45 if a return event of a right continue event has been generated. If it is determined in step S 45 that a return event of a right continue event has been generated, a tune which is reproducing is fastforwarded (S 46 ), and the flow advances to step S 47 . On the other hand, if it is determined in step S 45 that a return event of a right continue event has not been generated, the flow also advances to step S 47 .
It is checked in step S 47 if a return event of a left continue event has been generated. If it is determined in step S 47 that a return event of a left continue event has been generated, a tune which is reproducing is rewound (S 48 ), and the flow returns to step S 41 . On the other hand, if it is determined in step S 47 that a return event of a left continue event has not been generated, the flow also returns to step S 41 .
Therefore, according to the embodiment of the present invention, by assigning various functions to events generated by the jog switch 15 , the play list can be switched and tunes can be selected without any complicated operations.
Note that the operations of the notebook type personal computer of this embodiment are not limited to those described above. For example, in the above description, when the jog switch 15 is instantaneously flipped while the player is running (to generate a return event of a right or left event), the play list is switched, or when the jog switch 15 is kept flipped for a predetermined period of time (to generate a return event of a right or left continue event), a tune which is reproducing is fastforwarded or rewound. However, the present invention is not limited to these specific operations.
For example, when the jog switch 15 is instantaneously flipped while the player is running (to generate a return event of a right or left event), a tune which is reproducing is underway may be fastforwarded or rewound, or when the jog switch 15 is kept flipped for a predetermined period of time (to generate a return event of a right or left continue event), the previous or next play list may be selected.
In the above description, reproduce of digital audio data has been exemplified. Also, various functions can be assigned to the jog switch 15 even in the CD/DVD mode.
For example, when the jog switch 15 generates a return event of a right event while a tune recorded on a CD medium is being reproduced, the tune which is reproducing may be switched to the next tune; when the jog switch 15 generates a return event of a left event, the tune which is reproducing may be switched to the previous tune; when the jog switch 15 generates a return event of a right continue event, the tune which is reproducing may be fastforwarded; and when the jog switch 15 generates a return event of a left continue event, the tune which is reproducing may be rewound.
That is, a characteristic feature of the present invention is to execute processes corresponding to various events generated by the jog switch 15 , and various processes may be assigned as those corresponding to various events.
For example, upon switching the play list, a pointer 51 may be displayed on the display unit 47 , and may move in cooperation with the operation of the jog switch, as shown in FIG. 16 . In this case, when the jog switch 15 generates a return event of a right or left event, the pointer 51 is shifted downward or upward; when the jog switch 15 generates a return event of a right or left continue event, the pointer 51 is scrolled downward or upward.
Upon starting up the system, a screen shown in FIG. 17 and the pointer 51 may be displayed on the display unit 47 , and the pointer 51 may be moved in accordance with the operation of the jog switch 15 to select an arbitrary process. In this case as well, when the jog switch 15 generates a return event of a right or left event, the pointer 51 is shifted downward or upward; when the jog switch 15 generates a return event of a right or left continue event, the pointer 51 is scrolled downward or upward.
An informing method of depression of the operation buttons 14 and events from the jog switch 15 will be explained below with reference to FIG. 18 .
When the user has pressed one of the operation buttons 14 or has flipped the jog switch 15 , an operation button/jog switch 61 informs a BIOS 62 of a corresponding event.
The BIOS 62 informs an application program 63 of the event generated upon pressing one of the operation buttons 14 or flipping the jog switch 15 . Upon receiving an event generation message from the BIOS 62 , the application program 63 inquires the type of event of the BIOS 62 .
Upon receiving the event type inquiry from the application program 63 , the BIOS 62 informs the application program 63 of the type of event. Upon receiving an event type message from the BIOS 62 , the application program 63 generates an application command message corresponding to the received event, and executes a predetermined process such as operation of an objective player 64 by the generated application command message.
That is, an event generated by one of the operation buttons 14 or jog switch 15 is recognized by the BIOS 62 , and the application program 63 executes various processes on the basis of the type of recognized event.
Therefore, according to the notebook type personal computer of this embodiment, by operating the jog switch, various processes such as reproduce of CD/DVD data recorded on CD/DVD media, switching of the play list in digital audio data, switching of tunes, and the like can be easily executed.
<Another Embodiment>
A portable information device according to another embodiment will be described.
In the above embodiment, a change of audio data, fastforward, rewind, and change of play lists are performed according to the types of events generated from the jog switch, but it is not limited to this.
Namely, according to present invention, it is possible that various processes are performed in accordance with the types of the events.
In addition, the events generated from the jog switch is not limited to the events described in the above embodiment. For example, it may occur different events depending on hour during the jog switch is flipped.
In the above embodiment, when the jog switch is flipped during the predetermined time, the continuous event is generated. However, it may occur same event periodically.
With this structure that, when the jog switch is flipped during the predetermined time, the same event is generated periodically, for example, it can be applied to turn over a page of word processor, a movement of screen displayed on a browser, etc.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A portable information equipment of this invention has a jog switch for generating different events in correspondence with flip directions and times, and means for executing a process corresponding to a type of event generated by the jog switch. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a divisional of U.S. application Ser. No. 11/604,087, filed Nov. 25, 2006 now U.S. Pat. No. 8,262,548, which claims the benefit under 35 U.S.C §119(e) of U.S. Provisional Application No. 60/739,674, filed Nov. 25, 2005, each of which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
(Not applicable)
REFERENCE TO SEQUENTIAL LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING
APPENDIX SUBMITTED ON A COMPACT DISC
(Not applicable)
BACKGROUND OF THE INVENTION
1) Field of the Invention
This application relates to stationary versions of pneumatic rebound exercise devices.
2) Description of the Related Art
The closest prior art known to me are the following U.S. patents which were deemed pertinent: U.S. Pat. Nos. 4,124,202, 4,632,371, 5,628,496, 5,810,125, 5,887,857, 5,915,674, 5,921,899, 6,267,360, 6,446,943, 6,468,190, and 7,011,608. Also, patents for various types of valves in common use [Note: these patents were chosen as the oldest (cir.1976) from the lists of patents resulting from “Title” searches of the specified valve types on the PTO data base.] are listed as follows, and are intended to be incorporated herein by reference: U.S. Pat. No. 3,966,097 describes a “fluid metering valve”; U.S. Pat. No. 3,985,837 describes a needle valve that is vented for use in a carburetor; U.S. Pat. No. 3,960,361 describes a solenoid valve of that time; U.S. Pat. Nos. 4,083,382, 4,231,544, and 4,195,551 all describe valves with different types of detents; U.S. Pat. No. 4,092,505 describes an early valve “timer arrangement’; and U.S. Pat. No. 4,193,064 describes a “multiple pulse timer”; U.S. Pat. No. 4,112,959 describes one of several hits for patents titled “adjustable check valve”; and both U.S. Pat. Nos. 4,955,507 and 4,753,770 contain a “motorized control (fluid metering) valve” in their abstracts.
BRIEF SUMMARY OF THE INVENTION
The present invention pertains to a system of enhancing aerobic and anaerobic conditioning for fitness and athletic performance using pneumatically elevating rebound machines. This system provides repeatable levels of exercise difficulty for athletes, coaches and trainers that can be used as a gauge of progress in strength development or cardiovascular fitness as well as a motivating factor for the exerciser. The system is particularly well suited to High-Intensity Interval Training (HIIT).
The present inventor's above-mentioned patent (U.S. Pat. No. 5,087,037) describes versions of exercise machines that take advantage of air cylinders used as compression springs to achieve an easily adjustable low-impact vertical rebounding (bouncing) exercise.
The most novel feature described in the referenced patent by this inventor, allows the automatic upward extension, or lengthening of the air spring/cylinders(s) whenever the movable part of the apparatus is drawn far enough upward by the energetic bounding efforts of the exerciser. This motion creates a partial vacuum that draws more air into the spring/cylinders through check valves, effectively lengthening the air springs. It was found early on in the development of that invention that the check valves used needed to have the lowest “cracking pressure” available, which is the pressure at which the valve opens, allowing, in this case, air to be drawn into the cylinders. This ‘pumping-in’ of air is what allows the exerciser to bounce higher, which explains the need for a very low cracking pressure; otherwise, very few people would be able to operate the equipment as designed. When it is desired to descend, a valve is opened that bleeds air from the spring/cylinders. This “descent valve” is either a manual push-button bleeder valve or a common ball valve in all the early prototypes, as well as many of the later versions.
In the years that followed the above-mentioned original patent application process, many improvements were made in the machine design, most of which were focused on reducing friction in the air-spring/cylinders so that the bounding motion could be as free and easy as possible for the user. Much of the resulting reduction of friction was accomplished by reducing the suggested interference, or tightness between the bore of the cylinder and the U-cup piston seal. Although the friction was reduced considerably in this way, we found that there was a fine line between low friction and air leakage past the seal, and we had already seen that any leakage of air from the system was not appreciated by the users, as the air thus leaked had to be replaced by energetic efforts. Most of this early development was done by trial and error, as there were no precedents to be found for push-stroke air cylinders used in this way as low-friction air springs.
The high side-loads on the bearing surfaces required oversize, low friction bearings, even after the next notable improvement: that of joining two of the above-described spring/cylinders by rigidly attaching a footrest platform and handlebar between them. Compared with the earlier, single-cylinder designs shown in the early patent above-referenced, that change also greatly reduced the friction caused by side-loading of the sliding surfaces. This improvement not only increased the life expectancy of the machines by several times, but also made the bounding exercise easier and more enjoyable for the average exerciser, and for longer periods of use.
In our subsequent research into the popularity and usability of three popular competing exercise systems (treadmills, steppers, and stationary bikes), it was noted that all three had mechanisms to vary the degree of exercise exertion. For instance, bikes and steppers (including “ellipticals” and “cross-trainers”) use some form of braking, while treadmills mainly vary their speed and angle of incline. In this way, all three types of devices are able to accommodate a wide range of users' fitness levels. At the time, we did not see a practical method of producing repeatable levels of difficulty on our equipment. Adding friction braking was an obvious possibility, but would reduce the range of motion, the ease of ascending, and thus overall usability and enjoyment factors. Speed, elevation, and acceleration all affect each other on our equipment, and vary with each individual stroke and the temporary output whims of the user, so would also be impractical for measuring difficulty levels.
In the course of subsequent testing and experimenting with a prototype of this lower-friction design, it was noticed by this inventor that a more difficult exercise could be obtained by performing more than one ascent/descent cycle in succession. This is because ascending on the machine is so much more physically demanding than bouncing at the same elevation of the equipment. Since the speed at which ascents are performed also varies with the efforts of the user, any desired degree of difficulty is possible; however, the degree of difficulty so achieved could not be repeated with any precision. Knowing that this ascent phase of the exercise can be timed, different methods of controlling the check valve were, and are being considered. One such method is to vary the “cracking pressure” of the check valve. We have also realized that the flow capacity of the check valve (intake) flow path could be varied, and that a lower intake flow capacity would have a similar effect as a higher cracking pressure would, i.e., a more difficult ascent exercise. Though these advances were promising, the mental search continued for a more usable, easily repeatable exercise comparison system. It was not long after this time that the realization came that, instead of opening the descent valve to come down after each ascent, a bleed valve could be opened to some partial degree for an entire exercise interval of any desired length. This is how the realization came about that we could also control exercise difficulty by intentionally causing air leakage from the system, which is now the preferred method shown in this present invention.
As mentioned above, we had up this point gotten only negative feedback from users regarding any air leaks. This is understandable because any loss of air from the system immediately requires a higher level of exertion in order to pump in as much air through the check valves as is being lost through leakage; otherwise, the device will soon bottom out on the floor. Now I saw how the users could be timed to see how long they could ‘stay up’—keep from bottoming out—at a particular amount of bleed valve opening. It was also evident that repeatable degrees of valve opening would be necessary, not only for the effects of the exercise to be measured and studied, but also as gauging benchmarks for the athletes and coaches using the equipment.
In order to allow a modicum of precision in the repeatability of such experimenting, marks were inscribed on the body of a simple ball valve which was installed as the descent valve on the prototype machine being tested. These marks naturally corresponded with various degrees of opening of the valve when the handle was lined up with them. It was found that a fair degree of precision was obtained by this method, depending on the care taken to precisely line up the edge of the valve's handle with the marks. More sophisticated and exacting methods of metering the release of air have since been installed and tested, and are described below. Additionally, it was soon noticed that varying the ease of air intake also had a direct effect on the exercise difficulty. This could be accomplished either by varying the cracking pressure of the check valves used, or the flow capacity of same.
The main object of the present invention is to provide professional and commercial viability for pneumatically elevating rebound exercise devices. In order to accomplish this objective, it provides:
A wide range of repeatable levels of difficulty for cardiovascular exercise, Several options for achieving different exercise difficulty levels, and A capability for timed interval training for improving cardiovascular fitness, producing Comparative benchmarks of cardiovascular capacity for the athletes and their coaches. Motivation for athletes to improve and exceed previous efforts on the equipment. Encouragement for exercise competition between athletes. Virtually unlimited degrees of exertion, varying from gentle aerobic exercise levels for the casual exerciser, through anaerobic High-Intensity Interval Training (HIIT) levels for competitive athletes, Mitigated impact levels for high intensity plyometric (jumping) exercise, and Increased Range-Of-Motion (ROM) control.
Further objects and advantages may become evident from a consideration of the drawing and ensuing descriptions.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a simplified schematic view of the invention. The FIGURE has the reference numerals as follows:
4 extendable air spring (push-stroke air cylinder) 5 adjustable intake check valve 7 adjustable bleed valve 9 push-type “bleeder” descent valve 11 air compression chamber 12 cylinder barrel 13 cylinder head 15 piston 17 piston rod 19 footrest platform 23 base/stand 25 foot strap
DETAILED DESCRIPTION OF THE INVENTION
The FIGURE shows a schematic view of a basic form of the invention. An extendable air spring 4 is shown connected to a base/stand 23 by way of a piston rod 17 which is connected to piston 15 . The piston sealingly slides inside cylinder barrel 12 , which is sealingly closed off at the top by a cylinder head 13 . An extendable air compression chamber 11 is thus defined and confined inside the cylinder barrel 12 and between the piston 15 and cylinder head 13 . A foot strap 25 is connected to a footrest platform 19 which rigidly connects to the bottom of the cylinder barrel 12 and is shown being acted upon by a leg of an exercising user. The FIGURE also shows three different air valves opening into the air compression chamber 11 : adjustable intake check valve 5 , adjustable bleed valve 7 (a needle-type metering valve in the preferred embodiment), and a normally closed, push-type descent valve 9 .
The basic operation is as follows: In the FIGURE, a leg of an exercising user is shown as providing the motive force that is producing a bouncing motion of the air spring 4 and the user by its downward exertions against footrest platform 19 . The moving parts move as a unit, and include all the parts shown in the drawing except for the interconnected base/stand 23 , piston rod 17 , and piston 15 . It may be seen that the rebound motion is produced by the varying degrees of air pressure in the air compression chamber 11 . Thus, a harder, swifter downward exertion by the user's leg(s) produces a faster, higher bounce. When the user desires to “ascend” by extending the air spring in order to bounce at a higher elevation, he/she must bounce the apparatus high enough to draw more air into the air chamber 11 . This is accomplished by a hard downward leaping exertion at the bottom of a stroke followed at the top of the same stroke by a deep knee bend with a simultaneous lifting motion on the foot strap(s) 25 and/or handhold(s) (not shown). This motion produces a partial vacuum in the air chamber 11 , drawing more air into the air chamber 11 through adjustable intake check valve 5 , resulting in an effectively longer air spring with a higher mean bouncing elevation. Several such actions can be performed in rapid succession by exercisers, quickly producing a more challenging exercise as well as the maximum elevation or “topping out” of the equipment. Descent valve 9 can be pushed at any time to release air from the system, rapidly shortening the air spring and thus reducing the user's elevation, either all the way to the floor to disembark, or to continue the exercise as desired.
Exercisers desiring for greater exercise intensity may elect to employ the following, which is the crux of the preferred embodiment: The adjustable bleed valve 7 is opened to what is usually a predetermined setting, depending on the degree of intensity of exercise desired. The user then is required to repeat the above-described “ascending” exercise, or drawing in of air, repeatedly and with whatever higher degree of exertion may be needed to keep the equipment from “bottoming out” on the floor. Athletes and their coaches can soon determine what degree of air bleed, or opening of the bleed valve 7 is required to produce the desired intensity of timed exercise for a particular athlete, sport or occasion.
The operation of a second embodiment is the same as in the section immediately above, except that the exercise difficulty level is varied, not by controlling the release of air from the system, but by controlling how easily air is admitted into the system by intake check valve 5 . Control of the ease of air intake can be achieved by varying either the intake flow rate, the cracking pressure of the check valve 5 , or both, according to the following formula: The higher the ratio of cracking pressure to intake flow rate, the more difficult the ascent exercise. This could be expressed as D=P/F, where D is the rate of difficulty, or intensity of the exercise, P is the cracking pressure, and F is the flow rate of the valve when open. Once such a setting or a particular valve is selected, the user's ascent, or series of ascents can be timed with the user's objective of ‘topping out’, or taking the equipment up to its upper stops in the shortest possible time. After descending by actuating descent valve 9 , such an exercise interval could be repeated as many times as desired. This alternate embodiment would also work well in combination with the Preferred Embodiment detailed above.
Peer-reviewed research has shown High Intensity Interval Training (HIIT) to be the most effective way to train for both aerobic and anaerobic cardiovascular fitness. The first such study to show this was published in Medicine and Science in Sports and Exercise , published by the American College of Sports Medicine in 1996 (pp. 1327-1330). Many sports and activities require both types of fitness (anaerobic, as well as aerobic fitness), especially the many sports that require intermittent spurts of high-intensity effort. A short list of such sports would include football, basketball, soccer, ice hockey, field hockey, wrestling, boxing, and many sprinting sports both on the field and in the pool. One later mention of what has recently become accepted as the premier training protocol for such sports can be found in the concluding sentence in the Journal of Sports Sciences of March 2004 (p. 290), which states, “Consequently, short interval training may be recommended for physical preparation of field hockey players and participants in other field team sports of a high-intensity, intermittent nature where both aerobic and anaerobic capabilities are important.”(emphasis added)
In order to achieve the above results, the exerciser is taken to, or nearly to exhaustion, usually in intense intervals of less than one minute. This invention allows such exercise protocols to be safely performed and repeated with various degrees of precision, by controlling the ease of drawing air into the system as well as any outflow of air that may be desired or tolerated in order to increase the intensity of the exercise.
Thus the reader can see that this specification describes a practical and effective system that allows for a highly efficient cardiovascular exercise regimen for various exercisers, their coaches, and trainers. A needle-type metering valve has been chosen as the bleed valve means for the preferred embodiment because it provides a relatively inexpensive means to achieve precise repeatability in the amount of air being bled from the system. A fairly high degree of precision is helpful here for the comparisons that are necessary in judging improvement in the athlete's physical fitness, as well as an incentive for healthy competition, either among athletes, or for self-improvement.
There are several ways for enhancing the described invention. We have built and tested a version with a safety-belt, several automated safety controls and a timing display, in addition to an automated air-release system. That air-release system uses a series of three solenoid valves that allow seven precise levels of air release in addition to the default (“easy”) level which leaves all three valves closed. The three solenoid valves are fitted with outlet orifices that are sized to produce a smooth progression of the outlet/bleed combinations. Though this arrangement is usable and safe, it can be further enhanced with electronic controls. One way is to program the display to hold and record the elapsed time on a given difficulty level. This allows a scoring system based on the time elapsed and the difficulty level. Scores can then be stored and utilized on a database. The amounts of air, either added or bled off can also figure into such a score. Also, a limit switch or proximity switch could activate bleeding when the upper range of motion nears the top of the stroke.
Additionally, any plural number of solenoid valves may be used if more (or less) combinations of air release are required. There are also other, possibly more efficient valve means for metering air flow, for instance, a motorized metering valve that may effectively perform the function of several, even many, solenoid valves.
Additionally, a type of valve, or flow control mechanism that has several differently sized orifices in a plate that can be rotationally, linearly, or otherwise manipulated so that the different orifices, or combinations of them could be brought into play for releasing different amounts of air.
Other types of valves that make repeatable valve openings possible to some degree of precision may be used. Also, a plurality of valves, even though they may each have only fully open and fully closed capability, could be opened in combination, manually or otherwise, with the effect of providing a plurality of settings for air release, much like the solenoid valves mentioned above.
In addition to valves with markings on them, valves with detents—with or without markings—can serve the same purpose of achieving repeatable air flow rates.
A form of flow control that has been called Pulse Width Modulation—varying the (air) flow using timed pulses—may also be used for controlling the flow of air either into or out of the system.
In retrospect, all of the above-described ways of controlling the release of air from the system may be used as means of controlling the ease of pumping air into the system by controlling the flow rate. This may be in addition to, or instead of varying the check valve cracking pressure by, for instance, changing the check valve's spring pressure. Also, controlling the flow of air into the air springs may be done without using any check valve at all, by timing a valve's opening near the top of the stroke, or whenever negative pressure is detected in the air spring(s). Nonetheless, the scope of the invention should not be limited to the embodiments described, but by the appended claims and their legal equivalents. | An air management system that allows safe and convenient forms of interval training exercise to be performed on pneumatically elevating rebound exercise equipment. The system includes at least one air intake valve and bleed valve. By providing repeatable degrees of difficulty for both air intake and air release from the extendable air springs employed for the exercise, competitive athletes and their coaches can design, employ, repeat, and compare individualized medium- or high-intensity interval protocols for optimal cardiovascular training programs. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to a method and equipment with which an organic extraction solution is purified from entrainment of aqueous solution and impurities during hydrometallurgical liquid-liquid extraction.
BACKGROUND OF THE INVENTION
[0002] During liquid-liquid extraction, an organic reagent solution is mixed, in an extraction cell (mixer-settler) or in a column, into an aqueous solution, which contains a substance to be purified and concentrated as soluble, metal usually in ion form or as a complex together with several impurities. The valuable metal or substance to be refined reacts selectively with an organic extraction chemical, whereby it is separated from the aqueous solution into the extraction chemical as a pure form. The valuable metal or substance can then be separated from the organic solution back into the aqueous solution (stripping) with the inverted chemical reaction to extraction, from which aqueous solution it can be recovered again as a product e.g. by precipitation or reduction into metal.
[0003] The extraction process is thus mixing liquids physically insoluble in each other into droplets or a dispersion in the mixing section of the extraction equipment, and after chemical mass transfer occurs the droplets in the dispersion are made to coalesce i.e. to recombine back into the original layers of liquid in the settling section or settler. Intensive mixing or a significant change in the surface chemistry conditions of the process may result in very small droplets, which require a lot of time to disengage to its own liquid phase. These droplets do not necessarily have time to disengage in the actual settling section of the extraction step, but move further on in the process with the other phase. The inclusion of the original feed solution (aqueous solution) in the organic solution as it enters later process stages may weaken the purity of the final product and demand extra purification measures. Likewise the organic extractant may end up lost with the treated aqueous solution. In both cases the cost efficiency of the process is lessened.
[0004] In particular, a tank has been used for the removal of aqueous entrainment from a organic solution after the extraction cells, in which the entrained water droplets fall towards the bottom of the tank due to the force of gravity and the purified surface layer can be routed to the next process stage, which tank is then called an after-settler. The tank can also function simultaneously as a surge tank, which is needed to even out changes in the volume of organic solution occurring in various parts of the process. In this case the surface level of the solution in the tank varies.
[0005] The actual purification method of the organic solution, scrubbing, occurs using mixer-settler cells, in which basically the chemically bound impurities are removed by treating the organic solution with suitable aqueous solutions. In this case therefore a dispersion of extraction solution and aqueous solution is formed in order to achieve a large liquid-liquid surface area, as in an extraction cell. Besides chemical scrubbing, water droplets are also removed or the impurities contained in them are diluted. A mixer-settler cell built for scrubbing purposes generally consists of a pump, a mixer and a settling tank with its retaining fences, and is usually the size of an extraction cell. Changes in organic solution volume cannot be balanced with a scrubbing cell, so a separate surge tank as mentioned above is needed, which has the required volume capacity.
OBJECT OF THE INVENTION
[0006] The method according to the present invention treats an organic extraction solution from hydrometallurgical liquid-liquid extraction, which is loaded with a valuable metal or valuable substance from an aqueous solution. The purpose is to carry out the physical separation of water droplets and the chemical removal of impurities from the organic extraction solution simultaneously.
[0007] The organic solution to be purified is scrubbed with an acidic aqueous solution. The aqueous solution may be fed into the organic solution even before the solution is sent to the settling tank and/or it can be fed into the organic solution at the front end of the tank. The organic solution is made to discharge into the feed end in several separate sub-streams evenly across the whole width of the tank. In order to separate the small water droplets from the extraction solution and to wash it from impurities, the direction of the flow proceeding horizontally towards the rear end of the tank is diverted obliquely from time to time to the vertical. Simultaneously the cross-sectional area of the flow is momentarily decreased several times while the direction of the separated solutions is deflected sideways by means of picket fences. The pure organic extraction solution and the aqueous solution are removed from the settling tank from the rear end in several separate sub-streams.
[0008] When the organic solution and the scrubbing solution used for this purification are made to proceed from the feed end of the settling tank towards the rear end and when the solutions are made to proceed in a vertical direction in addition to a horizontal one, the solutions become well mixed. At the same time as the direction of flow is made partially vertical, the cross-sectional area of the flow is momentarily reduced, whereby the small water droplets are made to combine into larger drops and the scrubbing effect of the scrubbing solution is intensified. The solution stream also moves laterally when it moves through overlapping slots in the picket fence.
[0009] The settling equipment according to the invention consists of an essentially rectangular settling tank, which comprises a feed end and a rear end, two sides and a bottom. At least one feed pipe, which is connected at one end to the organic solution feed connection, is arranged into the settling tank feed end. The feed pipe is equipped with several separate discharge elements evenly spaced across the whole width of the tank, after which several picket fences are located when viewed in the direction of flow. The picket fences are arranged so as to be inclined towards the rear end of the tank and each of them is made up of several slotted elements extending from one side of the tank to the other. The width of the slots in each slotted element and their location in relation to each other in the picket fence is arranged to alter in order to change the direction of flow, at times diagonally vertical and/or sideways. The rear end of the tank is equipped with at least one organic solution outlet pipe, of which one end is connected to the corresponding outlet connection. The outlet pipe in turn is equipped with several suction elements to remove the scrubbed organic solution evenly throughout the whole width of the tank. There is a well in the bottom of the rear of the tank to collect the aqueous solution. The tank well is equipped with at least one aqueous solution outlet pipe, which is again equipped with several suction elements to remove the aqueous solution evenly throughout the whole width of the tank.
[0010] With the equipment according to the invention, the functions, which ordinarily have required both a separate after-settler and scrubbing equipment can now be performed in a single unit. One of the beneficial features of the equipment is its function as organic solution volume equalising tank for one extraction process unit. The tank also functions as a safety tank, in which organic solution can be stored in emergency situations, such as when there is a threat of fire or during malfunctions. The method and equipment of the invention are intended for application mainly in extraction processes operating horizontally, as distinct from columns.
[0011] The essential features of the invention will be made apparent in the attached claims.
SUMMARY OF THE INVENTION
[0012] The equipment consists of a rectangular-based settling tank, where organic solution is fed into the feed end and scrubbed solution is discharged from the other end. The height of the tank is such that it both allows for the total volume during process operation and thus a large variation in residence time, as well as acting as a storage tank for all the organic solution in the process. The residence time of the extraction solution in the tank is around 15-30 min.
[0013] The infeed of the solution into the settling tank occurs from at least one feed connection into at least one feed pipe, the “bypass manifold”. The settling tank is preferably located in the arrangement at a lower level than the extraction stages, so that the solution feed takes place advantageously by free flow. Pumping is undesirable at this stage, because it makes the water seepage droplets in the extraction solution decrease in size even more than before. The feed pipe is equipped with several discharge elements so that the volume flow of the solution entering the tank is divided evenly into several sub-streams. This avoids lateral flows and eddies that would disturb the free settling of the droplets. The discharge element may be either a pipe attached to the feed pipe or an opening in the feed pipe. The organic solution is fed below the surface of the liquid directing it diagonally downwards in the feed end to the aqueous layer at the bottom, whereby water coalescence occurs and a water contact surface is formed, to which the small water drops to be removed can join. If required, the bottom of the tank at the feed end can be equipped with a well. At least part of the aqueous solution for scrubbing the organic solution is preferably fed into the organic solution before it is sent to the settling tank.
[0014] In order for the extraction solution and the scrubbing solution to be dispersed in each other, the flow rate of the extraction solution sub-stream is 0.7-1.5 m/s, preferably 0.9-1.2 m/s. The feed pipes are placed upwards from the bottom of the tank so that there is a clearance below them of between 1/20- 1/10 of the depth of the tank. The downward-directed flow circulates first towards the feed end, turning from there towards the rear of the tank.
[0015] The first flow-balancing picket fence is located across the tank after the feed pipe, and consists of vertical slotted elements, which overlap each other. In the first two slotted elements of the first picket fence the slotted zone is only in part of the elements and otherwise they are solid. The third element consists of a full-height slotted zone. The fence evens out the solution streams in the vertical and horizontal directions so that the solution flow starts to advance as evenly as possible, approaching plug flow in form.
[0016] The function of the first picket fence is to even out the solution streams in the vertical and horizontal directions so that the solution flow starts to proceed evenly towards the rear of the tank. In addition, its function is to promote the separation of small water droplets or water seepage from the organic solution. One purpose is also to improve the contact between the extraction solution and the aqueous solution that will scrub it. Therefore this picket fence may also be called a contact fence.
[0017] In addition to the solution flow-equalising contact fence, at least one, preferably 3-5 additional picket fences are placed downstream, which have the function of both calming and directing the stream and also acting as impact surfaces, where the water droplets can combine into bigger droplets as they move through the slots in the fences. The slotted elements in the picket fences are mainly the same type as the third element of the first picket fence, or at least like the first, third and then every subsequent element of the fence. All the fences are inclined downstream, so that they direct the solution streams so that the water at the bottom of the tank rises along the inclined fence to intensify the scrubbing effect. In addition, there is a free area at the rear of the tank, where no fences or other barriers are placed in order to obtain as calm and non-turbulent a flow pattern as possible thus enabling the last droplets to settle before the solution discharging point.
[0018] The picket fences consist of narrow upright slotted elements made of lamella plates placed vertically, which are described in detail later. In one fence 3-6 elements are placed consecutively, so that the slots overlap in the direction of flow and the solution also has to flow laterally to contact as much of the element surface as possible.
[0019] In one embodiment of the present invention the second element of the picket fences following the contact fence differs from the others in that it is solid from the bottom of the tank upwards for a distance of 20-10% of the height of the tank. In this way the solid part of the element in the nearest picket fence to the contact fence is larger than in the fences further away in the direction of flow. The slots in the slotted zone of the second element are also 30-10% wider than the other element slots in the same picket fence so that the widest slots are in the picket fence elements following the contact fence.
[0020] The sloping of the picket fences together with the damming effect of the second fence element also in turn improves the contact between the extraction and scrubbing solution. The scrubbing solution has to rise along the lower section of the second element to the slotted zone, in which the flow occurring through the slots further disperses the scrubbing solution into the extraction solution. Thus part of the water seepage entrained in the organic solution is made to impact continuously with the scrubbing solution and separate into it. The chemical effect of the extraction solution continues at the same time.
[0021] In one embodiment of the invention a baffle element placed perpendicularly upwards is arranged between the picket fences, where the height of the element from the bottom upwards is 25-6% of the total height of the tank. The baffle element is higher the nearer it is to the contact fence. Depending on the location of the baffle element it may be solid at the lower section and have a slotted zone in the top section or the baffle element may be slotted throughout its height. The combined effect of the contact fence and the baffle element is that the whole stream of organic solution is forced to flow through the narrow slots of the contact fence or the baffle element at some stage, which intensifies the scrubbing effect of the solution.
[0022] In one embodiment of the invention the damming section of the second element of the picket fence is formed so that it is always larger than the damming effect of the baffle element before the picket fence concerned. The function of the baffle element, like that of the second element of the picket fence, is to dam up the aqueous solution (scrubbing solution) flowing into the bottom of the LO-cell, so that the organic and aqueous solutions come into contact each other. This enables the mechanical cleaning of the organic solution from residual water drops and also chemical cleaning as a result of the acid contained in the scrubbing solution.
[0023] In one embodiment of the invention mesh elements are placed in the passage formed between the picket fence elements. The mesh element preferably extends from one side of the LO tank to the other, like the picket fences. It is preferable to construct the mesh element from several modules, which are replaceable. The mesh size of the mesh element is preferably in the region of 5-10 mm. The mesh element further intensifies the formation of large water droplets, which settle to the bottom of the LO tank.
[0024] The settling equipment has a well at the solution discharge end, in which a water layer separated from the organic solution and moving against its lower edge accumulates. The aqueous solution is partially sent back to the front end of the tank, where it is fed again as droplets into the incoming solution. The aqueous solution or scrubbing solution is fed into the passages between the contact fence elements, preferably into the passage between the first and second elements. A second fraction of the water can be fed if necessary even before this into the scrubbing solution pipeline through suitable nozzles or freely from above the surface. Thirdly, the impurity-rich aqueous solution is removed from the process for instance by routing it to the extraction feed solution (aqueous solution), so that the valuable metal or substance can be recovered.
[0025] The removal of small water droplets is therefore based in this method on several factors. Before the settling tank the water stream to be fed into the pipeline is dispersed into the organic solution in droplets, of a considerably larger size than the droplets to be removed. These drops together form a surface area onto which some of the small droplets can coalesce. When the stream has proceeded to the feed end of the settling tank, by directing the organic solution the aqueous layer at the bottom is made to disperse into drops again, which travel with the flow, settling towards the bottom while trapping other water droplets. The water drops moving in the solution to be purified also collide with the picket fences and any mesh elements that may be between the elements, forming a continuous film of water on the surface: a hydrophilic surface, which provides the water droplets with a convenient adhesive base.
[0026] Extraction processes are used in conditions where the extraction chemicals work as selectively as possible, so that the desired valuable metal or substance can be recovered in a sufficiently pure form. Mostly, however, various impure substances bind themselves chemically to the extractant in addition to the desired substance in such great quantities that scrubbing methods have to be used to prevent the impurities from proceeding up to the end product. In this way scrubbing solutions based on the ion exchange effect, e.g. pH value, or those containing a purifying substance can be used, in order to displace impurities from the extraction chemicals.
[0027] In the equipment according to the invention, the above-mentioned chemical washing can be performed in combination with the physical removal of small water droplets. Aqueous solution containing valuable metals or substances to be cleaned e.g. from elsewhere in the process, is added to the water for water droplet collection, so that the valuable metal or substance is transferred in the ion exchange occurring during treatment to replace the impurities. Alternatively, the extractant complex containing impurities becomes unstable in the pH of the wash water, releasing the impurities into the scrubbing solution. The method can thus also be used to take care of the liquid balance of the process and to get the valuable metals or substances from the process waters back into circulation. The amount of aqueous solution circulating in the settling tank is quite small in relation to the amount of extraction solution, so the tank cannot be compared with the settler section in extraction. The amount of aqueous solution is around ⅙- 1/10 of the amount of organic solution when the scrubbing solution is fed into the tank, and even less if the purpose is to separate out only the water droplets in the organic solution. This equipment does not include a mixing section typical of extraction steps either.
[0028] The scrubbed extraction solution is removed from the equipment by suction with a pump through at least one outlet pipe, which is the same type as the feed pipe. The solution is thus sucked up evenly across the whole width of the tank via the suction elements connected to the outlet pipe in several separate sub-streams, which ensures that the flow remains non-turbulent at the rear of the tank. The suction element may be a pipe connected to the outlet pipe or an opening in the outlet pipe. Suction elements are preferably slanted upwards towards the rear of the tank, so that the suction direction slants downwards from the surface of the solution, but nevertheless below the surface. In the same way, the aqueous solution (scrubbing solution) that has separated to the bottom of the tank is removed via at least one outlet pipe and the water suction elements connected to it in several separate sub-streams. The suction element may be a pipe connected to the water outlet pipe or an opening in the outlet pipe. The water suction elements are preferably slanted towards the bottom i.e. the water suction streams occur diagonally from the bottom upwards.
[0029] The chemical purification of organic solution used in liquid-liquid extraction processes in a buffer tank to equalize the solution circuit is not restricted to a metal extraction process of certain kind. The method and equipment described above are, however, highly suitable for example when the valuable substance to be recovered is copper. The same kind of acidic wash is also suitable in most cases for the purification of extraction solution loaded with metal. In sulphate-based processes the oxidising acid used is sulphuric acid as one scrubbing solution component and the other component is generally the metal being extracted in the extraction process. When the final recovery of the metal in question occurs with the electrowinning principle, the electrolyte from electrolysis can be used to make the extraction process scrubbing solution. When for instance the metal to be extracted is copper, the electrolyte contains 30-60 g/l Cu and 150-200 g/l sulphuric acid. Electrolyte is added to pure water so that the H 2 SO 4 content of the scrubbing solution to be fed into the settler is in the region of 20-50 g/l.
[0030] The settling equipment according to the present invention i.e. an extraction solution scrubber tank with fittings, which for the sake of simplicity is referred to hereafter by the abbreviation LO tank (Organic solution Scrubber Tank), is preferably utilised in an extraction process where the solution streams are large. The extractants used in the recovery of copper extract very little other metals besides copper, so that an extraction solution is obtained that is almost pure enough with regard to copper. The meticulous removal of residual water drops combined with a certain chemical scrub often raises the purity of the extractants used sufficiently for the subsequent process, i.e. electrolysis, nor is a separate scrubbing stage always necessary.
[0031] If however, the extraction solution contains a larger amount of harmful substances, it should be treated further in a separate mixer-settler-type scrubbing step. In copper extraction these harmful substances are iron, molybdenum and manganese. When the amount of impurities is such that in an ordinary configuration one scrubbing step is not enough, it is now advantageous to use settling apparatus according to this invention in addition to a single scrubbing stage in order to achieve sufficient purity in the extraction solution. In this way the use of several scrubbing stages can be avoided. In some situations sufficient scrubbing can only be achieved with a large quantity of scrubbing solution, which consumes water and increases the circulation of metal via scrubbing. For instance many large copper extraction facilities are located in dry deserts where purified water is itself a significant cost factor. In addition, costs arise from copper circulation when the rinse water used is either routed back to the extraction stage or to the leaching preceding it. In these kinds of situation the use of an LO tank improves the economy of the process.
DESCRIPTION OF DRAWINGS
[0032] The equipment of the invention is further described by means of the attached drawings, in which
[0033] FIG. 1 shows one arrangement of an extraction facility according to the invention seen from above,
[0034] FIG. 2 shows a LO tank of the invention as a longitudinal cross-section,
[0035] FIG. 3 is a LO tank according to FIG. 2 seen from above, and
[0036] FIG. 4 shows another embodiment of the LO tank as a longitudinal cross-section.
DETAILED DESCRIPTION OF INVENTION
[0037] FIG. 1 shows how the LO tank 1 i.e. the settling and scrubbing tank of the organic solution, is connected to the rest of the extraction process. The extraction process in the drawing consists of extraction steps E 1 , E 2 and E 3 , a LO tank, one scrubbing stage W and a stripping stage S. Each extraction, scrubbing and stripping stage includes either one or more mixers 2 and a settler 3 and the necessary pumps and piping. As the drawing shows, there is no mixer section in the LO tank, instead, the organic solution containing a valuable substance is brought there and fed into the tank using a number of feed units 4 and outlet units 5 that is sufficient for the amount of feed. As stated above, the actual scrubbing stage can be omitted if the amount of impurities in the organic solution is small.
[0038] FIG. 2 shows an embodiment of the LO tank 1 of the invention in more detail. The feed end 6 and rear end 7 , bottom 8 and upper edge 9 of the tank are shown. In the bottom of the tank 1 , there is an additional well 10 at the rear end for the separated aqueous layer. The depth of the well at the rear is around ⅙-⅓ of the depth of the rest of the tank. The organic solution solution is fed into one or more feed pipes 11 situated in the feed end of the tank via feed unit(s) 4 , the number of which depends on the amount of organic solution. In the drawing there are two feed pipes. Each feed pipe is equipped with several discharge elements, which in this case are discharge pipes 12 . The discharge pipes are preferably directed diagonally downwards. The tank is equipped with at least two picket fences, of which the first, the contact fence 13 , differs somewhat in structure from the other picket fences 14 . All the picket fences are preferably inclined towards the rear of the tank. The preferred angle of inclination is about 45-70° to the horizontal.
[0039] The scrubbed organic solution in the rear 7 of the tank is recovered via one or more organic solution outlet pipes 15 , which are in turn connected to corresponding outlet units. The scrubbed organic solution is sucked evenly across the entire cross-section into the outlet pipes by means of suction pipes 16 . The outlet pipes and their suction pipes are arranged the same way as the feed pipes and discharge pipes i.e. a certain amount of the solution to be removed is sucked out via each outlet pipe. The outlet pipes are located at the same point as the well 10 at the bottom of the tank, but inside the organic solution. The suction pipes 16 are preferably directed diagonally upwards towards the rear end 7 . In the description of the invention the terms discharge pipes and suction pipes are used, but in principle these could also be openings in the feed and outlet pipes.
[0040] In one application of the invention, a protective structure 17 seen in the drawing is arranged on top of the outlet pipes, which consists of an essentially horizontal plate 18 on top of the outlet pipes and a vertical plate 19 attached to its front edge. The vertical plate is located in front of the first outlet pipe in the direction of flow and extends to about halfway down the pipe. The vertical plate may be perpendicular to the horizontal plate 18 as in the drawing or the joint may be profiled as a curve. The horizontally-positioned plate extends a little nearer to the rear end than the rearmost outlet pipe. The protective structure arranged on top of the outlet pipes ensures that only scrubbed organic solution flowing in the upper section that has circulated near the rear of the LO tank is sucked out of the tank and into the following stage.
[0041] The aqueous solution that has accumulated in the well 10 is also removed via one or more aqueous outlet pipes 23 and corresponding aqueous outlet units and routed to one or more points in the process, as explained above.
[0042] The number of LO tank feed and outlet connections is determined according to the amount of solution fed into the tank. FIG. 3 shows the LO tank as seen from above, where sides 21 and 22 are also seen. The extraction solution is fed into the feed end of the tank, in this case via two units 4 in the side 21 and removed via two outlet units 5 in the rear end. Each feed unit 4 is in turn connected to a feed pipe or “bypass manifold” 11 in order to distribute the incoming organic solution stream evenly over the entire width of the tank. If there are several feed pipes, the discharge pipes of each feed pipe feeds the organic solution into its own sub-section. The number of sub-sections is the same as the number of feed pipes. When the LO tank is wide, an even feed across the whole width of the tank without major pressure variations is ensured by the use of several feed pipes and discharge pipes situated in their own sub-sections. According to FIG. 3 the first feed pipe extends only about halfway across the width of the LO tank and its discharge pipes feed the solution for about half the width of the tank. The second feed pipe extends as far as the opposite side 22 of the tank, but the organic solution discharge pipes 12 are located only on the side of the tank where the first feed pipe does not reach.
[0043] The feed pipe or pipes are preferably placed so that they do not exactly touch the feed end 6 of the LO tank, but come a little short of it. The discharge pipes 12 are correspondingly preferably directed obliquely downwards towards the feed end. As a result, a solution circulation flow forms around the feed pipe. The length of the discharge pipe is preferably at least twice the diameter of the pipe, so that the discharge jets can be angled diagonally downwards towards the aqueous layer forming on the bottom.
[0044] Correspondingly, the scrubbed organic solution in the rear end of the tank 7 is sucked evenly across the whole cross-section via one or two outlet pipes 15 , which are equipped with suction pipes 16 . For reasons of clarity the protective structure 17 has been omitted in the drawing. The outlet pipes and their suction pipes are arranged in the same way as the feed pipes and discharge pipes i.e. as many parts of the solution to be removed are sucked up via each outlet pipe as is required by the number of outlet pipes.
[0045] The aqueous solution that has accumulated in the well 10 is removed in exactly the same way via one or more aqueous outlet pipes 23 , which are also equipped with their own suction pipes 24 . The aqueous suction pipes are preferably directed obliquely downwards. The suction pipes may also be directed to the rear section of the tank. The aqueous outlet pipes and their suction pipes are also arranged in the same way as the feed pipes and discharge pipes i.e. a certain amount of the solution to be removed is sucked up via each outlet pipe. It is advantageous to remove more solution via the aqueous suction line than the amount that is separated from or fed to the extraction solution, since in this way the purity of the organic solution is ensured as regards aqueous entrainment. Thus some organic solution from the bottom of the organic layer is also sucked up along with the aqueous solution. The amount of organic solution sucked up with the aqueous solution is at the most about half the amount of aqueous solution sucked up. Some of the aqueous solution, which consists mainly of scrubbing solution used for scrubbing the organic solution, is preferably to recirculate into the organic solution fed into the tank even before the latter is fed into the tank. Some of the scrubbing solution can be fed directly into the tank at the contact fence. It is however also appropriate to remove a part of the accumulated aqueous solution completely from the circuit from time to time, because it contains impurities that have dissolved out of the organic solution, such as iron.
[0046] If the number of feed or outlet pipes is increased, the discharge and suction pipes are distributed as described above. If there are three pipes, one third of the solution is fed from each pipe etc.
[0047] As shown in FIGS. 2 and 3 also, the LO tank is equipped with several picket fences 13 , 14 , which are set diagonally towards the rear of the tank. The purpose of these structures is to improve both the separation of the water seepage from the organic solution into larger droplets and to improve the contact between the extraction solution and the scrubbing solution. Each picket fence consists of several elements in the same direction.
[0048] The first picket fence 13 is located quite close to the organic solution feed pipes 11 . It consists of at least three elements, extending from one side of the LO tank to the other. FIG. 2 shows that the first element 25 of the contact fence is situated so as to extend as far as the bottom 8 of the LO tank and that its upper edge reaches a height which is preferably 50-70% of the height of the whole tank. About one third of the upper section of the first element is provided with a slotted zone otherwise the element is solid. Vertical slots are arranged in the slotted zone, with a preferred width of around 2-3 mm and a distance from each other that is 30-60 times the width of the slot. Only a small amount of the organic solution flows through the slots, as the rest flows above the element into the passage formed by the latter and the following element. The second element 26 is situated at a depth so that the distance between its lower edge and the bottom of the tank is 15-20% of the height of the tank and the distance of the upper edge from the upper edge of the tank is around 12-17% of the height of the tank. About one third of the lower section of the second element is preferably provided with the same kind of vertical slotted zone as the upper section of the first element, otherwise the element is solid. The narrow slots of the elements promote the formation of larger droplets from the water seepage. The third element 27 of the contact fence is situated so as to extend to the bottom and its upper edge to about the same height as the second element. The third element has vertical slots along the whole height of the element, but their width is 40-60 mm and the distance from each other is about twice that of the slot width. The distance of the passages left between the elements is basically the same.
[0049] When scrubbing solution is fed directly into the LO tank, it is done preferably by disseminating the droplets of scrubbing solution into the organic solution at the point of the contact fence. The contact of the solutions is further improved by guiding the scrubbing solution into the passage 28 between the first and second elements.
[0050] It is further preferable to place 2-5 other picket fences 14 in the LO tank, to promote the growth of small droplets of aqueous solution and the scrubbing of impurities from the organic solution. The subsequent picket fences of the contact fence are largely similar to each other i.e. they consist of several elements in the same direction and extending from one side of the tank to the other. The height of the elements is about the same as that of the third element 27 of the contact fence, in other words they extend from the bottom of the tank upwards and the distance of their upper edge from the upper edge of the tank is around 12-17% of the height of the tank. The elements are provided with the same type of slots as the third element of the contact fence, but the element slots are situated in relation to each other so that they overlap, so that the distance the solution flows between the elements is as long as possible. The number of elements in each picket fence is 3-6.
[0051] FIG. 4 presents an embodiment of the invention where at least one baffle element 29 placed perpendicularly upwards is arranged between the picket fences, with a height from the bottom 8 of 25-6% of the total height of the tank. Baffle elements are always placed between the picket fences and the height is bigger, the nearer they are to the contact fence. Thus the highest element is between the contact fence and the following picket fence and the second highest in the following gap. Depending on its location the baffle element may be solid in the lower section and have a slotted zone in the top or it may have a slotted zone throughout its height. The width of the slots in the slotted zone and the distance from each other is about the same as in the first and second elements of the contact fence. The width of the slots is thus 2-3 mm and the distance between them 30-60 times the width of the slot. At maximum the solid section is in the baffle element nearest the contact fence and it is around 40-60%. The proportion of solid section decreases in the direction of flow of the tank and the slotted zone of the final baffle element extends along the whole height of the element.
[0052] The invention is not restricted to the above-mentioned embodiments and it is possible to make adaptations and combinations of the above according to the patent claims within the scope and spirit of the invention. | The invention relates to a method and equipment with which an organic solution extraction solution is purified from entrainment of aqueous solution and impurities during hydrometallurgical liquid-liquid extraction. The method treats an organic extraction solution, which is loaded with a valuable metal or valuable substance from the aqueous solution. The purpose is to carry out the physical separation of water droplets and the chemical removal of impurities from the organic extraction solution simultaneously. | 2 |
FIELD OF THE INVENTION
The invention relates to novel monovinyltin trihalides from 1,3-diketones, tin (II) halides and halogen acids and to a process for the preparation of the novel monovinyltin trihalides.
BACKGROUND OF THE INVENTION
Organic tin compounds have been established for many years as a regular constituent of formulations in the pesticide and antifouling agent sectors, as stabilizers for thermoplastics, especially vinyl chloride polymers or copolymers, as catalysts for the manufacture of polyurethanes or silicone resins, and for the production of doped or undoped SnO 2 coatings on glass or ceramic surfaces.
The overwhelming number of published processes produce compounds which do not contain vinyl groups bonded to tin and which are thus excluded from further possible reactions of interest.
Processes for the preparation of organotin compounds with vinyl groups directly bonded to tin are known for example from W. P. Neumann, Die organische Chemie des Zinns (The Organic Chemistry of Tin), Ferdinand Enke Verlag, Stuttgart, 1967; P. G. Harrison, Chemistry of Tin, Blackie, Glasgow and London, 1989; M. Pereyre, J. P. Quintard and A. Rahm, Tin in Organic Synthesis, Butterworth, London, 1987; R. C. Poller, The Chemistry of Organotin Compounds, Logos Press Limited, 1970; W. P. Neumann, Synthesis, 1987, 665; T. N. Mitchell, Synthesis, 1992, 803; and I. Omae, Organotin Chemistry, Elsevier, Amsterdam, 1989.
The following synthesis variants are described in said publications:
alkylation of SnCl 4 or organotin compounds with vinyl-Grignard or vinyllithium compounds;
hydrostannation of substituted acetylene derivatives;
additions of triorganotin-metal compounds (e.g. R 3 SnSnR 3 , R 3 SnSiR 3 , Bu 3 SnAlEt 2 , (Bu 3 Sn) 2 Zn);
α, β-elimination of appropriately substituted alkyl radicals bonded to tin.
A common feature of all these variants is that they are very expensive and are therefore unsuitable or of only limited suitability for industrial scale production.
DE-OS 27 48 370 and J. Organomet. Chem., 165 (1979) 187-198, have disclosed a process for the preparation of vinyltin trihalides wherein acetylenecarboxylic acid esters are reacted with tin (II) halides and hydrogen halides in the presence of polar organic solvents, for reaction times of 10-40 hours, to give vinyltin compounds containing carboxylic acid ester groups.
BRIEF SUMMARY OF THE INVENTION
It has now been found that vinyltin compounds of the general formula (I): ##STR1## in which R and R 2 , which are identical or different, can be optionally substituted alkyl groups having 1-5 C atoms, cycloalkyl groups having 5-10 C atoms, aryl groups having 6-12 C atoms and alkylaryl groups and/or arylalkyl groups having 7-12 C atoms, R 1 is H, R or R 2 and X, X 1 and X 2 , which are identical or different, can be chlorine, bromine and iodine, are obtained in adequate purity under practical conditions, in short reaction times and without expensive working-up times, by reacting compounds of the general formula II: ##STR2## in which R, R 1 and R 2 are as defined above, R and R 2 preferably being a methyl radical or phenyl radical and R 1 preferably being hydrogen, with anhydrous tin(II) chloride, bromide or iodide, optionally in the presence of an inert solvent such as ethers or aliphatic hydrocarbons, at -10° to 100° C., preferably 20°-50° C., and with halogen acids of the general formula III:
X--R.sup.3 (III)
in which X can be Cl, Br or I and R 3 can be H or the radical --COR 4 , where R 4 can be --R 5 --CH 3 , --R 5 --CO--X, in which R 5 ═--(CH 2 ) n --, where n=0-10, preferably 0-5, or R 3 can be an optionally substituted cycloaliphatic, araliphatic or aromatic radical.
DETAILED DESCRIPTION OF THE INVENTION
The reaction times are between 0.5 and 5 h at the preferred reaction temperature of 20°-50° C., but are normally below 3 h in the range 1.5-2.5 h.
Suitable solvents which can optionally be used are aliphatic, cycloaliphatic or cyclic ether such as, in particular, diethyl ether, tetrahydrofuran or dioxane, and optionally halogenated hydrocarbons such as pentane, hexane, heptane, octane, decane or their isomers, methylene chloride, chloroform, carbon tetrachloride, dichloroethylene or perchloroethylene. It is preferable to use the relatively low boiling, toxicologically harmless, pure hydrocarbons having 6-10 C atoms and dialkyl ethers having 4-8 C atoms.
The tin(II) halides used according to the invention are commercially available products with purities of >95%.
The inorganic and/or organic halogen acids used according to the invention include hydrogen chloride, hydrogen bromide, hydrogen iodide and the acid halides of the organic homologous series of monocarboxylic and polycarboxylic acids, such as, in particular, acetyl chloride, propionyl chloride, butyryl chloride, valeroyl chloride, octyl chloride, malonyl chloride or succinyl chloride.
Cycloaliphatic and aromatic acid halides, derived from benzoic acid, phthalic acid, isophthalic acid, terephthalic acid, phenylenediaceticacid and their hexahydro variants, can also be used.
The acid chlorides of the short chain monocarboxylic acids, such as, in particular, acetyl chloride, n-propionyl chloride, n-butyryl chloride or benzoyl chloride, are preferred according to the invention.
The reaction can be carried out within a wide temperature range from -10° to 100° C., optionally at normal pressure at the reflux point of the solvent or optionally in a pressure reactor at the autogeneous system pressure.
To avoid secondary reactions and for reasons of process technology, such as reaction times and process control in particular, preferred reaction temperatures are 10°-80°, especially 20°-50° C., at normal pressure.
In the procedure preferred according to the invention, a tin(II) halide, preferably tin(II) chloride, a 1,3-diketone of the general formula II and optionally a solvent are placed in a reactor at room temperature, under an inert gas and with the exclusion of moisture, and the halogen acid or the acid halides preferred according to the invention are metered into the vigorously mixed reaction mixture.
During this process the reaction temperature can be controlled by the metering rate and/or by auxiliary external cooling or by evaporative cooling at the reflux point of the solvent.
After the halogen acid has been added, a postreaction time of 2-3 hours at the given reaction temperature, with continuous thorough mixing (e.g. stirring), is normally sufficient to complete the reaction.
The tin(II) halide, the compound of the formula II and the halogen acid of the formula III are preferably used in equimolar proportions according to the equation
SnX.sub.2 +R--C(O)--CH(R.sup.1)--C(O)--R.sup.2 +X--R.sup.3 →X.sub.3 Sn--C(R)═C(R.sup.1)--C(O)--R.sup.2 +HOR.sup.3
in which the substituents are defined as indicated. Although it is possible to use the individual components in excess, this is not preferred according to the invention because it could necessitate additional purification steps for the end product.
If solvents are used, their amount is proportioned so as to ensure perfect process control (thorough mixing, dissipation of the heat of reaction). However, because the reaction product should precipitate from the reaction mixture as quantitatively as possible, the amount of solvent has to be adapted to the solubility product.
When working under reflux conditions, all or part of the solvent can therefore already be distilled off, optionally below normal pressure and optionally with the aid of a carrier gas passed through the reaction mixture, it also being possible to remove the compound HOR 3 formed according to the equation, provided said compound distills under the given conditions.
If the reaction product is obtained immediately as a solid precipitate, it can be separated from by-products like HOR 3 by conventional methods (e.g. filtration) and solvents which are still present can be removed by drying. As a rule the purity of the resulting product is adequate for further use. Very high purities are achieved by rinsing again one or more times with a small amount of solvent.
If the end product is obtained as a viscous or partially crystalline mixture--when the reaction is carried out without a solvent or after the solvent has already been removed from the reaction mixture at an earlier stage--crystallization can be accelerated by the addition of small amounts of ethers or hydrocarbons, by-products like HOR 3 then being removable at the same time.
An aftertreatment with absorbents like activated charcoal is generally no longer necessary.
The compounds of the general formula I according to the invention are valuable intermediates for the manufacture of novel pesticides and antifouling paints, in which they can be incorporated into the possibly polymeric structure, as comonomers with a catalytic action or as catalysts in the manufacture of polyurethane foams or silicone compositions.
The process for the preparation of the compounds of the general formula (I) according to the invention will be illustrated in greater detail by means of the following examples.
EXAMPLES
Example 1
94.8 g (0.5 mol) of tin(II) chloride and 50 g (0.5 mol) of acetylacetone in 200 ml of diethyl ether were placed in a reactor at room temperature. 39.3 g (0.5 mol) of acetyl chloride were metered in over 15 min, the temperature rising to 36° C. After a postreaction time of 2 h at room temperature, the white crystals which had precipitated out were filtered off and washed twice with 50 ml of diethyl ether. After drying under vacuum, 88 g (57% of theory) of 1-methylbut-1-en-3-onyltin trichloride (Cl 3 Sn--C(CH 3 )═CH--CO--CH 3 ) melting at 129°-130° C. were isolated.
A further 45 g (29% of theory) could be precipitated from the mother liquor by the addition of 200 ml of n-pentane.
1 H NMR (CDCl 3 ): δ=2.51 (s, 3H, Sn--C(CH 3 )═C, 3 J Sn =144 Hz), 2.63 (s,3H, CO--CH 3 ), 7.24-7.29 (m, 1H, H vinyl , 3 J Sn =420 Hz)
13 C NMR (CDCl 3 ): δ=22.3 (═C--CH 3 ) , 28.6 (CO--H 3 ), 133.9 (C═CH), 168.4 (═C--CH 3 ), 201.1 (C═O)
Example 2
94.8 g (0.5 mol) of tin(II) chloride and 50 g (0.5 mol) of acetylacetone in 200 ml of n-pentane were placed in a reactor at room temperature. 61 g (0.5 mol) of acetyl bromide were metered in over 15 min. After a postreaction time of 2 h at room temperature the crystals which had precipitated out were separated off, washed with diethyl ether and dried under vacuum.
141 g (80% of theory) of 1-methylbut-1-en-3-onyltin bromide dichloride (BrCl 2 Sn--C(CH 3 )═CH--CO--CH 3 ) melting at 119° C. were isolated. The yield was increased to >95% by concentration of the mother liquor and repeat crystallization.
Example 3
94.8 g (0.5 mol) of tin(II) chloride and 50 g (0.5 mol) of acetylacetone were placed in a reactor at room temperature. 39.3 g (0.5 mol) of acetyl chloride were metered in over 45 min, the temperature rising to 45° C. The highly viscous, partially crystalline reaction mixture was stirred for 2 h, 50 ml of n-pentane were added and the solid formed was separated off. After washing with 100 ml of n-pentane and drying, 140 g (92% of theory) of 1-methylbut-1-en-3-onyltin trichloride were isolated.
Example 4
94.8 g (0.5 mol) of tin(II) chloride and 81.1 g (0.5 mol) of benzoylacetone in 200 ml of diethyl ether were placed in a reactor at room temperature. 39.3 g (0.5 mol) of acetyl chloride were metered in over 15 min, a rise in temperature to 36° C. being recorded. After a postreaction time of 2 h at room temperature, the light yellow crystalline precipitate which had formed was separated off, washed twice with 50 ml of diethyl ether and dried under vacuum.
110 g (60% of theory) of 1-methylprop-1-en-3-onyl-3-phenyltin trichloride (Cl 3 Sn--C(CH 3 )═CH--CO--Ph) melting at 206°-208° C. were isolated, the yield being increased to >90% by concentration of the mother liquor.
Cl content: found 28.3%; theoretical 28.7%
1 H NMR (acetone--d 6 ): δ=2.55 (s,3H, Sn--C(CH 3 )═C, 3 J Sn =148 Hz), 7.68-8.47 (m,5H arom , 1H vinyl )
13 C NMR (acetone--d 6 ): δ=22.2 (═C--CH 3 ), 125.3, 130.7 131.8, 133.7 (C arom ), 137.9 (C═C--H), 185.1 (═C--CH 3 ), 191.7 (C═O)
Example 5
94.8 g (0.5 mol) of tin(II) chloride in 200 ml of diethyl ether were placed in a reactor and 81.1 g (0.5 mol) of benzoylacetone were added. 61 g (0.5 mol) of acetyl bromide were metered in over 15 min, the reaction temperature rising to 38° C. After a postreaction time of 2 h at room temperature, the light yellow crystalline precipitate was filtered off, washed with a small amount (2×20 ml) of diethyl ether and dried under vacuum.
104 g (50% of theory) of 1-methylprop-1-en-3-onyl-3-phenyltin bromide dichloride (BrCl 2 Sn--C(CH 3 )═CH--CO--Ph) melting at 199°-201° C. were isolated, the yield being increased to >90% by working-up of the mother liquor. Sn content: found 28.3%; theoretical 28.6%.
Example 6
94.8 g (0.5 mol) of tin(II) chloride in 200 ml of diethyl ether were placed in a reactor and 50 g (0.5 mol) of acetylacetone were added. 70 g (0.5 mol) of benzoyl chloride were metered in over 15 min, the temperature rising to 30° C. After a postreaction time of 3 h at the reflux temperature, the white crystalline precipitate was separated off and dried under vacuum.
113 g (73% of theory) of 1-methylbut-1-en-3-onyltin trichloride melting at 128°-129° C. were isolated.
Example 7
The procedure was analogous to Example 6 except that the benzoyl chloride was replaced with 45.3 g (0.5 mol) of acryloyl chloride. The yield was 80% of theory.
Example 8
The procedure was analogous to Example 6 except that the benzoyl chloride was replaced with 38.7 g (0.26 mol) of cyclohexanecarboxylic acid chloride. The yield of directly precipitated product was 41 g (50% of theory), which was increased to >95% of theory by further concentration of the filtrate.
Example 9
The procedure was analogous to Example 6 except that the 0.5 mol of benzoyl chloride was replaced with 0.25 mol of phthaloyl dichloride. The yield was ca. 90% by the product was contaminated with phthalic acid.
Example 10
The procedure was analogous to Example 6. 50 g (0.26 mol) of tin(II) chloride and 25.6 g (0.26 mol) of acetylacetone was reacted with 44 g (0.26 mol) of cinnamoyl chloride in 150 ml of diethyl ether to give a quantitative yield of 81.4 g of 1-methylbut-1-en-3-onyltin trichloride.
Example 11
39.8 g (0.21 mol) of tin(II) chloride and 21.0 g (0.21 mol) of acetylacetone in 200 ml of diethyl ether were placed in a reactor. 38.8 g (0.21 mol) of benzoyl bromide were metered in over 15 min at room temperature, with stirring, a rise in temperature to the reflux point being recorded. After a postreaction time of 1 h at the reflux temperature, the mixture was cooled and the crystalline precipitate was separated off. 48 g (65% of theory) of 1-methylbut-1-en-3-onyltin bromide dichloride (BrCl 2 Sn--C(CH 3 )═CH--CO--CH 3 ) were isolated.
1 H NMR (CDCl 3 : δ=2.51 (s, 3H, Sn--C(CH 3 )═C, 3 J Sn =140 Hz, 2.63 (s, 3H, CO--CH 3 ), 7.16-7.25 (m, 1H, H vinyl )
13 C NMR (CDCl 3 ): δ=22.3 (═C--CH 3 , 2 J Sn =97 Hz), 28.7 (CO--CH 3 ), 133.7 (C═CH, 2 J Sn =89 Hz), 168.8 (═C--CH 3 , 1 J Sn =1006 Hz), 200.8 (C=0, 3 J Sn =83 Hz)
Example 12
The procedure was analogous to Example 6. 22.4 g (0.08 mol) of tin(II) bromide and 8.0 g (0.08 mol) of acetylacetone were reacted with 9.8 g (0.08 mol) of acetyl bromide in 200 ml of diethyl ether and the reaction solution was concentrated to give 34.0 g (96% of theory) of 1-methylbut-1-en-3-onyltin tribromide (Br 3 Sn--C(CH 3 )═CH--CO--CH 3 ) melting at 110°-112° C.
1 H NMR (CDCl 3 ): δ=2.47 (s, 3H, Sn--C(CH 3 )═C, 3 J Sn =140 hz), 2.63 (s, 3H, CO--CH 3 ), 7.09-7.11 (m, 1H, H vinyl , 3 J Sn =391; 407 hz)
13 C NMR (CDCl 3 ): δ=22.3 (═C--CH 3 , 2 J Sn = 96 hz), 28.9 (CO--CH 3 ), 133.7 (C═CH, 2 J Sn =77 Hz), 168.2 (═C--CH 3 ), 200.7 (C═O)
Example 13
The procedure was analogous to Example 6. 26.6 g (0.096 mol) of tin(II) bromide and 9.6 g (0.096 mol) of acetylacetone were reacted with 7.6 g (0.096 mol) of acetyl chloride in 200 ml of diethyl ether and the reaction solution was concentrated to give 36.4 g (96% of theory) of 1-methylbut-1-en-3-onyltin dibromide chloride (Br 2 ClSn--C(CH 3 )═CH--CO--CH 3 ) melting at 112°-115° C.
1 H NMR (CDCl 3 ): δ=2.48 (s, 3H, Sn--C(CH 3 )═C, 3 J Sn =140 hz), 2.63 (s, 3H, CO--CH 3 ), 7.08-7.22 (m, 1, H vinyl )
13 C NMR (CDCl 3 ): δ=22.4 (═C--CH 3 , 2 J Sn =96 Hz), 28.9 (CO--CH 3 ), 133.3 (C═CH, 2 J Sn= 78 Hz), 168.8 (═C--CH 3 ), 200.8 (C═O) | Disclosed are monovinyltin trihalides of he general formula (I):
(x)(x.sup.1)(x.sup.2)Sn--C(R)═C(R.sup.1)--C(O)--R.sup.2(I)
and a process for their preparation from 1,3-diketones, tin(II) halides and halogen acids. | 2 |
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a vehicular lamp.
2. Background Art
Depending on the driving situation, a vehicular lamp (headlamp) is expected to have two light distribution patterns: a pattern in which diffused light is distributed in front of the vehicle and partially condensed light is weakened; and a pattern in which less diffused light is distributed to the front of the vehicle and localized condensed light is strengthened, such that a clear boundary appears between an irradiated portion and a non-irradiated portion. Especially in times of rain or the like, a distribution pattern with lowered illumination intensity toward a vehicle front side is effective. The difference between the two light distribution patterns lies in the intensity of the condensed light and the vertical-direction expansion of the light distribution patterns.
Many vehicular lamps that use a semiconductor light-emitting element as a light source have been developed in recent years. An LED chip used as a light source normally has a light-emitting surface with a generally oblong shape. The LED chip is disposed so as to coincide with a focus line of a reflective surface formed from a curved surface or the like whose light-emitting surface has one side end with a parabolic and cylindrical shape (see Patent Document 1 for an example).
[Patent Document 1] Japanese Patent Application Publication No. JP-A-2003-31011.
In order to realize the two light distribution patterns described above, the conventional vehicular lamps include a unit that combined a plurality of headlamps.
SUMMARY OF INVENTION
One or more embodiments of the present invention provide a vehicular lamp capable of changing an intensity of condensed light and a vertical-direction expansion of a light distribution pattern.
One or more embodiments of the present invention relate to a vehicular lamp provided with a light source, a reflector that radiates light from the light source forward of the lamp, and driving means that moves relative positions of the light source and the reflector, wherein the light source is provided with a light-emitting surface whose outer peripheral shape is generally oblong, the reflector is provided with a parabolic surface that has a focus line in the horizontal direction, and the driving means is structured such that rotation is possible within a horizontal plane of the light-emitting surface from a first position where a short side of the light-emitting surface is generally parallel to the focus line up to a second position where a long side of the light-emitting surface is generally parallel to the focus line. According to such a configuration, rotating the generally oblong light source enables an increase in a component of light advancing directly forward, and suppression of a component of light advancing forward and downward. Thus, it is possible to change an intensity of condensed light and a vertical-direction expansion of a light distribution pattern.
Furthermore, one or more embodiments of the present invention relate to a vehicular lamp provided with a light source, and a reflector that radiates light from the light source forward of the lamp, wherein the reflector is provided with a parabolic surface that has a focus line in the horizontal direction, and the light source is structured such that a unitary light source, which is provided with a light-emitting surface whose outer peripheral shape is generally oblong, is disposed at a first position where a short side of the light-emitting surface is generally parallel to the focus line and at a second position where a long side of the light-emitting surface is generally parallel to the focus line, so as to have one of a general L-shape and a general T-shape as a light source shape. According to such a configuration, light is selectively emitted from either a portion of the light source disposed in a general L-shape or a general T-shape at the first position or the second position. Therefore, a component of light advancing directly forward can be increased, and a component of light advancing forward and downward can be suppressed. Thus, it is possible to change an intensity of condensed light and a vertical-direction expansion of a light distribution pattern.
According to one or more embodiments of the present invention, a component of light advancing directly forward can be increased, and a component of light advancing forward and downward can be suppressed. Thus, it is possible to change an intensity of condensed light and a vertical-direction expansion of a light distribution pattern.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram of a configuration of a vehicular lamp according to an embodiment of the present invention.
FIG. 2 is a view showing in detail a configuration of a semiconductor light-emitting element of a vehicular lamp according to an embodiment of the present invention.
FIG. 3 shows schematic diagrams for describing how the semiconductor light-emitting element is rotated by a driving portion of the vehicular lamp according to an embodiment of the present invention (in a first position).
FIG. 4 shows schematic diagrams for describing how the semiconductor light-emitting element is rotated by a driving portion of the vehicular lamp according to an embodiment of the present invention (in a second position).
FIG. 5 is a schematic diagram for describing a change in a light path due to the rotation of the semiconductor light-emitting element portion.
FIG. 6 is a schematic diagram showing a light distribution pattern at the first position, where a short side of a light-emitting surface is generally parallel to a focus line, of the vehicular lamp according to an embodiment of the present invention.
FIG. 7 is a schematic diagram showing a light distribution pattern at the second position, where a long side of the light-emitting surface is generally parallel to the focus line, of the vehicular lamp according to an embodiment of the present invention.
FIG. 8 is a schematic diagram showing a light distribution pattern, when the semiconductor light-emitting element is at a 40° rotation angle, of a vehicular lamp according to an embodiment of the present invention.
FIG. 9 is a schematic diagram showing a light distribution pattern, when the semiconductor light-emitting element is at a 60° rotation angle, of a vehicular lamp according to an embodiment of the present invention.
FIG. 10 is a schematic diagram showing a light distribution pattern, when the semiconductor light-emitting element is at an 80° rotation angle, of a vehicular lamp according to an embodiment of the present invention.
FIG. 11 shows schematic diagrams illustrating a configuration of a vehicular lamp when the light-emitting surface of the semiconductor light-emitting element is L-shaped.
FIG. 12 shows schematic diagrams illustrating a configuration of a vehicular lamp when the light-emitting surface of the semiconductor light-emitting element is T-shaped.
DETAILED DESCRIPTION
FIG. 1 is a schematic diagram of a configuration of a vehicular lamp according to an embodiment of the present invention. A vehicular lamp unit 100 is provided with a semiconductor light-emitting element portion 10 that constitutes a light source, a driving portion 20 that rotates the semiconductor light-emitting element portion 10 within a horizontal plane, a support bracket 30 that fixes the driving portion 20 and also functions as a light-controlling member, and a reflector 40 that is disposed on a downward side of the support bracket 30 .
The reflector 40 has a reflective surface 40 a , which is formed from a curved surface with a parabolic and cylindrical shape and has a focus line FL that extends in the horizontal direction. Both sides of the reflective surface 40 a are formed with a pair of side walls 40 b . In such case, the focus line FL is set so as to extend in a direction orthogonal to a unit center axis Ax 1 of the lamp unit 100 . The unit center axis Ax 1 is an axis of a parabola that constitutes a vertical cross section of the parabolic and cylindrical surface. The pair of side walls 40 b has a symmetrical shape with respect to the unit center axis Ax 1 , and the side walls 40 b are formed as vertical walls that broaden in the forward direction.
FIG. 2 is a view showing in detail a configuration of a semiconductor light-emitting element of a vehicular lamp according to an embodiment of the present invention. The semiconductor light-emitting element portion 10 is formed so as to constitute a light-emitting surface, where a plurality of white light-emitting diodes 10 b having light-emitting chips such as LEDs are disposed on a substrate 10 a . In the semiconductor light-emitting element portion 10 , an end 10 d of the light-emitting surface 10 c is held by a tip of a rotation axis 20 a of the driving portion 20 such that the light-emitting surface 10 c faces vertically downward. The semiconductor light-emitting element portion 10 is thus rotatable in a 90° range from a position where a short side D of the generally oblong light-emitting surface 10 c coincides with the focus line FL to a position where a long side W coincides with the focus line of the reflective curved surface. Further details regarding the rotation range of the light-emitting surface 10 c will be given later.
The driving portion 20 is constituted by a drive part such as a motor, and is fixed on the support bracket 30 . The rotation axis 20 a is inserted into a hole portion formed in the support bracket 30 . As mentioned above, the tip of the rotation axis 20 a is held by an end 10 d of the semiconductor light-emitting element portion 10 . Therefore, it is possible to transmit the rotation force of the driving portion 20 and rotate the semiconductor light-emitting element portion 10 within a horizontal plane.
FIGS. 3 and 4 are schematic diagrams showing how the semiconductor light-emitting element is rotated by the driving portion of the vehicular lamp according to an embodiment of the present invention. Note that for the sake of convenience, the driving portion 20 is omitted from the figures. Normally, the semiconductor light-emitting element portion 10 is positioned, as shown by an overhead view in FIG. 3( a ), such that the short side D thereof coincides with the focus line FL and the long side W is disposed along the unit center axis Ax 1 . The light-emitting surface extends, as shown by a vertical cross-sectional view in FIG. 3( b ), from the vicinity of an intersection point between the unit center axis Ax 1 and the focus line FL toward the rear of the lamp. Hereinafter, such an arrangement of the semiconductor light-emitting element portion 10 as described above will be referred to as a “first position”.
Meanwhile, if the semiconductor light-emitting element portion 10 is rotated approximately 90° in the counter-clockwise direction due to rotation of the driving portion 20 , as shown by an overhead view in FIG. 4( a ), the long side W of the semiconductor light-emitting element portion 10 coincides with the focus line FL, and moves from the vicinity of the intersection point between the unit center axis Ax 1 and the focus line FL to a position disposed along the focus line. The light-emitting surface, as shown by a vertical cross-sectional view in FIG. 4( b ), extends in the vicinity of the focus line FL along the focus line, with little expansion in the direction of the unit center axis Ax 1 . Hereinafter, such an arrangement of the semiconductor light-emitting element portion 10 as described above will be referred to as a “second position”. Expressed as a rotation angle from a reference position that uses the first position as the reference, the second position is a 90° position.
FIG. 5 is a schematic diagram for describing a change in a light path due to the rotation of the semiconductor light-emitting element portion. As FIG. 5 shows, when lighting at the first position, there is a light path advancing immediately forward and downward of the lamp, in addition to light directly advancing in the forward direction of the lamp parallel to the unit center axis Ax 1 . Accordingly, it is possible to irradiate a relatively broad range.
FIG. 6 is a schematic diagram showing a light distribution pattern at the first position (at a 0° rotation angle), where the short side of the light-emitting surface is generally parallel to the focus line, of the vehicular lamp according to an embodiment of the present invention. As FIG. 6 shows, diffused light is radiated in front of the vehicle, and the intensity of condensed light is weak.
Meanwhile, when lighting at the second position after rotating the semiconductor light-emitting element portion 10 , the light-emitting surface is concentrated in the vicinity of the focus line FL. Therefore, light directly advancing in the forward direction of the lamp parallel to the unit center axis Ax 1 is condensed. Accordingly, it is possible to irradiate a relatively narrow range in a concentrated manner.
FIG. 7 is a schematic diagram showing a light distribution pattern at the second position (at a 90° rotation angle), where the long side of the light-emitting surface is generally parallel to the focus line, of the vehicular lamp according to an embodiment of the present invention. As FIG. 7 shows, diffused light at the front of the vehicle is reduced, and condensed light forward of the vehicle is strengthened.
Note that the rotation angle achieved by the driving portion 20 is not particularly limited to 0° and 90°, and it is possible to stop at an arbitrary angle from 0° to 90°. For example, FIGS. 8 to 10 are schematic diagrams showing light distribution patterns, when the semiconductor light-emitting element is at a 40°, 60°, and 80° rotation angle, of a vehicular lamp according to embodiments of the present invention. As the figures show, it is clear that the light distribution pattern gradually changes from 0° to 90°.
During rotation, there is no sudden change in the irradiation state that the eyes of a driver of the vehicle would be incapable of following. Therefore, there is no risk of an unsafe state generated by rotation of the semiconductor light-emitting element portion during driving. As a consequence, it is possible to allow the driver to select a light distribution pattern at an arbitrary angle depending on outside weather conditions, driving circumstances or the like, by operating the driving portion while driving. In addition, the rotation angle may be automatically set after determining various conditions such as a level of brightness outside the vehicle.
Note that in the above embodiments, an example using a motor as the driving portion 20 was described. However, the present invention is not particularly limited to this case, and any means may be used provided that the means is an actuator or the like enabling rotation of the semiconductor light-emitting element portion 10 .
FIGS. 11 are schematic diagrams showing a configuration of the vehicular lamp when the light-emitting surface of the semiconductor light-emitting element is L-shaped. Provided that LED chips or the like are suitably arranged so as to form an L-shaped light-emitting surface as shown in the figures, it is possible to selectively realize light emission at the first position ( FIG. 11( a )) and light emission at the second position ( FIG. 11( b )) without providing the driving portion 20 . Thus, an effect similar to the above embodiments can be obtained. However, because the driving portion is unnecessary in such an embodiment, a space-saving type of vehicular lamp can be achieved.
FIGS. 12 are schematic diagrams showing a configuration of the vehicular lamp when the light-emitting surface of the semiconductor light-emitting element is T-shaped. Provided that LED chips or the like are suitably arranged so as to form a T-shaped light-emitting surface as shown in the figures, it is possible to selectively realize light emission at the first position ( FIG. 12( a )) and light emission at the second position ( FIG. 12( b )) without providing the driving portion 20 . Thus, an effect similar to the above embodiments can be obtained. However, because the driving portion is unnecessary in such an embodiment, a space-saving type of vehicular lamp can be achieved.
According to the above embodiments, it is possible to arbitrarily change the light distribution pattern of one lamp without disposing a plurality of lamps with different light distribution patterns. By changing the intensity of the condensed light and the vertical-direction expansion of the light distribution pattern, it is possible to lower illumination intensity toward a vehicle front side especially in times of rain or the like, and thus reduce glare.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
Description of the Reference Numerals
10 SEMICONDUCTOR LIGHT-EMITTING ELEMENT PORTION
10 a SUBSTRATE
10 b WHITE LIGHT-EMITTING DIODE
10 c LIGHT-EMITTING SURFACE
20 DRIVING PORTION
20 a ROTATION AXIS
30 SUPPORT BRACKET
40 REFLECTOR
40 a REFLECTIVE SURFACE
40 b SIDE WALL
100 LAMP UNIT
Ax 1 UNIT CENTER AXIS
FL FOCUS LINE | A lamp unit includes a semiconductor light-emitting element portion, a reflector that radiates light from a light source forward of the lamp, and a driving portion that moves relative positions of the semiconductor light-emitting element portion and the reflector. The semiconductor light-emitting element portion is provided with a light-emitting surface whose outer peripheral shape is generally oblong, the reflector is provided with a parabolic surface that has a focus line in the horizontal direction, and the driving portion is configured such that rotation is possible within a horizontal plane of the light-emitting surface from a first position where a short side of the light-emitting surface is generally parallel to the focus line up to a second position where a long side of the light-emitting surface is generally parallel to the focus line. | 5 |
[0001] The present application is a continuation of application Ser. No. 10/067,859, filed Feb. 8, 2002, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a thin film magnetic head used for recording/reproducing of a magnetic disk drive or the like, in particular a perpendicular magnetic recording head, and a magnetic disk drive using these heads.
[0003] At present, in a magnetic disk drive used as an external storage for information in information equipment such as a computer or the like, mainly a head which has a read element and a write element is used: a head designed to perform recording by an inductive thin film head, and reproducing by a magnetoresistive effect type head. As a recording system for forming a recording pattern on a medium based on a magnetic flux extending outside a write gap from a recording head, there are two representative types, i.e., an in-plane (longitudinal) recording system and a perpendicular recording system. To achieve a higher recording density, as a future magnetic recording system to replace the conventional in-plane (longitudinal) recording system, a perpendicular magnetic recording system is promising.
[0004] In the case of the in-plane (longitudinal) recording system, the magnetic flux extending outside the write gap of the recording head causes a magnetic layer on the medium to be magnetized in a direction equal to/reverse to the advancing direction (trailing direction) of the medium, thus forming a recording pattern on the medium. On the other hand, in the case of the recent perpendicular magnetic recording system devised for the magnetic disk drive or the like, as disclosed in a gazette of Japanese Patent Laid-Open Hei 4 (1992)-57205, a recording head is composed of main and auxiliary poles, a recording medium is mainly a double-layer recording medium, and composed of a recording layer (perpendicular magnetization layer) formed in a side near the recording head, and a soft magnetic underlayer. The main pole, the soft magnetic underlayer and the auxiliary pole of the recording head are magnetically coupled together to form a closed magnetic flux loop. According to this system, if a distance between the main pole of the recording head and the soft magnetic underlayer of the medium is sufficiently smaller than a space between the main and auxiliary poles, a magnetic flux leaked from the main pole magnetizes the recording layer in a film thickness direction, i.e., perpendicularly to a medium surface, passes through the soft magnetic underlayer, and returns to the auxiliary pole. Thus, a recording pattern on the medium is formed in the film thickness direction of the medium, which is the origin of the naming of the perpendicular magnetic recording.
[0005] Note that, in the perpendicular magnetic recording system, as in the case of the in-plane (longitudinal) magnetic recording system, as a reproducing head, a magnetoresistive effect element, in particular a GMR head using a huge magnetoresistive effect, a TMR head using a tunnel magnetoresistive effect or the like is used.
[0006] FIG. 1 schematically shows a structure of a perpendicular magnetic recording head of the conventional type, which has a read element and a write element. In FIG. 1 , the recording head for perpendicular magnetic recording has a structure of being laminated on a reproducing head using a magnetoresistive effect element. The thin film head for perpendicular magnetic recording in FIG. 1 is composed of main and auxiliary poles 1 and 2 , a conductor coil 3 , and an insulating film 4 for insulating the conductor coil 3 , and the main and auxiliary poles 1 and 2 . In the head for perpendicular magnetic recording, for the purpose of setting the width of a recording track where signals are recorded by the main pole to be narrow, and a density of a magnetic flux leaked from the main pole to be high, the main pole may be trimmed by FIB or the like after the formation of the main pole by electroplating or the like. Consequently, after the formation of the reproducing head on a substrate, the auxiliary pole, and the main pole are often formed in this order. A big difference between the recording head for perpendicular magnetic recording and the recording head for in-plane magnetic recording is that the head for in-plane recording has a very narrow space (e.g., 0.2 μm) between the main and auxiliary poles when seen from the surface facing to the recording medium, while the head for perpendicular magnetic recording has a larger space (5 to 10 μm).
[0007] In FIG. 1 , the reproducing head includes a magnetoresistive effect film 5 having electrical resistance changed depending on an applied magnetic field, a magnetoresistive effect element composed of a magnetic domain control film 6 and an electrode 7 , an upper shield layer 2 and a lower shield layer 8 for cutting off unnecessary magnetic fields, and a not-shown insulating film for insulating the magnetoresistive effect element and the shields from each other. In the head which has the read element and the write element, shown in FIG. 1 , the auxiliary pole 2 of the recording head also serves as an upper shield for the reproducing head. If the auxiliary pole of the recording head and the upper shield of the reproducing head are separately provided, a magnetic separation layer is present between these layers made of magnetic materials.
[0008] In the magnetic disk drive, there is a magnetic medium rotating on its axis, and there is a slider includes the foregoing head having the read and write elements mounted. This slider records/reproduces a signal while floating with a constant space kept to the medium surface. In this case, a track for recording/reproducing a signal has a concentric circular structure. Positioning must be controlled to accurately record/reproduce a signal (magnetization pattern) in a track on the medium. Currently, positioning control using a sector servo system is mainly used. In the sector servo system, a circumferential track is divided into a plurality of sectors, a servo area is provided at the head of each sector, after this area, a data area is provided for recording a signal. When recording/reproducing is performed, the magnetic head is positioned on the track by using a servo pattern provided in the sector region. In addition, in the current magnetic disk drive, the root of a suspension having a slider mounted on its tip is fixed, and the suspension has a structure of being moved around its fixed point. Thus, when a signal on a track located near the internal circumference of external circumference of the medium is recorded/reproduced, the slider has a yaw angle with respect to the track.
[0009] Compared with the head for in-plane recording, the conventional thin film single pole head for perpendicular magnetic recording has a larger space of 5 to 10 μm between the main and auxiliary poles when seen from a surface facing to the medium, and the reproducing head, the auxiliary pole, and the main pole are formed in this order on the substrate. Thus, a space between the main pole and the reproducing head is 10 μm or more. In the sector servo system, the servo pattern recorded in the servo area is detected by the reproducing head, and positioned on the track. After this operation, a signal is recorded in the data area on the track. When a space between the main pole and the reproducing head becomes wider as described above, it takes time for the recording head to reach the data area after the detection of the servo pattern in the servo area. In other words, a length of an area present between the servo area and the data area, which cannot be used for signal recording, is increased. Consequently, in the perpendicular recording system using the conventional thin film single pole head for perpendicular magnetic recording, compared with the in-plane (longitudinal) recording system, the occupation ratio of the data area per track, i.e., a formatted volume, is reduced.
[0010] When a signal is recorded on the track, the slider must be moved in such a way as to move the recording head onto the track after the detection of the servo pattern by the reproducing head located on the track. As a yaw angle is set in a track near the internal circumference or external circumference of the medium, the moving distance of the slider is increased, making it difficult to perform positioning control (servo). When a space is widened between the main pole and the reproducing head, the moving distance of the slider is increased more, making it difficult to design a servo system. Thus, in the perpendicular recording system using the conventional thin film single pole head for perpendicular magnetic recording, servo is more difficult compared with the in-plane (longitudinal) recording system.
[0011] In addition, in the perpendicular recording system using the conventional thin film single pole head for perpendicular magnetic recording, the auxiliary pole is formed so as to be on the same recording track of the main pole. Accordingly, as represented by erasure after recording, the recording pattern on the medium is easily affected by a magnetic flux supplied from the main pole, passed through the soft magnetic underlayer of the medium, and returned to the auxiliary pole. Further, since the main pole is laminated after the formation of the auxiliary pole, the number of process steps is increased, extending time for forming the recording head.
[0012] Note that, IEEE Trans, Magn., vol. MAG-23, No. 5, pp. 2070-2072 (1987) describes a bulkhead including a plurality of auxiliary poles disposed around a main pole. However, the head described therein is one for both recording and reproducing, and has no elements dedicated for reproducing, such as an MR element. Thus, nothing is suggested regarding a problem caused by the large space between the reproducing element and the main pole, which the invention tries to solve, or a specific method of reducing the space between the reproducing element and the main pole.
SUMMARY OF THE INVENTION
[0013] The present invention was made with the foregoing problems in mind, and objects of the invention are to provide a thin film single pole head for perpendicular magnetic recording, which has a larger formatted volume than that of the conventional thin film single pole head for perpendicular magnetic recording, and easier servo, and a magnetic disk drive using the same. Other objects of the invention are to provide a thin film pole head for perpendicular magnetic recording, which is capable of making it difficult for a return flux to disturb a recording pattern on a medium like that represented by erasure after recording, and a magnetic disk drive using the same. Further, other objects of the invention are to provide a thin film single pole head for perpendicular magnetic recording, which has a structure capable of shortening process time, and a magnetic disk drive using the same.
[0014] In order to achieve the foregoing objects, the present invention provides a thin film single pole head for perpendicular magnetic recording which has a read element and a write element, which comprises a reproducing head and a recording head, and has a structure where no auxiliary poles are disposed between the reproducing element of the reproducing head and the main pole of the recording head when seen from a surface facing to recording media.
[0015] With regard to the disposition example of a main pole and an auxiliary pole when seen from the surface facing to the medium to achieve the objects of the invention, various dispositions like those shown in FIGS. 2 to 6 can be employed. In FIGS. 2 to 6 , the thin film single pole head for perpendicular magnetic recording is formed above the reproducing head, which is composed of a pair of shield layers 10 and 12 formed on a substrate 13 , and a reproducing element 11 formed between 10 and 12 .
[0016] First, as shown in FIG. 2 , one auxiliary pole 9 magnetically connected to a main pole 1 may be disposed in a direction orthogonal to a trailing direction 14 with respect to the main pole 1 . Secondly, as shown in FIG. 3 , the number of auxiliary poles magnetically connected to the main pole 1 may be two, and the two auxiliary poles 9 and 17 sandwiching the main pole 1 may be disposed in the direction orthogonal to the trailing direction 14 . Also, as shown in FIG. 4 , the number of auxiliary poles magnetically connected to the main pole 1 may be three. In this case, the first auxiliary pole 9 and the second auxiliary pole 17 may be disposed in such a manner that their surfaces near the reproducing head are on the same straight line 15 roughly orthogonal to the trailing direction 14 . The third auxiliary pole 18 may be disposed in such a manner that a straight line 19 connecting the center of the third auxiliary pole 18 with the center of the main pole 1 is in a direction roughly parallel to the trailing direction 14 . An area of the third auxiliary pole 18 may be larger than that of each of the first and second auxiliary poles 9 and 17 .
[0017] In FIGS. 2 to 4 , the main and auxiliary poles are disposed when seen from the surface facing to the medium such that the surfaces of the main pole and the auxiliary pole near the reproducing head are on the same straight line 15 . However, other disposing methods are possible. For example, when seen from the surface facing to the medium as shown in FIG. 5 , a straight line 20 connecting the center of the main pole with the center of the auxiliary pole can be set in a direction roughly orthogonal to the trailing direction 14 . In addition, when there are two or more auxiliary poles, as shown in FIG. 6 , the surfaces of the auxiliary poles near the reproducing head can be set on the same straight line 15 in a direction orthogonal to the trailing direction 14 , and the surface of the main pole 1 near the reproducing head can be disposed not to be on the same straight line 15 . In the case of the disposition of FIG. 6 , a distance from the reproducing element 11 to the upper surface of the main pole 1 is smaller than that from the reproducing element 11 to each of the auxiliary poles 9 and 17 . It should be noted that the dispositions of the main and auxiliary poles, and the number of auxiliary poles are not limited to the foregoing.
[0018] When the main and auxiliary poles are disposed as shown in FIGS. 2 to 6 , preferably, a straight line connecting the center of the reproducing element 11 constituting the reproducing head with the center of the main pole 1 should be set to 5 μm or lower, more preferably 3 μm or lower, when it is projected in the trailing direction 14 . By narrowing a space between the main pole and the reproducing head as much as possible in the above manner, it is possible to increase the formatted volume of a recording track, and facilitate servo.
[0019] The dispositions of the main and auxiliary poles shown in FIGS. 2 to 6 represents one where no auxiliary poles are present between the reproducing element and the main pole of the recording head when seen from the surface facing to recording media. When the main and auxiliary poles are disposed in such a manner, the auxiliary poles can be disposed to be present on a track different from the recording track, on which a recording pattern is formed by the main pole. In other words, a space d between the main and an auxiliary pole can be set larger than a recording track width on the medium. Preferably, the space d between the main and auxiliary poles should be set in the range between 0.5 μm and 1 μm so as to be larger than the recording track width. However, the space d can be set shorter or longer than the above. Thus, when the space d between the main and auxiliary poles is set larger than the recording track width, as shown in FIG. 7 , a magnetic flux 21 leaked from the main pole 1 magnetizes the recording layer 23 of the medium 22 in a film thickness direction, i.e., perpendicularly to the medium surface, passes through a soft magnetic underlayer 24 , and returns to the auxiliary pole 9 formed on a recording track 26 different from a recording track 25 under the main pole. Thus, the possibility of recording pattern disturbance caused by the return magnetic flux like that represented by erasure after recording is reduced. Moreover, by increasing the number of auxiliary poles to two or more, a density of a magnetic flux returning to the auxiliary poles can be reduced more compared with the case of one auxiliary pole. Thus, it is possible to further prevent the disturbance phenomena of the recording pattern like that represented by erasure after recording.
[0020] As shown in FIGS. 2 to 4 , when seen from the surface facing to the medium, if the respective poles are disposed such that the surfaces of the main pole 1 and the auxiliary pole 9 ( 17 ) near the reproducing head are on the same straight line 15 , the main and auxiliary poles can be formed on the same film which flattens the roughness of underlayers and shields the magnetic interaction between a read element and a write element. For the film which flattens the roughness of underlayers and shields the magnetic interaction between a read element and a write element, a film made of Al 2 O 3 , a film made of SiO 2 , or a mixed film containing Al 2 O 3 and SiO 2 can be used. A thickness of the film which flattens the roughness of underlayers and shields the magnetic interaction between a read element and a write element in the trailing direction only needs to be about 0.5 μm to 1 μm. Thus, by forming the main and auxiliary poles on the same film which flattens the roughness of underlayers and shields the magnetic interaction between a read element and a write element, the number of process steps of manufacturing the recording head can be reduced, making it possible to shorten process time as a result.
[0021] In the case of disposing the main and auxiliary poles as shown in FIG. 4 , when seen from the surface facing to recording media, if the third auxiliary pole 18 is formed above the first and second auxiliary poles 9 , 17 and the main pole 1 , and an area of the third auxiliary pole 18 is set larger than that of the first or second auxiliary poles 9 or 17 , the third auxiliary pole 18 can also function as a shield for preventing an antenna effect with respect to the recording head. The antenna effect is a problem intrinsic to perpendicular recording. That is, the antenna effect is a phenomenon, where while the recording head is not engaged in a recording operation, a magnetic flux from a magnetic field generation source inside/outside a hard disk case enters the main and auxiliary poles, and consequently disturbs the recording pattern on the medium. The antenna effect can be considered as a kind of erasure after recording. As shown in FIG. 4 , by disposing the auxiliary pole occupying a large area around the main pole to serve also as a shield, it is possible to prevent the foregoing antenna effect.
[0022] In the case of disposing the main and auxiliary poles as shown in FIG. 2 , a coil which creates a magnetic flux used for recording by the main pole can be formed like that shown in FIG. 8 . Specifically, a magnetic film pillar 27 connected to the main pole 1 is formed so as to be parallel to the surface facing to recording media, and a coil which creates a magnetic flux 3 is formed so as to surround the same. Since the coil which creates the magnetic flux 3 can be disposed in a position near the tip of the surface of the main pole 1 facing to the medium, this shape enables recording magnetic field intensity to be enhanced. Even in the case of disposing the main and auxiliary poles different from that shown in FIG. 2 , a coil which creates a magnetic flux can be formed so as to surround the magnetic film pillar magnetically connected to the main pole, and formed to be parallel to the surface facing to recording media. Also, the coil disposition other than that shown in FIG. 8 is possible.
[0023] In the case of the perpendicular recording head constructed like that shown in FIG. 2 , as a reproducing head, it is possible to use a magnetoresistive effect element having electrical resistance changed corresponding to the change of an applied magnetic field. In this case, preferably, a huge magnetoresistive effect element using a huge magnetoresistive effect or a tunnel magnetoresistive effect element using a tunnel magnetoresistive effect should be used. However, magnetoresistive effect elements other than the above can be used.
[0024] FIG. 11 shows the formation example of a coil which creates a magnetic flux for the main pole when the main and auxiliary poles are disposed as shown in FIG. 5 . This coil disposition is basically similar to that of FIG. 8 . It should be noted, however, that a film which shields the magnetic interaction between a read element and a write element between the main pole 1 and an upper shield 10 has a thickness thicker than that between the auxiliary pole 9 and the upper shield 10 .
[0025] FIG. 12 shows the formation example of a coil which creates a magnetic flux for the main pole when the main and auxiliary poles are disposed as shown in FIG. 6 . The main pole 1 is formed in a position nearer the upper shield 10 than the auxiliary poles 9 and 17 . Magnetic film pillar parallel to the surface facing to recording media were connected to the poles 1 , 9 and 17 . The main pole, and the first and second auxiliary poles were magnetically coupled together by connecting these three pillars in the upper sides. Then, a coil which creates a magnetic flux 3 was formed so as to surround the magnetic film pillar 27 connected to the main pole 1 .
[0026] Summing up the foregoing, the magnetic head of the invention comprises: a reproducing head provided with a pair of magnetic shield layers and a reproducing element formed between these shield layers; and a head for perpendicular magnetic recording, provided with main and auxiliary poles made of thin films of soft magnetic materials, which are disposed to face each other through a magnetic gap in a surface facing to recording media, and connected inside, and a coil magnetically coupled to a magnetic circuit composed of the main and auxiliary poles. In this case, the auxiliary pole is disposed in an area excluding a portion between the reproducing element and the main pole when seen from the surface facing to recording media.
[0027] When seen from the surface facing to recording media, preferably, a straight line connecting a center of the reproducing element with a center of the main pole has a length of 5 μm or lower when it is projected in a trailing direction. When the length exceeds 5 μm, servo becomes difficult.
[0028] The magnetic head according to the first aspect of the invention comprises: one or a plurality of auxiliary poles. In this case, when seen from the surface facing to recording media, a straight line connecting at least one auxiliary pole with a center of the main pole is non-parallel to a trailing direction.
[0029] The magnetic head according to another aspect of the invention, comprises: one or a plurality of auxiliary poles. In this case, the main pole and the auxiliary pole are disposed in a manner that a part or all parts of at least one auxiliary pole face a recording track different from a recording track of the recording medium, to which the main pole faces.
[0030] The magnetic head according to yet another aspect of the invention, comprises: first, second and third auxiliary poles. In this case, when seen from the surface facing to recording media, a straight line connecting a center of the first auxiliary pole with a center of the second auxiliary pole is roughly orthogonal to a trailing direction, a straight line connecting a center of the third auxiliary pole with a center of the main pole is roughly parallel to the trailing direction, and an area of the third auxiliary pole is larger than an area of the first or second auxiliary pole.
[0031] The magnetic disk drive of the invention comprises: a magnetic disk; disk driving means for driving the magnetic disk; a magnetic head provided with a reproducing head and a recording head; and means for positioning the magnetic head with respect to the magnetic disk. In this case, the magnetic disk is one provided with recording and soft magnetic layers, and designed for perpendicular magnetic recording, and the magnetic head is one specified in any one of the foregoing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a schematic view showing a conventional thin film head which has a read element and a write element for perpendicular magnetic recording.
[0033] FIG. 2 is a schematic view showing a disposition example of main and auxiliary poles of a magnetic head according to the present invention.
[0034] FIG. 3 is a schematic view showing a disposition example of the main and auxiliary poles of the magnetic head of the invention.
[0035] FIG. 4 is a schematic view showing a disposition example of the main and auxiliary poles of the magnetic head of the invention.
[0036] FIG. 5 is a schematic view showing a disposition example of the main and auxiliary poles of the magnetic head of the invention.
[0037] FIG. 6 is a schematic view showing a disposition example of the main and auxiliary poles of the magnetic head of the invention.
[0038] FIG. 7 is a view schematically showing a magnetic flux path, through which a magnetic flux leaked from the main pole enters the auxiliary pole after passing through a recording medium.
[0039] FIG. 8 is a view showing an arrangement example of a coil which creates a magnetic flux for the disposition of FIG. 2 .
[0040] FIG. 9 is a view showing an arrangement example of a coil which creates a magnetic flux for the disposition of FIG. 3 .
[0041] FIG. 10 is a view showing an arrangement example of a coil which creates a magnetic flux for the disposition of FIG. 4 .
[0042] FIG. 11 is a view showing an arrangement example of a coil which creates a magnetic flux for the disposition of FIG. 5 .
[0043] FIG. 12 is a view showing an arrangement example of a coil which creates a magnetic flux for the disposition of FIG. 6 .
[0044] FIG. 13 is a schematic view showing a magnetic disk drive according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] Next, the preferred embodiments of the present invention will be described with reference to the accompanying drawings. However, the embodiments are not intended to limit the invention in any way. In the following drawings, same function parts will be denoted by same reference numerals, and described in a manner of preventing overlapped explanation.
[0046] FIG. 13 is a perspective view showing an example of an entire magnetic disk drive according to the invention. This magnetic disk drive comprises a magnetic disk 31 , a motor 30 for rotary-driving the magnetic disk, a magnetic head 32 for recording/reproducing, a suspension 33 for supporting the magnetic head, an actuator 34 , a voice coil motor 35 , a recording/reproducing circuit 36 , a positioning circuit 37 , an interface control circuit 38 , and others. The magnetic disk 31 includes a double-layer recording medium for perpendicular magnetic recording, and a protective film is covered with a lubricant film.
First Embodiment
[0047] FIG. 2 shows a magnetic head according to the first embodiment of the invention when seen from a surface facing to a medium. In FIG. 2 , a flattening film made of Al 2 O 3 was formed to have a film thickness of 1 μm by a sputtering method on the upper shield 10 (film thickness of 2 μm) of a reproducing head formed on a substrate 13 made of AlTiC. A resist film was formed on the flattening film, and a frame for electroplating was formed by photolithography for the purpose of forming a main pole. Then, a main pole made of an alloy mainly containing permalloy or cobalt/nickel/iron was formed by electroplating. The formed main pole 1 had a length of 0.2 μm in a track width direction, and a height of 0.2 μm in a trailing direction when seen from the surface facing to the medium. In this case, the main pole was disposed in such a way as to set a straight line connecting the main pole 1 with the center of a reproducing element 11 to be roughly parallel to a trailing direction 14 . A space between the main pole 1 and the reproducing element 11 was about 3 μm.
[0048] Subsequently, a frame for electroplating was formed by photolithography for the purpose of forming an auxiliary pole 9 in a place away from the main pole 1 by 1 μm on the flattening film made of Al 2 O 3 having the main pole 1 formed thereon, and the auxiliary pole 9 was formed by electroplating. A composition of the auxiliary pole was the same as that of the main pole. When seen from the surface facing to the medium, the auxiliary pole 9 had a length of 2 μm in the track width direction, and a height of 2 μm in the trailing direction. In addition, the structure was made, where the main pole 1 and the auxiliary pole 9 were magnetically coupled together as shown in FIG. 8 .
[0049] A head which has a read element and a write element, which used a GMR element as a reproducing head and used the thin film single pole head for perpendicular magnetic recording formed in the foregoing process as a reproducing head, and the double-layer perpendicular recording medium were combined together to assemble the magnetic disk drive schematically shown in FIG. 13 , and then a formatted volume and tracking performance were examined. As a result, compared with the conventional thin film single pole head for perpendicular magnetic recording shown in FIG. 1 , it was discovered that the formatted volume was increased by 4%, and the tracking performance was good.
Second Embodiment
[0050] As shown in FIG. 3 , in addition to the auxiliary pole 9 formed in the first embodiment, a second auxiliary pole 17 was formed in an opposite side of the auxiliary pole 9 sandwiching the main pole 1 in a manner similar to that for the first auxiliary pole 9 . In this case, a size of the second auxiliary pole 17 and its distance from the main pole 1 were set equal to those of the first auxiliary pole 9 . Regarding the main pole 1 , and the first and second auxiliary poles 9 and 17 , as schematically shown in FIG. 9 , a magnetic film pillar parallel to the surface facing to recording media were respectively connected to the poles 1 , 9 and 17 , and the main pole and the first and second auxiliary poles were magnetically coupled together by connecting the upper sides of the three pillars. Then, a coil which creates a magnetic flux 3 was formed so as to surround the magnetic film pillar 27 connected to the main pole 1 .
[0051] A head which has a read element and a write element, using a GMR head element as a reproducing head and the above thin film single pole head for perpendicular magnetic recording as a recording head, was produced experimentally. This head and the double-layer perpendicular recording medium were combined to assemble a magnetic disk drive schematically shown in FIG. 13 , then the formatted volume and tracking performance were examined. As a result, compared with the conventional thin film single pole head for perpendicular magnetic recording shown in FIG. 1 , it was discovered that the formatted volume was increased by 4%, and tracking performance was good.
[0052] Further, examination was made as to recording current intensity dependence and recording frequency dependence of a reproducing output characteristic of the head produced experimentally. As a result, compared with the conventional thin film single pole head for perpendicular magnetic recording shown in FIG. 1 , it was discovered that no disturbance phenomena of the recording pattern caused by a return magnetic flux like that represented by erasure after recording was difficult to be measured in the head produced experimentally in the present embodiment.
Third Embodiment
[0053] As shown in FIG. 4 , three auxiliary poles 9 , 17 and 18 were disposed so as to surround the main pole 1 when seen from the surface facing to the medium. In this case, the first auxiliary pole 9 and the second auxiliary pole 17 , and the main pole 1 were formed on the same film which flattens the roughness of underlayers. The sizes of the auxiliary poles 9 and 17 and the main pole 1 , and the spaces from one another were set equal to those of the second embodiment. In addition, third auxiliary pole 18 , the main pole 1 and the reproducing element 11 were disposed such that the respective centers thereof were positioned on the same straight line roughly parallel to the trailing direction 14 . When seen from the surface facing to the medium, the third auxiliary pole 18 had a length of 6 μm in the tracking width direction, and a height of 2 μm in the trailing direction. The main pole 1 , and the first, second and third auxiliary poles 9 , 17 and 18 were connected as schematically shown in FIG. 10 . Specifically, magnetic film pillars parallel to the surface facing to recording media were respectively connected to the main pole 1 and the first and second auxiliary poles 9 and 17 . The first, second and third auxiliary poles were magnetically coupled together by connecting the third auxiliary pole 18 to the upper parts of the three pillars. Then, a coil which creates a magnetic flux 3 was formed so as to surround the magnetic film pillar connected to the main pole 1 .
[0054] A head which has a read element and a write element, using a GMR element as a reproducing head and the thin film single pole head for perpendicular magnetic recording as a recording head, was produced experimentally. Then, this head and the double-layer perpendicular recording medium were combined to assemble a magnetic disk drive schematically shown in FIG. 13 , and the formatted volume and tracking performance were examined. As a result, compared with the conventional thin film single pole head for perpendicular magnetic recording as shown in FIG. 1 , it was discovered that the formatted volume was increased by 4%, and tracking performance was good. In addition, examination was made as to recording current intensity dependence and recording frequency dependence of a reproducing output characteristic of the head produced experimentally. As a result, compared with the conventional thin film single pole head for perpendicular magnetic recording as shown in FIG. 1 , it was discovered that the measurement of the disturbance phenomena of the recording pattern caused by a return magnetic flux like that represented by erasure after recording was difficult.
[0055] Furthermore, the head produced experimentally in the present embodiment and the double-layer perpendicular recording medium were combined, and applied magnetic field intensity dependence of a reproducing output characteristic was measured. This measurement was carried out to check a change in reproducing signal intensity by forming a recording pattern beforehand in a predetermined track on the recording medium, and applying a magnetic field in a predetermined direction. At that time, magnetic field intensity was set in the range between 0 and 4000 A/m (about 0 to 50 Oe), as a magnetic field applying direction, the trailing direction 14 and an element height direction orthogonal to the track width direction were selected. Assume that the intensity of reproducing signal was 1 with the intensity of applied magnetic field set at 0 A/m, the intensity of reproducing signal was 0.6 to 0.7 when the intensity of applied magnetic field was 4000 A/m in the case of the conventional thin film single pole head for perpendicular magnetic recording. On the other hand, it was about 0.9 in the case of the head produced experimentally in the third embodiment. As a result, compared with the conventional thin film single pole head for perpendicular magnetic recording shown in FIG. 1 , it was difficult for an antenna effect to take place in the case of the head produced experimentally in the third embodiment.
[0056] According to the present invention, it is possible to provide a thin film single magnetic pole head for perpendicular magnetic recording, which provides a higher formatted volume than that of the conventional thin film single pole head for perpendicular magnetic recording, and easy servo. | Provided is a thin film single pole head for perpendicular magnetic recording, which has a structure offering a high formatted volume, easy servo, difficulty of influencing a recording pattern on a medium, and capability of shortening processing time. This thin film single pole head for perpendicular magnetic recording is formed on a reproducing head composed of a pair of shield layers formed on a substrate, and a reproducing element formed therebetween. A structure is provided, where an auxiliary pole is not disposed between the reproducing element of the reproducing head and the main pole of a recording head when seen from a surface facing to recording media. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for detecting malfunctioning of a fuel feed system of an internal combustion engine (hereinafter referred to as an “engine”), and more specifically to an apparatus for detecting malfunctioning of a fuel feed system based on an output of an air-fuel (A/F) ratio sensor provided in an exhaust system of the engine.
The Japanese Laid-Open Patent Application No. 8-121226 describes a scheme for detecting malfunctioning of a fuel feed system of an engine comprising an O 2 sensor for detecting an A/F ratio in exhaust gas and a purge control valve placed between a fuel tank and an air intake pipe. According to the scheme, during a failure monitoring, purging is forced to stop when a malfunction determination parameter KO 2 AVE, a learning value of an A/F ratio feedback coefficient, decreases below a first decision value. Then, whether or not the decrease is caused by purging is determined. If it is caused by purging, subsequent failure monitoring is suspended. When the A/F ratio feedback coefficient rises beyond a second decision value after a predetermined period has elapsed, a process determines that purging cannot affect the decision to resume the failure monitoring.
According to the scheme described above, the frequency of the failure monitoring may decrease because the monitoring does not resume until the predetermined period elapses. In addition, the monitoring may be resumed even if there is influence of purging because the monitoring is resumed in accordance with the rise of the wide-variable A/F ratio feedback coefficient beyond the predetermined decision value. Therefore, there is a need for a highly stable failure diagnosing system that is free from influence of purging.
SUMMARY OF THE INVENTION
In order to solve the above-mentioned problem, according to one aspect of the invention, a monitoring apparatus is provided for monitoring a fuel feed system of an engine having an A/F ratio controller. The controller carries out feedback control of the A/F ratio based on an output of an A/F ratio detector provided in an exhaust system of the engine.
The monitoring apparatus includes means for calculating an A/F ratio feedback coefficient based on an output of the detector and means for calculating a malfunction determination parameter based on the A/F ratio feedback coefficient. The apparatus also includes a purge cut controller for cutting purge when the parameter reaches a first decision value, and a monitor controller for suspending the monitoring when the parameter reaches a second decision value in a purge cutting state. The apparatus further includes means for estimating a value of a malfunction determination parameter that would be taken if the purge cutting had not been carried out. The estimation is performed responsive to the malfunction determination parameter reaching the second decision value and uses as an initial value the value when the parameter reached the first decision value. The monitor controller causes the monitoring to be resumed responsive to the estimated value of the malfunction determination parameter reaching the second decision value.
When the malfunction determination parameter reaches the second decision value in the purge cutting state, that is, when the fuel feed system is normally functioning but the malfunction determination parameter is determined to have decreased below the first decision value due to the influence of purging, estimation of the malfunction determination parameter starts. This estimation is carried out using as a starting value the value of the malfunction determination parameter at the time the first decision value is reached. The estimated value of the malfunction determination parameter simulates the operation of keeping monitoring the malfunction determination parameter without purge cutting after the malfunction determination parameter reached the first decision value.
When the estimated value of the malfunction determination parameter reaches the second decision value, it is determined that the condition is over in which the malfunction determination parameter decreases below the first decision value due to influence of the purging, and the failure monitoring of the fuel system is resumed.
According to the present invention, whether purging causes a decrease in the malfunction determination parameter below the first decision value is determined based on the malfunction determination parameter in accordance with the real flow of time. In addition, whether failure monitoring of the fuel system is to be resumed is determined based on the estimated value of the malfunction determination parameter which is a value of the parameter if the purge cutting is not carried out. Since the actual malfunction determination parameter is a value resulting from the purge cutting, the parameter would require a considerable period to return to a value unaffected by the purge cutting after the resumption of purging. By using the estimated value of the malfunction determination parameter, the invention allows to quickly determine whether the failure monitoring of the fuel system can be resumed. Furthermore, since the resumption of the failure monitoring is decided on the malfunction determination parameter, which is more stable than the A/F ratio feedback coefficient and its learning value, the system can operate in a stable manner.
According to another aspect of the invention, the malfunctioning determination parameter is decided in accordance with an average of the A/F ratio feedback coefficient. In addition, the monitoring apparatus further includes a determining unit, which determines that the fuel system is malfunctioning if the malfunction determination parameter fails to reach the second decision value after the purge cutting.
Since the malfunction determination parameter is decided according to the average of the A/F ratio feedback coefficient, the parameter becomes more stable than the feedback coefficient and its learning value. Therefore, stability of system control based on the malfunction determination parameter is enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the general configuration of an engine system to which the present invention is applied.
FIG. 2 is a block diagram illustrating the general configuration of a failure monitoring apparatus for a fuel feed system in a preferred embodiment of the invention.
FIGS. 3 ( a ) and 3 ( b ) are waveform diagrams illustrating the relationships between KO 2 , KAV and KO 2 AVE.
FIG. 4 is a flowchart illustrating the process of calculating the malfunction determination parameter KO 2 AVE.
FIG. 5 is a timing chart of actions in the preferred embodiment of the invention.
FIG. 6 is a flow chart illustrating the process of a failure monitoring on the fuel feed system of the preferred embodiment of the invention.
FIG. 7 is a flow chart illustrating the process of judging whether the conditions for the implementation of the monitoring are satisfied in the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a block diagram illustrating the general configuration of a fuel feed system of an engine to which the invention is applied. An engine 1 is, for example, a six-cylinder four-stroke engine provided with a throttle body 3 at a point in an air intake pipe 2 , and a throttle valve 3 ′ is placed in the throttle body 3 . To the throttle valve 3 ′ is connected a throttle valve opening angle (θTH) sensor 4 , which sends an output signal corresponding to the opening angle of the throttle valve 3 ′ to an electronic control unit (ECU) 5 .
Each cylinder of the engine is provided with a fuel injection valve 6 , which is connected to a fuel tank 8 via each fuel pump 7 . The opening of the fuel injection valve 6 is controlled with signals sent from the ECU 5 .
Downstream from the throttle valve 3 ′ is provided an air intake pipe pressure (PBA) sensor 10 via a pipe 9 , and output signal of the sensor 10 is sent to the ECU 5 . Further, downstream from the air intake pipe pressure sensor 10 is an air intake temperature (TA) sensor 11 , whose output signal is sent to the ECU 5 .
An engine water temperature (TW) sensor 12 , comprising a thermistor or the like, is fixed to the cylinder block of the engine 1 to send its output signal to the ECU 5 . An engine revolution (NE) sensor 13 and a cylinder-identifying (CYL) sensor 14 are fixed to camshafts or crankshafts of the engine 1 . The engine revolution sensor 13 generates a signal pulse (TDC signal pulse) at a predetermined crank angle position every 120-degree turn of the crankshaft of the engine 1 , which is sent to the ECU 5 . The cylinder-identifying sensor 14 generates a signal pulse at a predetermined crank angle position of a specified cylinder, which is sent to the ECU 5 .
A ternary catalyst 15 is placed on an exhaust manifold 17 of exhaust pipes 16 L and 16 R, each provided for left and right cylinder groups of the engine 1 . The catalyst 15 eliminates such ingredients as HC, CO and NOx of the exhaust gas. O 2 sensors 18 L and 18 R, A/F ratio detectors, are provided in the exhaust pipes 16 L and 16 R, and generate outputs whose values change substantially in a digital manner across the boundary of the stoichiometry or theoretical A/F ratio. This output is sent to the ECU 5 and used for the feedback control of the A/F ratio.
A vehicle speed sensor 23 detects the velocity V of the vehicle on which the engine 1 is mounted, and sends its output to the ECU 5 . An indicator 19 , comprising a light emitting diode or the like, is turned on when the ECU 5 detects the abnormal fuel feed system.
The top of the sealed fuel tank 8 is connected to the air intake pipe 2 via a two-way valve 20 , a canister 21 and a purge control valve 22 . The ECU 5 controls opening and closing of the purge control valve 22 . The vaporized gas generated in the fuel tank 8 pushes and opens the positive pressure valve of the two-way valve 20 when it reaches a predetermined pressure. Then the gas flows into the canister 21 , where the gas is absorbed and stored in activated carbon. When the purge control valve 22 is opened in response to a signal from the ECU 5 , the vaporized gas stored in the canister 21 is sucked into the air intake pipe 2 by negative pressure alongwith the external air taken in through an air intake port provided in the canister 21 .
When the fuel tank 8 is cooled by the external atmosphere or the like and the pressure in the tank decreases, the negative pressure valve of the two-way valve opens and the vaporized gas stored in the canister 21 is returned to the tank 8 . Thus, the vaporized fuel generated in the fuel tank 8 is prevented from being released into the atmosphere.
The ECU 5 is provided with an input interface 5 a and a central processing unit (CPU) 5 b having such functions as shaping input signals sent from various sensors and to converting analog signals into digital. The CPU 5 b carries out various operations to control the engine system in accordance with programs stored in a read only memory (ROM) or in a random access memory (RAM) with a back-up function which may be a part of a storage unit (memory) 5 c . The memory 5 c includes a regular RAM, which provides a primary storage area for various data and operation results.
An output interface 5 d sends control signals based on the results of the operation by the CPU 5 b to the fuel injection valve 6 , the purge control valve 22 , the indicator 19 , spark plugs and other elements.
FIG. 2 is a block diagram illustrating the general configuration of the failure monitoring apparatus on the fuel feed system according to one preferred embodiment of the invention. The functional blocks illustrated herein are realized with the CPU 5 b , the memory 5 c comprising RAM and ROM, and the program and data tables stored in the ROM for use with various operations.
An droving conditions detecting unit 31 receives outputs from the sensors in various parts of the engine system via the input interface 5 a . The detecting unit determines whether A/F ratio feedback-controlled operation or open loop-controlled operation is to be selected according to the state of operation, and sends to a fuel injection rate control unit 33 a signal indicating the operation mode along with such information as engine revolution NE and air intake pipe pressure PB. Since the present invention concerns the engine operated in the A/F ratio feedback-controlled mode, the following description relates to operation in the A/F ratio feedback-controlled mode.
The fuel injection rate control unit 33 calculates the injection time TOUT of the fuel injection valve according to the following equation;
TOUT= Ti×K 1 × KO 2 + K 2 . (1)
Ti is a reference value for the injection time TOUT, and is read out from a Ti map (stored in the ROM of the ECU 5 ) having the engine revolution NE and the air intake pipe pressure PB as parameters. K 1 and K 2 are respectively a correction coefficient and a correction variable calculated according to various engine parameters, and set so as to optimize the fuel consumption characteristics, the acceleration characteristics or the like according to the droving conditions of the engine.
KO 2 is a feedback correction coefficient for the A/F ratio, and is calculated by a KO 2 calculating unit 32 based on the output from the O 2 sensor. KO 2 varies as illustrated in FIG. 3 ( a ). When the output level of the O 2 sensor changes from one level to the other, for example, from rich to lean, KO 2 is set so that the A/F ratio moves to the opposite direction, i.e. to become rich, by adding a proportional term (P term). Subsequently KO 2 is set to gradually become rich by adding an integral term (I term) until the O 2 sensor senses rich. When the output level of the O 2 sensor changes from lean to rich, KO 2 is set so that the operation stated above is done the other way round (to become lean). This setting scheme is well known, and in this embodiment the proportional term and the integral term are read out from a table whose parameters are engine revolution NE and air intake pipe pressure PB.
A KAV calculating unit 35 calculates KAV, the learning value of the A/F ratio feedback coefficient KO 2 . KAV is calculated according to the following equation every time the proportional term is added to KO 2 , and varies as indicated by a dotted line in FIG. 3 ( a ).
KAV=KO 2 × CO 2 /100+ KAV ′×(1− CO 2 /100) (2)
CO 2 is a variable for setting conformity of KAV with respect to variations of the correction coefficient (A/F ratio feedback coefficient) KO 2 , and is set to a relatively large value within a range of 1 to 100. KAV′ is a preceding value of KAV, and its initial value is set according to the value of the feedback coefficient KO 2 at the time of entering a specific operation range.
A KO 2 AVE calculating unit 36 calculates a malfunction determination parameter KO 2 AVE following the flow shown in FIG. 4 . First, whether the learning value KAV of KO 2 is greater than a sum of the malfunction determination parameter KO 2 AVE plus a deviation for determining the secular change ΔKO 2 AVE (e.g. 0.0078) is determined ( 401 ). If greater, the value of KO 2 AVE is updated according to the following equation;
KO 2 AVE=KO 2 AVE+ΔKO 2 AVE/ 2. (3)
If the determination at step 401 is NO, the process proceeds to step 402 , where whether the learning value KAV is smaller than the balance of the value of KO 2 AVE minus the deviation ΔKO 2 AVE is determined. If smaller, the value of KO 2 AVE is updated according to the following equation. If the determination at step 402 is NO, the process ends.
KO 2 AVE=KO 2 AVE−ΔKO 2 AVE /2 (4)
The process described above holds the value of the malfunction determination parameter KO 2 AVE as its preceding value if the learning value KAV is within the range of KO 2 AVE±ΔKO 2 AVE, and updates the parameter KO 2 AVE according to above-stated Equation (3) or (4) if KAV is out of the range. FIG. 3 ( b ) shows the relationship between the value of KAV and that of KO 2 AVE.
Next, function of a KO 2 AVE monitoring unit 42 (FIG. 2) will be described with reference to FIG. 5 . The KO 2 AVE monitoring unit 42 monitors whether the value of KO 2 AVE becomes smaller than a first decision value (e.g. 0.813). When KO 2 AVE becomes smaller, the unit stores the value of KO 2 AVE at that time into a KO 2 AVE holding memory area (in the memory 5 c ). FIG. 5 ( d ) shows the timing of holding the value of KO 2 AVE. At the same time, the unit 42 sends a purge cut request signal to a purge cut control unit 41 to close the purge control valve 22 to suspend purging. FIG. 5 ( f ) shows the timing of purge cutting.
As the fuel fed to the air intake pipe decreases when purging is suspended, KO 2 begins to rise. The KO 2 AVE monitoring unit 42 sends a signal to a monitoring condition judging unit 43 almost simultaneously with the purge cutting. The signal causes the calculation of KAV and KO 2 AVE to be stopped by resetting a monitor permit flag to suspend failure monitoring for a stabilizing period, which is a duration for the KO 2 to become stable after increase of KO 2 is stopped by purge cutting, and is, for example, about six seconds. The timing of the above operation is shown in FIGS. 5 ( a ) and 5 ( g ). After the stabilizing period elapses, the failure monitoring is resumed and the value of KO 2 AVE is updated and rises in accordance with the above-mentioned updating scheme for KAV and KO 2 AVE. When KO 2 AVE becomes greater than a second decision value (e.g. 0.828), the KO 2 AVE monitoring unit 42 sets a PGOK flag, which indicates that the purging causes KO 2 AVE to decrease below the first decision value and the fuel feed system is normal. The timing of the above operation is shown in FIG. 5 ( e ).
If KO 2 AVE has not become greater than the second decision value when a predetermined period, e.g. 30 seconds, elapses after the purge cutting (FIG. 5 ( f )), a malfunction determining unit 45 determines that the fuel feed system failed and displays a failure indication on the indicator 19 (FIG. 1 ).
If the influence of purging is great, the KO 2 AVE monitoring unit 42 resets the purge cut request signal to the purge cut control unit 41 and sets the PGOK flag to resume purging (FIG. 5 ( f )). Approximately simultaneously, the monitoring condition judging unit 43 prohibits the failure monitoring on the fuel feed system in response to a signal from the KO 2 AVE monitoring unit 42 . The timing of the above operation is shown in FIG. 5 ( a ). Otherwise if the failure monitoring is continued, purge cutting might be requested again when the KO 2 AVE become smaller than the first decision value by the resumption of purging. The prohibition of failure monitoring is intended to prevent the further request.
The KO 2 AVE monitoring unit 42 sets a KMCND flag allowing to estimate a value of the malfunction determination parameter KO 2 AVES during the prohibition of failure monitoring after the lapse of a stabilizing period. The stabilizing period is from the time immediately after the failure monitoring is prohibited as described above to the time the KO 2 stops decreasing as purging is resumed and is stabilized. It is, for example, about five seconds. The timing of the above operation is shown in FIG. 5 ( b ).
Then the KO 2 AVE monitoring unit 42 sends a signal to a KO 2 AVES estimating unit 37 , and start calculation of the estimated value KO 2 AVES using the earlier held value of KO 2 AVE as an initial value. The calculation of KO 2 AVES is carried out along the flow shown in FIG. 4, wherein an initial value of KAV is the value of KO 2 when the aforementioned stabilizing period elapses after the resumption of purging.
The monitoring condition judging unit 43 resumes the failure monitoring on the fuel feed system if the value of KO 2 AVES estimated and updated in aforementioned manner becomes greater than the second decision value. The timing of the above operation is shown in FIG. 5 ( a ). This means that the influence of purging is regarded as being decreased when the estimated value of the malfunction determination parameter KO 2 AVES becomes greater than the second decision value.
In one embodiment of the invention, when a predetermined period, e.g. five minutes, elapses after the failure monitoring on the fuel feed system is prohibited at the timing of FIG. 5 ( a ), the monitoring condition judging unit 43 allows the failure monitoring even if the estimated value of the malfunction determination parameter KO 2 AVES has not become greater than the second decision value. This enables quick resumption of failure monitoring even if the influence of purging is relatively great.
Although KO 2 is illustrated as a schematic linear waveform in FIG. 5, KO 2 actually varies finely as shown in FIG. 3 ( a ). The waveform of KO 2 in FIG. 5 shows that it varies faster than those of KAV and KO 2 AVE, and varies abruptly by purge cutting. KAV follows KO 2 as the learning value of KO 2 , and KO 2 AVE modestly follows KAV in accordance with the relationships represented by the above-mentioned two equations.
Next, the flow of the monitoring on the fuel feed system in one embodiment of the invention will be described with reference to FIG. 6 . The process of FIG. 6 is carried out every 10 milliseconds, for example. First, whether the condition for monitoring is satisfied is determined ( 101 ). This determination of the monitoring condition is established in a flow of determining whether the monitoring condition is satisfied, which will be described below with reference to FIG. 7 . If the failure monitoring is prohibited at step 101 , the process proceeds to step 102 to determine whether the KMCND flag is set. As stated above, this flag indicates a permission to calculate the estimated value of the malfunction determination parameter KO 2 AVES during the prohibition of the failure monitoring after the resumption of purging. The flag is set at step 224 and reset at steps 203 or 225 in FIG. 7 .
If at step 102 the KMCND flag is set, the process proceeds to step 103 . If the KMCND flag is not set, a KAV calculation timer is set ( 136 ) and the operation exits this process.
On the other hand, if the monitoring permission flag is set at step 101 , whether the learning value KAV of KO 2 is initialized is determined according to a KAV flag ( 103 ). If initialized, the process directly proceeds to step 107 . If not initialized, the current A/F ratio feedback coefficient (correction coefficient) KO 2 is set as an initial value and the KAV flag is set to 1at step 106 , and then the process proceeds to step 107 .
If the output of the O 2 sensor is determined to have reversed at step 107 , the learning value KAV of KO 2 is calculated in accordance with Equation (2) stated above as well as setting the KAV flag ( 110 ). If the output of the O 2 sensor does not reverse at step 107 , the process proceeds to step 111 . At step 111 , whether the KAV calculation period set at step 136 has elapsed is determined. This period is set to two seconds for example, and consequently the process from step 113 onward is carried out according to the KAV averaged and updated for two seconds. If the set period has not elapsed, the operation exits this process.
If the KAV calculation period has elapsed, whether the PGOK flag is set to 1 is determined ( 113 ). As this flag will be set to 1 at step 127 but is initially 0, the process proceeds to a malfunction determination parameter KO 2 AVE calculation routine 115 . The routine 115 calculates the malfunction determination parameter KO 2 AVE in accordance with above-stated Equations (3) and (4). Then, whether the purge cut request flag PGREQ explained with reference to FIG. 5 ( f ) is set to 1 is determined ( 116 ). If it is not set, the current value of KO 2 AVE is held in the memory as an initial value of the estimated value of the malfunction determination parameter KO 2 AVES ( 117 ), and the process proceeds to step 118 . If the purge cut request flag PGREQ is set to 1, the process directly proceeds to step 118 .
At step 118 , whether the malfunction determination parameter KO 2 AVE exceeds the upper limit, e.g. 1.190, is determined. Exceeding the upper limit means that the fuel feed system is malfunctioning. Therefore, the purge cut request flag PGREQ is set to 0, a forced purge cut flag FMPG is set to 0 ( 119 ), a flag indicating the fuel system is malfunctioning is set to 1 ( 120 ), an FSDD flag is set to 1 ( 121 ), the KAV calculation timer is set ( 136 ), and the operation ends this process. In continuous monitoring of the fuel system and misfiring, the FSDD flag is intended to prevent normal failure monitoring from being resumed in the operation cycle in which malfunctioning fuel feed system has been detected, even if the fuel feed system is detected normal afterwards.
If KO 2 AVE is the upper limit or less at step 118 , the process proceeds to step 123 to determine whether the forced purge cut flag FMPG is set to 1. FMPG is set to 1 ( 229 ) when the purge request flag PGREQ is set to 1in the flow of FIG. 7 to be explained below ( 227 ).
Since no forced purge cutting is carried out at first, the process proceeds to step 128 and whether the malfunction determination parameter KO 2 AVE is smaller than the first decision value (see FIG. 5) is determined ( 128 ). If smaller, this means that the fuel feed system may be malfunctioning, and whether the aforementioned FSDD flag is set to 1 is determined ( 129 ). If this flag is set to 1, this means that malfunction of a fuel system has already been detected, the operation exits this process after going through step 119 thereafter. If the FSDD flag is not set to 1, the purge cut request flag PGREQ is set to 1 ( 130 ), the KAV calculation timer is set ( 136 ) and the operation exits this process.
If KO 2 AVE is the first decision value or more at step 128 , the fuel feed system is determined to be normal. A fuel system normal flag is set ( 131 ), the KAV calculation timer is set ( 136 ) and the operation exits this process.
If forced purge cutting is in the execution at step 123 , the process will proceeds to steps 124 and 125 to wait for the lapse of a predetermined period of around 30 seconds. A counter is incremented at step 124 and whether the count has reached a value corresponding to 30 seconds for example is determined at step 125 . If reached, the KAV calculation timer is set to end the process and the process reaches step 124 again in the next processing cycle. When a preset period has elapsed in cycles, whether the malfunction determination parameter KO 2 AVE has reached or exceeded the second decision value (see FIG. 5) is determined at step 126 . If KO 2 AVE has reached or exceeded the second decision value, the decrease of KO 2 AVE below the first decision value is determined to be caused by purging and not by any failure in the fuel feed system, as stated with reference to FIG. 5 .
Therefore, the process proceeds to step 127 , where the PGOK flag indicating the above-mentioned determination is set to 1, the counter used at steps 124 and 125 is reset, and the purge cut request flag PGREQ is set to 0. Then, the process proceeds to step 131 , where the fuel system normal flag indicating the normal fuel feed system is set, and the KAV calculation timer is set ( 136 ) and the operation exits this process.
Reaching step 113 in the next processing cycle, as the PGOK flag is set to 1this time, the process enters into the routine to calculate the estimated value of malfunction determination parameter KO 2 AVES ( 114 ). In this routine, the estimated value KO 2 AVES is calculated with the malfunction determination parameter KO 2 AVE as the initial value in accordance with Equations (3) and (4) stated above. The parameter KO 2 AVE is already held in the memory at step 117 in the immediately preceding processing cycle in which the purge cut request flag PGREQ was set to 1.
FIG. 7 illustrates a flow to determine whether the implementing conditions for the monitoring are satisfied. While the processing shown in FIG. 6 is carried out every 10 milliseconds, the processing shown in FIG. 7 is carried out, for example, every 200 milliseconds.
In the flow of FIG. 7, the monitoring permission flag at step 201 is a flag to be set when a central management unit of the ECU 5 permits the monitoring on the fuel feed system through managing various processes. When the monitoring is permitted, whether each of the engine revolution NE, air intake pipe pressure PB, engine water temperature TW and air intake temperature TA or the like is within each appropriate range is determined ( 216 ). If each parameter is determined to be within each preset appropriate range, whether the engine is operated in the A/F ratio feedback control mode is determined according to an A/F ratio feedback control mode flag ( 217 ).
If determined “NO” at steps 201 , 216 and 217 , a predetermined period, e.g. two seconds, is set on a TMCND timer ( 202 ). If operated in the feedback control at step 217 , the process proceeds to step 218 , where whether the period set at step 202 has elapsed is determined. This period is the waiting time for the stabilization of the operating mode.
If the predetermined period has elapsed at step 218 , whether the PGOK flag is set to 1 is determined ( 219 ). The PGOK flag is a flag set to 1at step 127 in FIG. 6, and its timing is shown in FIG. 5 ( e ). As stated above, this flag indicates that the purging causes the decrease of the malfunction determination parameter KO 2 AVE below the first decision value and the fuel feed system itself is normal. Therefore, when this flag is set, the process enters into a determining process whether the estimated value of the malfunction determination parameter KO 2 AVES becomes greater than the second decision value.
If the PGOK flag is set to 0 at step 219 , the process proceeds to step 211 . At step 211 , the predetermined value mentioned above is set in the TKMCND timer to be referenced at step 220 , and the aforementioned period, e.g. five minutes, is set in the suspending period timer to be referenced at step 223 . These settings intend to provide for entering into the flow of step 220 from step 219 when the PGOK flag is set in the next and subsequent processing cycles.
Then whether the purge cut request flag PGREQ is set to 1 is determined ( 227 ). If it is not set to 1, a post-purge cut stabilization timer TFMPGS is set ( 232 ), a failure monitoring condition satisfied flag is set ( 231 ) and the operation exits this process. If the purge cut request flag PGREQ is set to 1, the process proceeds to step 229 , and the forced purge cut flag is set to 1 ( 229 ) to suspend purging. Then whether a post-purge cut stabilization period TFMPGS, e.g. six seconds, has elapsed is determined at step 230 . The monitoring condition is kept unsatisfied until the post-purge cut stabilization period TFMPGS elapses. Therefore, the A/F ratio correction coefficient KO 2 can rise by the shifting of the A/F ratio to the lean side because of the purge cutting. Furthermore, misdiagnosis can be avoided by suspending various calculations until this rise in KO 2 ends and is stabilized. If the post-purge cut stabilization period TFMPGS has elapsed, the monitoring condition is set satisfied ( 231 ). If it has not, the monitoring condition is not satisfied ( 206 ).
If the PGOK flag is set to 1at step 219 , the process proceeds to step 220 , and whether a stabilization period, e.g. five seconds, has elapsed is determined ( 220 ). The stabilizing period is an estimated period for the decrease of KO 2 due to the resumption of purging to stop. As seen in FIG. 5, simultaneously with the setting of the PGOK flag to 1, the purge cut request flag PGREQ is set to 0 to resume the purging, and then KO 2 decreases by the resumed purging. Consequently, KAV calculation is suspended until the decrease stops and misdiagnosis can be avoided. If the determination at step 220 is “YES”, whether KO 2 AVES becomes the second decision value (see FIG. 5) or more is determined ( 222 ). If the determination is “YES”, the PGOK flag (FIG. 5 ( e )) is set to 0, and the aforementioned KMCND flag is set to 0 ( 225 ).
The forced purge cut flag FMPG is set to 0 ( 205 ). Setting the PGOK flag to 0 ( 225 ) causes the next processing cycle to enter into the flow of step 211 from step 219 , and the monitoring condition is satisfied at step 231 .
If the predetermined period has not elapsed at step 220 , the KAV flag is set to 0 ( 221 ), and the aforementioned KMCND flag is set to 0 ( 203 ). When the determination at step 222 is “NO”, whether a period set as the maximum permissible duration, e.g. five minutes, for suspending the fuel feed system monitoring has elapsed is determined ( 223 ). If elapsed, the process proceeds to step 225 and the monitoring condition is satisfied ( 231 ) to resume the failure monitoring on the fuel feed system. If the period for suspending has not elapsed at step 223 , the KMCND flag indicating the estimation of KO 2 AVES is set to 1 ( 224 ). The process proceeds to step 205 to set an FMPG flag to 0, the monitoring condition is determined unsatisfied ( 206 ) and the operation exits from this process.
Although the preferred embodiments of the present invention have been described in the foregoing, the invention is not confined to such embodiments.
According to one aspect of the invention, a state allowing a resumption of a failure monitoring on a fuel system can be quickly determined. Further, according to another aspect of the invention, a more stable system operation can be achieved because the resumption of the failure monitoring is decided based on malfunction determination parameter, which is a more stable factor than an A/F ratio coefficient and its learning value. | A highly stable engine failure diagnosing system free from influence of purging is presented. A monitoring apparatus for monitoring a fuel feed system of an internal combustion engine is provided with an A/F ratio detector and an A/F ratio controller for performing feedback control of the A/F ratio. An A/F ratio feedback coefficient is calculated according to the output of the detector. A malfunction determination parameter is calculated based on the coefficient. A purging is suspended when the parameter reaches a first decision value. The monitoring is suspended when the parameter reaches a second decision value in a purge cutting state. A value of the malfunction determination parameter it would take if the purge cut was not carried out is estimated using the value when the parameter reached the first decision value. The monitoring is resumed when the estimated value of the malfunction determination parameter reaches the second decision value. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of Provisional Patent Application Ser. No. 60/352,096 filed Jan. 25, 2002.
BACKGROUND
[0002] 1. Field of Invention
[0003] This invention relates to universal electronic data monitoring including their collection, wire or wireless transmission, computer analysis, detection and the classification of abnormalities in the data, where such abnormalities result in automatic alarms that are transmitted to recipients locally or world wide, thereby providing a basis for taking corrective action at the source of the data.
[0004] 2.Discussion of Prior Art
[0005] Methods Using Hard Wired Transmission:
[0006] The prior art U.S. Pat. No. 4,583,524 to Hutchins (1986) shows a instructional system for reviving the victim of a heart attach. U.S. Pat. No. 5,199,439 to Zimmerman et al. (1993) shows the use of a quality control chart for direct and simple monitoring of data. However, the chart is used in a way that is not statistically valid. The reason is as follows. Statistical quality control charts assume that the data on which they are based are independent. That is, each measurement is completely unrelated to all previous measurements. In reality, the measurements are serially related. This is known as autocorrelation. None of these patents employs correlation as part of its analysis. Since correlation analysis is at least one of the requirements to make the charts valid, no valid conclusions can be drawn from the charts that use these patents.
[0007] U.S. Pat. No. 4,545,388 to John (1985), U.S. Pat. No. 4,519,395 to Hrushesky (1985), U.S. Pat. No. 4,844,086 to Duffy (1989), U.S. Pat. No. 5,215,098 to Steinhaus et al. (1993), and U.S. Pat. No. 5,564,433 to Thornton (1996) employ relatively static measures of correlation, but do not apply them to the dynamic creation of a valid quality control chart.
[0008] U.S. Pat. No. 5,941,820 to Zimmerman (1999), employs correlation. However, correlation is limited to autocorrelation in a single variable. It does not employ cross correlation analysis to incorporate the effects of other related variables. Also, it does not split the data into separate correlated and uncorrelated components of the data. Instead, autocorrelation is used to modify control chart limits, such that different control limits exist on a single chart. This is done in an attempt to create control limits which are more appropriate. Varying limits, all existing on the same chart, make the chart far more complicated, very difficult to read and very confusing. This patent shows software that to function, requires an expensive and dedicated medical prescription sensor/monitor, currently used in hospitals.
[0009] U.S. Pat. No. 5,505,199 to Kim requires a combination of pulse oximeter, motion detector, and video camera connected to a central unit, making it cost prohibitive for most home users. U.S. Pat. No. 5,490,523 to Isaacson et al. (1996) uses a pulse oximeter with built in readout but no alarm feature. U.S. Pat. No. 6,011,477 to Teodorescu, et al. (2000) does not affix any biomedical sensors to the human body and does not measure any actual internal biomedical vital signs. Any external motion detector is likely to alarm when it is too late to take corrective action.
[0010] None of these patents employs wireless transmission of data. Data sensors must be physically attached to a human being and hard wired to some other device. This limits the mobility of the person being monitored. Movement can cause wires to come loose. Wires can also be hazardous, especially to babies.
[0011] Methods Using Wireless Transmission:
[0012] U.S. Pat. No. 6,047,201 to Jackson (2000), uses a battery operated sensor (pulse oximeter) to collect data from a human baby, and transmits the data via the 900 MHz band to a battery operated monitor. The radio frequency operation prohibits its use in hospitals. Transmission in the 900 MHz band is very demanding on the battery. The sensor must be removed from the baby, periodically, to recharge the battery. Because of the charger port, the sensor cannot be sealed for water proofing. The monitor must also be recharged. Therefore, continuous monitoring is not possible for any appreciable length of time. The patent shows 8 hours. A baby can fall asleep anytime without notice. If the baby falls asleep while the sensor is being charged, there will be no data collection and therefore no monitoring. In any case the patent is limited to babies that are asleep. However, a baby can experience respiratory and/or cardiac difficulties while awake. The patent shows a 900 MHz band transmitting antenna as a wire with no constructed ground plane. In the 900 MHz frequency band, a wire antenna, or any other antenna without a ground plane, de-tunes when it is in proximity to the human body which also acts as an antenna. The receiving antenna is subject to the same defect. De-tuning means that the transmission frequency varies. Therefore, the signal is either altered so that the monitor receives incorrect and dangerously misleading values, or it becomes lost altogether between the transmitter and the receiver in the monitor. The user cannot change the transmission frequency to avoid interference from other devices transmitting at the same frequency. The monitor is limited to oxygen data, and shows only one oxygen measurement at a time. If the measurement drops below a predetermined level it sounds an alarm. There is no alarm for the case when a biomedical vital sign goes above a predetermined level. This patent is limited to monitoring a single vital sign in actual units. There is no alarm for the case when there is a sudden change in the vital sign. This patent does not employ autocorrelation or cross correlation and does not use a quality control chart. Therefore, there is no way to get a picture, pattern or any other sense of how the data is developing over time. U.S. Pat. No. 5,549,113 to Halleck, et al. (1996) shares similar features and shortcomings. It promises a transmission range of only 90 feet, which after accounting for adverse prevailing conditions (interference, metal sidings and walls containing electrical wires, etc.), is limited to just the room where the sensor is located. Continuous transmission at the frequency shown is not permitted by the FCC. Transmission is only intermittent. Therefore, there is no continuous monitoring.
[0013] Additional Shortcomings of the Prior Art.
[0014] In addition to the shortcomings listed above for each of the two sets of monitors, the following are shortcomings common to both. They all require expensive prescription sensor/monitors. None of them does multivariate data analysis designed to collectively support diagnosis, decision making and corrective action. None of them cross correlates two or more related variables. Therefore, only one variable at a time is monitored. None of them decomposes the data and displays them on common cause charts of internal systematically related effects and special cause charts of external random unrelated effects. None of them provides long duration independent sensors that can be connected to a monitor either by wire or wireless means. Either the battery has to be replaced or the sensor has to be removed and recharged during the time when it is required to be in operation. None of them provides universal ability to read data formats from different sources containing various combinations of variables. They all provide a limited alarm function. None of them provides graduated progressive sound, color, print and world wide, fax, email and telephone alarm signals when the chart values exceed predetermined or user specified limits, either in terms of actual units or standard deviations, or when any particular pattern occurs.
[0015] The patents closest to the present invention are U.S. Pat. No. 5,941,820 to Zimmerman et al. (1999) and U.S. Pat. No. 6,047,201 to Jackson (2000). U.S. Pat. No. 5,941,820 to Zimmerman et al. (1999) shows charting, albeit a single chart only. However, it shows no wireless means or graduated alarms. U.S. Pat. No. 6,047,201 to Jackson (2000) shows wireless means of transmission, albeit of short duration only. However, it shows no charts and no graduated alarms. The present invention shows hard wired and wireless means of transmission, multiple variables—each with dual charts, and a system of graduated multiple alarm types.
SUMMARY
[0016] In accordance with the present invention, a computer powered wire(less) ultra-intelligent real-time monitor exists in two arrangements, a short range monitor and a long range monitor. The short range monitor is comprised of a sensor/transmitter (if wireless), a receiver and computer software. The long range monitor is comprised of a sensor/transmitter (if wireless), a repeater (if wireless), a receiver and computer software. A suitable sensor/transmitter is of the type described in U.S. Pat. No. 4,625,733 to Saynajakangas (1986) and U.S. Pat. No. 5,491,474 to Suni, et al. (1996). The software operates on a computer to accept, time and date stamp, analyze and transform data, to display charts, upper and lower control limits, and summary data, and to initiate a sequence of graduated progressive sound and color alarms that are audible and visible from a distance. It also initiates print, and local or world wide fax, email, and pager/beep or telephone alarms. The alarms provide notification of the onset of abnormalities in the data being monitored so that corrective action can be taken at the source. The synergistic combination of these component parts greatly exceeds the sum of what each of them can accomplish separately.
[0017] Several of the examples given below use biological vital signs data for the purpose of illustration. These are not in any way intended to imply a limitation of the scope and universal applicability of the monitor. The principles developed apply similarly to other data.
OBJECTS AND ADVANTAGES
[0018] Accordingly, several objects and advantages of my invention are:
[0019] a) To provide a method for long term continuous uninterrupted wireless transmission of the data to a computer which acts as the monitoring device. The very low frequency (5 KHz band) and low power transmitter and receiver in the short range monitor (for example the baby monitoring application) operate for at least 2500 hours on a single miniature battery.
[0020] b) To provide a comfortable ultra light weight sensor/transmitter, free of large batteries, and radio frequency transmitters, suitable for wearing by a baby or an adult.
[0021] c) To provide an inexpensive, easy to use, fully automatic, full featured, over the counter, vital signs monitor for home use.
[0022] d) To provide a short range monitor for hospital use (due to very low frequency {5 kHz band} and short range {approximately 3 feet}, interference with other hospital equipment is easily avoided).
[0023] e) To provide a water proof sensor/transmitter that can be used in a wet environment. A wet environment can arise from bed wetting/incontinence. When the long range monitor is to be operated in a wet environment, the repeater is simply placed in a sealed water proof box.
[0024] f) To eliminate batteries in the receiver. The absence of batteries is a highly desirable feature and is very important in applications such as a heart monitor where reliability is important.
[0025] g) To prevent de-tuning of the sensor/transmitter. At low frequency (5 KHz band), very low power and short range, the transmitter uses no external antenna and never de-tunes, even when affixed to the human body.
[0026] h) To provide a very long transmission range, limited only by the FCC government regulation of 1,000 feet. A 900 MHz band repeater, not affixed to the human body, is used to extend the range of operation by means of external transmitter and receiver whip antennae. Using different frequencies, 5 KHz for the input and 900 MHz for the output prevents signal cancellation and any other potential conflict.
[0027] i) To prevent de-tuning during long range transmission. The transmitter and receiver in the long range monitor use a carefully constructed ground plane to prevent de-tuning. If the repeater is to be placed in contact with the body, the external transmitter whip antenna is replaced by a special internal loop transmitter antenna to prevent de-tuning.
[0028] j) To permit the user to change the 900 MHz band transmission frequency channel to avoid interference from other devices that would otherwise be transmitting at the same frequency as the repeater.
[0029] k) To provide a uniquely coded data transmission for security and integrity.
[0030] l) To provide software filtering of extraneous transmissions received at the computer.
[0031] m) To provide universal ability to read data formats containing various combinations of variables, from different sources including a serial, USB or other port, a keyboard, a data file created by another application, data copied from the computer screen, or data downloaded from another computer or from the internet.
[0032] n) To provide continuous data collection, time and date stamping, transformation according to desired mathematical formula and storage, including retrievable backup data from a prior monitoring session.
[0033] o) To provide a continuous display of various user specified time spans of data (example: last 5 minutes, last 8 hours, etc.) by automatically grouping the data, accordingly.
[0034] p) To continuously display summary data (example: mean, standard deviation, number of breaches of the upper and lower control limits, etc.).
[0035] q) To provide a monitor not only for babies but human beings of all ages, designed so that it can be customized according to age group.
[0036] r) To provide a monitor whose sensor/transmitter operates continuously, free of need to be recharged, while the person being monitored is awake or asleep.
[0037] s) To provide a monitor that is automatically calibrating, and whose user may set age and sex specific, or other upper and lower control limits. The alarm is initiated when the custom chart limits are exceeded or when sudden changes occur in the data. Sudden changes are measured relative to recent past data values. Therefore, the monitor also automatically customizes itself to the individual human being, regardless of age or sex. Abnormality is judged relative to
[0038] 1) known medical standards for the relevant human sub population (age and sex), or user specified standards,
[0039] 2) the recent past data for the individual being monitored.
[0040] t) To provide dual quality control charts, correcting for the effects of autocorrelation in each variable being monitored, and cross correlation with other variables. At least three embodiments of this feature for applications in biomedical, manufacturing and auditing applications are as follows:
[0041] Biomedical
[0042] The meaning and the importance of the new dual chart system is summarized as follows by considering its application to biological vital signs data such as heart rate and oxygen saturation. The principle of the dual chart system applies similarly to other data. Unlike a simple machine, the human body has natural internal self-correcting mechanisms. Biological data collected serially over time are therefore related to each other. That is, they are systematic and correlated. They are not independent data. They cannot be represented and analyzed by the existing method of standard control charts because such charts are valid only for independent data. Even a simple visual analysis is misleading. Biological data also contain a component that is not correlated. That is, a random and independent component. When the data are represented by the existing method of a single chart, the systematic and random effects are confounded, preventing proper and/or accurate diagnosis of the human biological condition.
[0043] The invention splits the data into systematic (correlated) and random (independent) components. It creates and uses the common cause effects chart to represent the part of the data that is systematically related, and the special cause effects chart to represent the part of the data that is randomly independent. The common cause chart identifies what is systematically occurring, internally, inside the body, due either to normal health, healing or failing health. The special cause chart identifies what is occurring in the external environment, and impacting on the body. For example the effects of a one of a kind loud noise that is startling, raises heart rate temporarily but does not repeat in a systematic way. Dual charts permit and facilitate proper analysis and diagnosis of the human biological condition as far as can be determined from the data. The dual chart system also reduces the number of false alarms or false positives that distract the attention of valuable personnel away from real and important problems, and reduces the number of false negatives when real and important problems go unnoticed. These features are greatly needed.
[0044] This new method of splitting the data and the notion of the presence of the elements of the new dual chart system are both initially counter intuitive, and are therefore unobvious to any person who has ordinary skill in the specific technologies involved in the invention.
[0045] Manufacturing
[0046] Consider next, the application to an industrial process. The common cause effects chart for this type of data may be a recurring cyclical pattern caused by, for example, a worn machine bearing, internal to the process. By examining the common cause effects chart, the pattern can be associated with its probable cause and the defective bearing identified and located. All parts must wear, and must wear out eventually. The defective bearing can be changed during the next scheduled plant maintenance shut down. Otherwise, the bearing wear may reduce product quality. It will eventually fail, forcing an unscheduled shut down, a new bearing anyway, and all attendant costs of a forced shut down. The special cause effects chart for this type of data may reveal for example, a random one-time raw material departure from what is required. This is, an external effect due to a bad batch of raw material. In that case, the supplier must be contacted to rectify the problem.
[0047] Auditing
[0048] Consider next, the application to financial auditing. The common cause effects chart for this type of data will reflect seasonal and other systematic expenditure patterns that are considered normal. The special cause effects chart will indicate unusual expenditures that might otherwise go unnoticed, due their interaction with the systematic effects. They may simply be obscured if the systematic effects are large. The unusual expenditures are marked for further investigation to determine whether they were authorized or unauthorized. Even if the unusual expenditures would have eventually been found by a manual search, the special cause effects chart saves valuable time and effort.
[0049] u) To create separate disk files of common cause variations and the special cause variations data that can be read by other computer programs and used to manipulate and control other devices and processes. Such other computer programs may be activated independently or activated by the program embodied in this invention.
[0050] v) To provide statistically unbiased quality control charts.
[0051] w) To initiate sound and color alarms when a value on either the aggregate history chart, the common cause chart, or the special cause chart exceeds the upper control limit or the lower control limit, in
[0052] 1) actual units
[0053] 2) standard deviations.
[0054] x) To mark and display current and historical breaches of the upper and lower chart limits for use as an additional diagnostic tool.
[0055] y) To initiate a graduated progressive and therefore false alarm free sound, color, print and world wide email, fax, and telephone alarm sequence if any chart values persistently breach either the upper or lower limit of any chart. The user sets the time delay until when the breaches are considered to be persistent.
[0056] z) To initiate a graduated progressive and therefore false alarm free sound, color, print and world wide email, fax, and telephone alarm sequence if the sensor/transmitter is removed, if there is a loss of power anywhere in the system, or if there is a disconnect or a break in data transmission for any reason.
[0057] aa) To copy and paste the charts into another computer program, such as a word processor, so as to prepare a more extensive report that incorporates information from the chart.
[0058] These innovations are unobvious to any person who has ordinary skill in the specific technologies involved in the invention.
OTHER OBJECTS AND ADVANTAGES
[0059] Consider an industrial application wherein as an after thought, a new variable is to be monitored, but where no wiring currently exists, or where installing wires is not immediately technically feasible. It may be possible to easily retrofit the monitor to such an infrastructure. The sensor/transmitter can be installed to collect and transmit data to the repeater which is conveniently located at a feasible location within about 3 feet of the sensor/transmitter. The repeater then transmits data to a control room where the computer is located.
[0060] Consider a heart attack victim for which the emergency telephone alarm is initiated. By printing up to date charts as part of the alarm sequence, an emergency medical team that is responding to the computer activated telephone call can simply and immediately pick up, examine, and transport the printed charts and the victim to a hospital. Such charts would not otherwise be immediately available.
[0061] In a noisy environment, the sound alarm could go unnoticed. However, it is very difficult not to notice a combination of full screen color, print, fax, email and pager/beeper or telephone alarms, especially when the telephone and fax machine are elsewhere in a quiet location. Also, the system is false alarm free since the graduated method allows the responder to gauge the severity of the abnormality in the data that has caused the alarm, and to respond accordingly.
[0062] The long range monitor allows the user to travel within an area of over three million square feet (over seventy acres). A home user, even allowing for adverse prevailing conditions (interference, metal sidings and walls containing electrical wires, etc.), can move in and around a very large house and property to perform activities such as gardening, croquet, putting out the trash and retrieving the mail.
[0063] The long range monitor functions as an electronic travel limit detector, since it will alarm when the wearer of the sensor/transmitter moves outside the range of the transmitter. A person suffering from presenile dementia or other mental degeneration such as alzheimer's disease can benefit from this feature. The range may be shortened by attenuating (reducing) the transmitter antenna power. For example, if the wearer is a baby, then the area in which the baby can travel before the alarm is initiated, can be reduced.
[0064] This invention uses a computer to execute the related software, to display the charts and data, and to activate the alarms. This reduces the cost to the user who may utilize any existing computer that they already own. The user can continue to use their computer simultaneously, while the monitor is in operation.
[0065] Still further objects and advantages will become apparent from consideration of the drawings and ensuing description.
DRAWINGS
[0066] [0066]FIG. 1. Picture of sample working prototype sensor/transmitter, repeater, receiver & computer program menus.
[0067] [0067]FIG. 2. Short range (3 ft) computer powered wire(less) ultra intelligent real-time monitor—A.
[0068] Long range (1000 ft) computer powered wire(less) ultra intelligent real-time monitor—B.
[0069] Power supply & dc voltage level amplifier for data receiver—C.
[0070] [0070]FIG. 3-A. Old method of single chart statistical process control.
[0071] [0071]FIG. 3-B. New method of splitting biological vital signs data into dual common cause chart (CCC) of systematic effects and special cause chart (SCC) of random one of kind effects, by the Moving Window Spectral Antithetic time series model, and attending to the causes of any chart breaches.
[0072] [0072]FIG. 3-C. New method of splitting industrial process data into dual common cause chart (CCC) of systematic effects and special cause chart (SCC) of random one of kind effects, by the Moving Window Spectral Antithetic time series model, and attending to the causes of any chart breaches.
[0073] [0073]FIG. 3-D. New method of splitting accounting cash flow data into dual common cause chart (CCC) of systematic effects and special cause chart (SCC) of random one of kind effects, by the Moving Window Spectral Antithetic time series model, and attending to the causes of any chart breaches.
[0074] [0074]FIG. 4-A. Simple aggregate history chart in original units.
[0075] [0075]FIG. 4-B. Sample common cause variations chart in original units.
[0076] [0076]FIG. 4-C. Sample common cause variations chart in standard deviations.
[0077] [0077]FIG. 4-D. Sample special cause variations chart in original units.
[0078] [0078]FIG. 4-E. Sample special cause variations chart in standard deviations.
[0079] [0079]FIG. 5. Hypothetical family of cycles for window #1 in the moving window spectral antithetic time series model.
LIST OF PARTS
[0080] The list of parts shown below are given as examples only, to match the sample working prototype shown in FIG. 1 & FIG. 2. Because part numbers are necessary for their identification, a particular supplier may be implied, incidentally. However, based on their functional description, each part may be replaced by its equivalent from any other supplier, without changing the invention.
[0081] Short Range (3 ft) Computer Powered Wire(less) Ultra Intelligent Real-Time Monitor
[0082] FOURCAST.ZIP object code
[0083] Software:FOURCAST BioMediControl/SleepAnalyzer/SPControl/Auditor Sensor/Transmitter: 5 KHz transmitter & chest strap—adjustable to any size
[0084] Receiver
[0085] Receiver: Polar 5 KHz smart receiver
[0086] Power supply & dc voltage level amplifier for data receiver
[0087] CMOS line driver: DS14C88
[0088] Capacitor: 68 μF rated for 16 Volts
[0089] Capacitor: 22 μF rated for 16 Volts
[0090] Resistor: 270 Ω
[0091] Resistor: 470 Ω
[0092] Three diodes: 1N4148
[0093] Printed circuit board: 1.75″×1.75″
[0094] Project enclosure: 4″×2″×1″
[0095] Female DB9 RS2325 ft cable
[0096] Long Range (1000 ft) Computer Powered Wire(less) Ultra Intelligent Real-Time Monitor
[0097] FOURCAST.ZIP object code
[0098] Software:FOURCAST BioMediControl/SleepAnalyzer/SPControl/Auditor Sensor/Transmitter: 5 KHz transmitter, coded transmitter & chest strap—adjustable to any size
[0099] Repeater
[0100] Receiver: Polar 5 KHz smart receiver
[0101] Transmitter: 900 MHz band
[0102] 9 Volt rechargeable battery
[0103] LED switch: 0.512″×0.75″
[0104] Current limiting resistor: 2.2 kΩ
[0105] Project enclosure: 6″×2″×1″
[0106] Battery charger: 120 vac/9 vdc at 500 milliamps
[0107] Female plug for 9 vdc charger jack plug.
[0108] Voltage dropper: 270 Ω resistor
[0109] Three pole dip switch
[0110] Receiver
[0111] Receiver: 900 MHz band
[0112] Power supply & dc voltage level amplifier for data receiver
[0113] CMOS line driver: DS14C88
[0114] Capacitor: 68 μF rated for 16 Volts
[0115] Capacitor: 22 μF rated for 16 Volts
[0116] Resistor: 270 Ω
[0117] Resistor: 470 Ω
[0118] Three diodes: 1N4148
[0119] Printed circuit board: 1.75″×1.75″
[0120] Project enclosure: 4″×2″×1″
[0121] Female DB9 RS2325 ft cable
[0122] Three pole dip switch
DETAILED DESCRIPTION OF THE INVENTION
[0123] Automatic Data Acquisition and Hardware
[0124] [0124]FIG. 1 is a picture of a working prototype of a computer powered wire(less) ultra-intelligent real-time monitor. This monitor is comprised of a high speed electronic sensor/transmitter, a new battery operated repeater and battery charger, a receiver, and a new computer software program named FOURCAST SPControl/BioMediControl/SleepAnalyzer/Auditor (the main menu screen is shown). The object code (FOURCAST.ZIP) is included in this patent application on a single 3.5″ floppy disk. The sensor measures voltage pulses on the skin of a human being or animal. Any combination of separate clothing may be worn over the sensor/transmitter. Each pulse corresponds to a heartbeat. Various sensors can be used to measure different variables, including but not limited to biological heart rate, oxygen saturation, blood pressure, blood sugar, brain waves, temperature, industrial electrical voltage, electrical current, temperature, speed etc., and create analog data representing those variables. Such analog data are transmitted by existing and new hardwire or very low power 5 KHz wireless means to existing and new electronic analog to digital converters where they are converted to digital serial binary coded data. Such digital data are transmitted to an existing or new receiver, then to an existing or new computer where they are analyzed and charted.
[0125] [0125]FIG. 2 shows the schematic diagrams for a very low power short range transmission monitor (FIG. 2)-A, a very low power long range transmission monitor (FIG. 2)-B, and a power supply & dc voltage level amplifier for the data receiver (FIG. 2)-C. Digital data are transmitted by 5 KHz wireless (FIG. 2)-A or 900 MHz band wireless repeater (FIG. 2)-B means, to the receiver, then to the computer, at its serial port by means of an existing or new DB9 or DB25 plug or other plugs and adapters. The wireless receiver (5 KHz or 900 MHz) is powered from the serial port of the computer by a special electronic interfacing device (FIG. 2)-C, so that no batteries are required. The interfacing device rectifies the serial port pin voltages so as to provide a positive operating supply voltage to the receiver. It also amplifies the direct current (dc) signal from the receiver so that the voltage entering the serial port is correct and adequate to operate the serial port. Ordinarily, it is possible for all of the available serial port pin voltages to be negative, in which case no positive voltage can be obtained and the receiver cannot operate. The computer software program embodied in the invention, and described below, manipulates the voltages at DB9 plug pins 3, 4 & 7 or DB25 plug pins 2, 20 & 4 in an innovative way so as to cause a positive voltage to occur at one or more of the pins.
[0126] Data may also be entered into the computer directly via a computer keyboard. Data may also be imported from a data file created by another application, or copied from the screen of the computer or downloaded from another particular computer or from the internet.
[0127] Computer Software Program Data Storage and Display
[0128] The computer executes the software program under existing and new upwardly compatible versions of the operating systems: Windows 3.1, 95, 98, 2000, NT, XP or ME. The program reads the data, deciphers any associated security transmission codes, accepts only data with the same transmission code, separates, arranges and places the data into individual files, one for each variable. These files are then read, and the data in them analyzed. In that way if the files are updated by any of the means described above or by any other means whatsoever, the program will always analyze current data. The program analyzes the data by a new method named “moving window spectral antithetic time series analysis,”,which is described below in the sub section titled “mathematical operations.”
[0129] FIGS. 3 -A, 3 -B, 3 -C & 3 -D illustrate that the program displays aggregate historical data (FIG. 3-A), as well as data split into uniquely new unbiased common cause effects and special cause effects (FIGS. 3 -B, 3 -C & 3 -D). The aggregate data approach (FIG. 3-A) is comparable to the traditional method of standard statistical process control.
[0130] [0130]FIG. 3-B shows the splitting of biological vital signs data. The data are continuously updated regardless of the size of the pulse measurement. Breaches of the common cause chart (CCC) are attributed to systematic recurring internal biological common causes that are to be treated accordingly. Breaches of the special cause chart (SCC) are attributed to one of a kind external environmental special causes, that are to be removed if harmful. They may also be the effect of a one time application of a medication, the effect of which will eventually work itself into the common cause chart.
[0131] [0131]FIG. 3-C shows the splitting of industrial process measurement data. The data are continuously updated until there is a breach of either chart, and the process is stopped to prevent the production of defective items. Breaches of the common cause chart (CCC), are attributed to systematic recurring internal machine common causes, such as a worn part that is to be located and replaced. Breaches of the special cause chart (SCC), are attributed to one of a kind external environmental special causes, such as a batch of raw material.
[0132] [0132]FIG. 3-D shows the splitting of accounting cash flow data. The data are continuously updated regardless. The common cause chart (CCC) patterns are attributed to systematic changes such as those due to seasonality. Breaches of the special cause chart (SCC), are attributed to one of a kind expenditures, to be investigated so as to determine if they were authorized.
[0133] Computer Generated Charts
[0134] [0134]FIG. 4-A is a simple history chart of PULSE measured in beats per minute. The normal range for the category of person being monitored in this case is 55-95 beats per minute. The chart does not indicate any abnormal condition. Such a chart may be selected and produced by the new computer program in this invention, except that it would contain more data, such as that appearing on the more advanced common cause and special cause charts, described next.
[0135] FIGS. 4 -B, 4 -C, 4 -D & 4 -E illustrate how the data in FIG. 4-A are spilt into common cause variations and special cause variations, and displayed on the computer screen. Two sets of dual common cause variations and special cause variations charts are displayed. One set is displayed in terms of the original units of the data and the other set is displayed in terms of standard deviations from the mean of the original data. The methodology for creating the dual common cause variations and special cause variations charts is an innovation that is central and unique to the invention. Also, the invention gains its practical utility from the new information that is conveyed by the new unbiased dual common cause variations and special cause variations charts, the devices operated by the program, and the decisions made and the actions taken by the program and the user of the program. The common cause variations and the special cause variations data are also written to separate disk files where they can be read by other computer programs and used to manipulate and control other devices and processes. Such other computer programs may be activated independently or activated by the program embodied in the invention.
[0136] Each chart is labeled with
[0137] the heading common cause variations or special cause variations as the case may be
[0138] the name of the variable plotted on the chart
[0139] the current time and date
[0140] the time, date and number of the earliest and latest data points
[0141] the time interval between plotted data points
[0142] the value of the most recent data point
[0143] the units of the data plotted on the chart
[0144] user selected upper and lower control limits in terms of the original data and standard deviations
[0145] the greatest percentage change in the data from the lowest value to the highest value or vice versa summary statistics including
[0146] the Chi Squared statistic and test result for normality in the distribution of the data
[0147] mean
[0148] root mean square deviation
[0149] minimum value
[0150] maximum value
[0151] control limits in units of original data and equivalent standard deviations
[0152] control limits in units of standard deviations and equivalent in original data units
[0153] number and percentage of breaches of the upper control limit
[0154] number and percentage of breaches of the lower control limit
[0155] Each breach is marked and numbered with the data point reference number. The charts contain 4 menu selections that permit selective and immediate spontaneous on the fly operations. ‘Print’ enables printing/faxing. ‘Edit’ enables copy/cut and past into another application like a word processor where a report can be produced and further edited and/or emailing to a remote location via a local area network or world wide via the internet. ‘Customize’ enables a custom multiple chart arrangement sub menu as follows: cascade (partially overlaping), full screen (one chart at a time rotating between charts) and layout (all charts on one screen). ‘Transformations’ enables mathematical transformations.
[0156] [0156]FIG. 4-B shows chart breaches— 83 & 167 of the 55 beats per minute lower control limit. This indicates that with random effects removed, a systematic condition exists which is abnormal for the category in which the person being monitored belongs.
[0157] [0157]FIG. 4-C shows a chart breach— 167 of the 3 standard deviation lower control limit. This indicates that with random effects removed, a systematic condition exists which is abnormal for the individual being monitored.
[0158] Complete List of the Program Menus
[0159] The following main and sub menus are used to direct various program operations that facilitate the main functions of the program that are describe above. Additional sub and sub-sub menus can be viewed by clicking on the main selection with the mouse. The immediately relevant menu selections [customize, communications (monitor) and stop] and the preferred mode of operation are described further, below, in the section titled “OPERATION.”
[0160] Main menu: File. Edit. File Operations. Data Conversion/Importation. Communications (monitor). Calculate. Report. Customize. Help. Readme. Stop. Start Keyborad macro. Reset/Close/Record. Save Keyboard macro.
[0161] Sub menus:
[0162] File: Create input data. Open/Import (list/update input data). Run description. Specify variables. Plot variables [Graphics(looking for trends). Detailed (for data checking). Histogram (data distribution)]. Print all output windows displayed. Look at (edit) any file/directory. Erase a file. Exit.
[0163] Edit: Cut. Copy. Paste.
[0164] File Operations: Transformations [M moving average. Cumulative (inv. of D). Differencing (inv. of C). Aggregate]. Multiply the contents of two files. Add the contents of two files. Subtract one file from another. Divide one file into another. Take reciprocals of a file. Exponentiate a file. Divide by time. Divide by square root of time. Take natural logs of a file. Take logs (base 10) of a file. Take inverse natural logs of a file. Take inverse logs (base 10) of a file. Multiply a file by a constant. Divide a file by a constant. Add a constant to a file.
[0165] Data Conversion/Importation: MSDOS prompt. Convert non-standard file to FOURCAST.
[0166] Communications (monitor): Automatic logon. Edit automatic logon file. Monitor [select a chart code (0,1,2,3,4,5,6). Select an option (C-create. S-resume. R-restore)]. Create/edit small communications file.
[0167] Calculate: Model parameters.
[0168] Report: Model parameters. Plot special cause chart (residuals). Plot common cause chart (fitted values). Histogram of residuals. Histogram of fitted values. Review current output text.
[0169] Customize: FOURCAST. SPControl. BioMediControl. SleepAnalyzer. Auditor. As before in last session. Font style and color. Background color. Save for next session. Personalized legend.
[0170] Help: What is FOURCAST SPControl/BioMediControl/SleepAnalyzer/Auditor ? View on screen. Demonstration macros. Creating input data. Updating input data. Output. Printing. About FOURCAST SPControl/BioMediControl/SleepAnalyzer/Auditor. Shareware registration.
[0171] Readme:
[0172] Stop. Do you want to print all charts? Yes. No. Do you wish to terminate monitor ? Yes. No.
[0173] Start Keyborad macro: Preset teaching demonstration macros. User recorded macros.
[0174] Reset/Close/Record: Start/restart keyboard macro recording. Customize record/playback options. Clear/close all windows.
[0175] Save Keyboard macro: End user recording of a macro and save it.
[0176] Operation
[0177] Before the user can use the computer powered wire(less) ultra-intelligent real-time monitor, user supplied computer equipment and related utility software must be installed as follows. Install a computer. Install a mouse if menu selections are to be made by using the mouse. Install a printer and standard 8.5″×11″ paper if the printing features of the program are to be used. Install a modem and make arrangements for internet email services and telephone services, and install the related software if the Fax/Email and Telephone-Caller ID alarm features of the program are to be used. Plug the modem into a telephone wall receptacle. Turn on the computer and start the windows operating system. Install the software program winzip. The computer, mouse, printer, paper, modem, internet services, telephone wall receptacle, windows, and winzip are commonly, readily and easily available items, provided separately by the user. If winzip is unavailable an unzipped arrangement of the program files is available on floppy disk.
[0178] For Short Range Operation Install the Short Range Receiver as Follows
[0179] Select the short range 5 KHz receiver. Insert the DB9 plug (or other appropriate plug and/or connector) into the serial port of the computer. Place the receiver box at least one foot away from the computer or any other device that might interfere with its operation. The operating range of the transmitter and receiver is the responsibility of the manufacturer and not this invention. As per the recommendation of the manufacturer of the transmitter and receiver, place the receiver within 3 feet of the transmitter. The maximum distance of 3 feet assumes optimal orientation and electromagnetic environmental conditions. Therefore, under many actual circumstances, a shorter distance will be necessary to insure proper operation.
[0180] The application being described in this example is one in which the user is relatively stationary, such as when they are lying down and/or sleeping. In this case, the preferred location of the receiver is directly below the chest area, under the mattress, and centered between the sides of the bed on which the user is lying. Then, the user can roll on the bed and still remain within the operating range.
[0181] If the monitor is being used in a nursery or other multiple client facility, security is of paramount importance. Therefore, the beds or other monitoring stations should be well in excess of 3 feet apart. Furthermore, only coded transmitters should be used.
[0182] For Long Range Operation Install the Long Range Receiver as Follows
[0183] Select the long range 900 MHz band receiver. Insert the DB9 plug (or other appropriate plug and/or connector) into the serial port of the computer. Place the receiver box at least one foot away from the computer or any other device that might interfere with its operation. Select one of the available channels by setting the 3 pole dip switch on the repeater box and make the identical selection on the receiver box. Plug the battery charger into a 120V receptacle, and into the charging jack of the repeater. Use the lighted LED switch on the repeater to turn it on. The LED glows in the on position. The operating range of the transmitter and receiver is the responsibility of the manufacturer and not this invention. As per the recommendation of the manufacturer of the transmitter and receiver, place the repeater within 3 feet of the transmitter. The maximum distance of 3 feet assumes optimal orientation and electromagnetic environmental conditions. Therefore, under many actual circumstances, a shorter distance will be necessary to insure proper operation. If the battery is charged, then the charger may be unplugged from the repeater. The user of the sensor/transmitter and the repeater, moving together may travel away from the receiver, but, as per the recommendation of the manufacturer of the transmitter and receiver, no farther than 1000 feet. The maximum distance of 1000 feet is based on an assumption that optional external antennae are installed on the repeater and the receiver, and optimal orientation and electromagnetic environmental conditions. Therefore, under many actual circumstances, a shorter distance will be necessary to insure proper operation. The repeater and receiver are provided with internal loop antennae for which the specified operating distance is a maximum of 400 feet. This maximum distance of 400 feet is based on an assumption that the provided internal loop antennae is installed in the repeater and the receiver, and optimal orientation and electromagnetic environmental conditions. Therefore, under many actual circumstances, a shorter distance will be necessary to insure proper operation.
[0184] The application being described in this example is one in which the user of the sensor/transmitter seeks mobility in and around a house. As an example, consider a square, one level, 5000 square foot house. The maximum distance that could be required is only 100 feet. If the house is built on two levels, the maximum distance required is only 50 feet. Such a house is very large and well above average in size. Therefore, the normal range of 400 feet is expected to meet and exceed most if not all such needs. If the user chooses to travel outside the house, then the actual range is limited to whatever the prevailing conditions will bear. If the battery in the repeater discharges, the user and the repeater must return together to the location of the charger, where the charger must be plugged into the charging jack of the repeater.
[0185] The application being described in this example is one in which at certain times, the user is relatively stationary, such as when they are lying down and/or sleeping. In this case, the preferred location of the repeater is directly below the chest area, under the mattress, and centered between the sides of the bed on which the user is lying. Then, the user can roll on the bed and still remain within the operating range. The battery inside the repeater may discharge during the period when the user is asleep. Therefore, the preferred location of the charger is near the bed in which the user lies down to sleep, and plugged into the repeater. When the user awakes and is ready to travel away from the bed, the charger is unplugged from the repeater. The user can then travel with the repeater as described above.
[0186] Installing the Computer Program
[0187] The program is installed as follows:
[0188] 1. Execute winzip to expand (unzip) FOURCAST.ZIP into its component parts, including the object codes FOURCAST.EXE, SETUP.EXE, and other related files, object codes, and a run time module.
[0189] 2. Execute the program SETUP.EXE to install FOURCAST.EXE.
[0190] 3. Execute the program FOURCAST.EXE to obtain the initial screen (FIG. 1) and operating menus.
[0191] Computer Program Customization
[0192] In addition to the unique methodological innovation of moving window spectral antithetic time series analysis and the dual common cause variations and special cause variations charts, the program calculates and creates new and unique practical decision making diagnostic support information. It also features a sophisticated and progressive alarm system that maximizes the state of the art in wireless and computer technology, including sound, color, print/fax/email, and a telephone-caller ID alarm. To help explain these features and their importance, consider first the options available to the user. Some of these options are related to the computational methodology which is described below in the sub section titled “mathematical operations.”
[0193] Click on the main menu item CUSTOMIZE, and customize the program features by making the following menu selections:
[0194] a) The type of monitor, based on the monitoring activity to be performed. The choices are FOURCAST where the specific data type are unknown, SPControl for monitoring industrial data, BioMediControl for monitoring biological data, SleepAnalyzer for monitoring sleep data and Auditor for monitoring accounting and financial data. For example, if the type of monitor selected is BioMediControl, the options are as follows.
[0195] b) Names and/or labels that appear as a legend on all charts and text associated with the chart data.
[0196] c) The electronic sensor/transmitter used to measure the variables that are to be monitored.
[0197] d) An industry or human population group classification and its associated upper and lower values within which normal conditions are considered to exist. The default classifications for the human population include but are not limited to the following. For oxygen saturation, 94% to 100% for all human beings, where % mean percent.
[0198] For heart rate
[0199] in newborn infants, 70-170 bpm
[0200] infants 1 year old, 80-160 bpm
[0201] 1-2 years old, 80-130 bpm
[0202] 2-4 years old, 80-120 bpm
[0203] 4-6 years old, 75-115 bpm
[0204] 6-10 years old, 70-110 bpm
[0205] males 10-12 years old, 65-105 bpm
[0206] females 10-12 years old, 70-110 bpm
[0207] males 12-14 years old, 60-100 bpm
[0208] females 12-14 years old, 65-105 bpm
[0209] males 14-16 years old, 55-95 bpm
[0210] females 14-16 years old, 60-100 bpm
[0211] males 16 years and older, 50-90 bpm
[0212] females 16 years and older, 55-95 bpm
[0213] where bpm means beats per minute. The upper and lower values of each group may be edited separately within the program by opening the file in which the above selection is stored. The program gives instructions for doing that.
[0214] e) Yes, to turn on the automatic Print/Fax/Email alarm, otherwise No.
[0215] f) The maximum number of standard deviations within which normal conditions are considered to exist.
[0216] g) The criterion for activating the automatic alarm. Selection “t” sets the criterion to the length of time for which an abnormal condition exists. Selection “n” sets the criterion to the number of times that consecutive data values fall outside the range specified for normal conditions.
[0217] h) If the time criterion “t” is selected, the threshold time for which an abnormal condition must exist before the print/fax/email and telephone caller-ID alarm are initiated. If the number criterion “n” is selected, the number of consecutive times that the range specified for normal conditions is exceeded before the print/fax/email and telephone caller-ID alarm are initiated.
[0218] i) The viewing time, from 1 to 10 seconds per chart, between when the charts are to be updated. Data are collected as they occur, possibly at shorter intervals, and held in memory for periodic updating of the charts.
[0219] j) The time length, in minutes, of historical data to be displayed on each chart, limited only by the ability of the computer to store data. The default sampling interval of 1 may be increased. Upon request, observations are grouped and averaged as necessary so as to span the history that is requested. It may be necessary to display more data than actually requested so as to make each group equal in size.
[0220] k) The shortest window length, longest window length, and increment to select the optimal multivariate moving window spectral antithetic time series model that will analyze the data and split it into common cause effects and special cause effects for display on the dual common cause variations and special cause variations charts.
[0221] l) The differencing and antithetic times series analysis options for selecting the optimal multivariate moving window spectral antithetic time series model.
[0222] m) The communications protocol used for reading data from the automatic measuring sensors that collect data to be monitored. These include the identification number of the serial communications port, the communicating speed or baud rate in bits per second, the data byte size in bits per byte, and the number of start and stop bits. The telephone number that the computer will dial, the email message, and the communications protocol, in case the telephone-caller ID alarm is initiated.
[0223] n) The names of the variables to be monitored. In the case of certain measuring sensors, the names are automatically supplied by the program, in accordance with the type of sensor. For example, in the case for a heart rate sensor, the name defaults to PULSEbpm. In the case of a pulse oximeter, the names default to SPO2% and PULSEbpm. The names may be edited.
[0224] o) A run description that describes the nature of the monitoring activity, and appears as a legend on all charts and text associated with the chart data.
[0225] p) The program automatically supplies a run description. For example if BioMediControl was selected, the run description will default to “FOURCAST BioMediControl.” The run description may be edited.
[0226] Starting the Monitor
[0227] Select the main menu item COMMUNICATIONS (MONITOR). Select the type or types of charts to be plotted from:
[0228] 0-History only
[0229] 1-History & standard deviations
[0230] 2-Special cause
[0231] 3-Common cause
[0232] 4-History & special cause
[0233] 5-History & common cause
[0234] 6-Special cause & common cause
[0235] where selection 2 through 6 include standard deviations. Select one of the following:
[0236] c—to create new charts. Data from the last session will be copied to a backup file.
[0237] s—to resume updating of already existing charts from the last session.
[0238] r—to restore the charts from the backup files, and resume updating of the restored charts.
[0239] Before installing the sensor, check the connection between the receiver and the computer as follows. Start the monitor and select “c” to create a new chart. After a about 5 seconds, with no signal from the transmitter, a “O” followed by the time and date should appear at the top left hand corner of the data display area of the screen.
[0240] Installing the Sensor
[0241] Place the wireless Sensor/Transmitter and chest strap pictured in FIG. 1 around the chest of the human body so that the plastic part is at the front on the chest and the strap is at the back of the chest. Adjust the strap for a firm but comfortable fit. Use water to moisten the part of the plastic that is in contact with the skin of the user. The Sensor/Transmitter will automatically sense a voltage pulse each time the heart beats, and transmit a signal to the 5 KHz receiver.
[0242] Continuous Updating of the Charts
[0243] Consider for example, selection “c” to create new charts and chart selection “6” to plot special cause & common cause charts. The program automatically opens the serial port of the computer, reads the data at the port and creates the charts (FIGS. 4 -B, 4 -C, 4 -D & 4 -E). The program continuously reads the sensor data arriving at the serial port and updates the charts. A new plot is made at each update. The values updated are:
[0244] the current time and date
[0245] the time, date and number of the earliest and latest data points
[0246] the time interval between plotted data points
[0247] the value of the most recent data point
[0248] the units of the data plotted on the chart
[0249] the user selected upper and lower control limits in terms of the original data
[0250] the user selected upper and lower control limits in terms of standard deviations from the mean
[0251] the greatest percentage change in the data, from the lowest value to the highest value or vice versa
[0252] summary statistics including
[0253] the Chi Squared statistic and test result for normality in the distribution of the data
[0254] mean
[0255] root mean square deviation
[0256] minimum value
[0257] maximum value
[0258] control limits in units of original data and equivalent standard deviations
[0259] control limits in units of standard deviations and equivalent in original data units
[0260] number and percentage of breaches of the upper control limit
[0261] number and percentage of breaches of the lower control limit
[0262] Each breach is marked and numbered with the data point reference number.
[0263] Progressive Alarm Systems
[0264] Under normal conditions, defined as data points falling between the upper and lower control limits, the color of the charts is white. If at any time a data point falls above the upper control limit or below the lower control limit, an abnormal condition exists, and there is an alarm as follows. A single breach of the control limits results in a sound alarm and a blue screen, and the beaching point is marked with the number of the observation for reference. If the condition returns to normal, the sound stops and the screen returns to white. Two consecutive breaches will sound the alarm and turn the screen yellow for caution. Three breaches will sound the alarm and turn the screen red to signal danger. The home user and/or an attending observer such as a friend or family member is alerted to give assistance. By adding external speakers, a mother can hear the computer sound alarm from anywhere in the house, and respond to her baby. In an institution, a professional caregiver is alerted to investigate a biological condition. Once again if the condition returns to normal, by itself or due to intervention, the sound alarm stops and the screen returns to white. If the screen remains red for a period of time longer than the period specified in the computer program customization menu item h above, the program will continue the sound and color graphics alarms. However, it will also initiate the Print/Fax/Email alarm, dial and send a telephone alert, and a caller ID to the telephone number specified in the computer program customization menu item m above. This permits a professional caregiver to read the charts from anywhere in the world. Through existing local area networking methods, a computer located at a central station can display the screen of any one of several bedside computers where the program is running and charting the data.
[0265] If the data transmission code changes and therefore cannot be verified, the data are ignored. If verifiable data ceases to arrive at the serial port due to a disconnect or an out of range transmitter, the sound alarm, red color alarm and telephone caller-ID alarm are initiated. A screen message “NO SIGNAL” will appear. Changing the antennae circuit so as to limit the transmission range will limit the radius within which the user may travel before the alarm is activated.
[0266] Stopping the Monitor
[0267] The monitor is stopped by clicking on the stop icon, then selecting YES to print all charts or NO otherwise, then selecting YES to terminate the monitor.
[0268] Mathematical Operations: Moving Window Spectral Antithetic (MWSA) Time Series Model
[0269] The MWSA algorithm is a particular method of time series analysis. It may be viewed as performing a decomposition of a stationary time series into component cycles. It is based on modeling in the frequency domain. It is assumed that the time series is comprised of a family of several hidden cyclical components as depicted in FIG. 5. While it may be relatively easy to observe a simple trend, it becomes increasingly difficult to sort out and assess the interaction of several component cycles as the number of cycles increases. A mathematical model can assist in representing the component cycles, and in measuring the way in which the cycles may be changing, both in amplitude and phase, over time.
[0270] Consider the continuous process variable measured by the sensor/transmitter at discrete time intervals, represented as the time series y(t), t=1,2, . . . , n. The time series is assumed to contain trend, constant frequency periodic (cyclical), and random components. In order to estimate the correlation structure of y(t), a moving window of length T<n is defined in the time domain. The moving window is used to generate sequences of data points in the time domain: y(1) to y(T), y(2) to y(T+1) , . . . ,y(n−T+1) to y(n). Each pair of adjacent windows in the sequence contains an observation on the input and output process for each frequency in the frequency domain. This creates multiple observations for obtaining least squares estimates of the parameters that describe the behavior of the component cycles over time. The time series is assumed to contain a fundamental cycle of period T as well as other shorter cycles having frequencies that are multiples of the fundamental frequency. The window length T is chosen to obtain the best fit (minimum means square error) of a Tth order discrete autoregressive time domain model given by:
y ( t )=Σ k=1 T y ( t−k ) b ( k )+ε( t ), t=T+ 1 , T+ 2 , T+ 3, . . . , ∞
[0271] where
[0272] b(k)=parameter, coefficient of y lagged k time periods, Σ k−1 T b(k)<∞, ∀T,
[0273] ε(t)=an unobservable error term, sequence of IID normally distributed random variables with mean zero and variance σ 2 .
[0274] Model Estimation
[0275] A Fourier transform is used to estimate the spectral density function for each window y(m−1+t), m=1,2, . . . ,n−T+1, from
Y m (ω)=Σ t=1 T y ( m− 1 +t ) exp (− iωt ), m= 1,2, . . . , n−T+ 1, −π<ω<π,
[0276] where m is the window number, and the index of the realization of a cycle at frequency ω, and i={square root}{square root over (−1)}.
[0277] The frequency domain model is specified as follows
Y m (ω)= Y m−1 (ω) B (ω)+ V m (ω), m= 2,3, . . . , n−T+ 1, −π<ω<π
[0278] where V m (ω) is the corresponding error term.
[0279] Assuming that the time series is stationary, then the random component cycles (random amplitude and phase) will be statistically independent (orthogonal). Then, the estimation of B(ω) can be conducted on a frequency by frequency basis. The least squares estimators of B(ω) are found from
{circumflex over (B)} (ω)=Σ m=2 n−T−1 Y′ a m−1 Y m (ω)/Σ m=2 n−T−1 |Y m−1 (ω)| 2 , −π<ω<π,
[0280] where ′ denotes the complex conjugate.
[0281] Model Fitting
[0282] Since the window length is T, the first fitted time period is T+1. Denoting the fitted values of y(t) by ŷ(t) and Y(ω) by Ŷ(ω), the fitted values in the frequency domain are obtained from
Ŷ m+1 (ω)=Y m (ω) {circumflex over (B)} (ω), m= 1,2, . . . , n−T+ 1, −π<ω<π,
[0283] which are inverse transformed to obtain the time domain fitted values
ŷ ( m+T−k)=( 1 /T )Σ ω=−π π Y m (ω) exp ( iωk ), m= 2,3, . . . ,n−T+1 , k= 1,2, . . . , T.
[0284] Rewrite these fitted values as follows
ŷ ( t ), t=T+ 1 ,T+ 2 ,T+ 3, . . . , n
[0285] Next, the antithetic time series process is applied to y(t), removing any bias that it may contain, as follows
ŷ c ( t )= wŷ ( t )+(1 −w ) ŷ ′( t ), t=T+ 1 ,T+ 2 ,T+ 3 . . . , n
[0286] where
y ^ ′ ( t ) = y _ + ( 1 - k n - t + 1 ) r ZZ P ( s z / s z P ) { z ^ t p - z _ p } ,
t=T− 1 ,T+ 2, T+ 3 , . . . ,n,
[0287] where
[0288] z(t)=y(t)+λ, the exponent of the power transformation is set to p=−0.001, and w, k and a location shifting constant λ are determined so as to minimize the mean square of the fitted error ŷ(t)−y(t), where y t are observed values, and s and r represent standard deviation and correlation coefficient respectively. These new unbiased fitted values ŷ c (t) are plotted on the new common cause variations chart.
[0289] Finally, the new special cause variations chart of residuals are obtained from
{circumflex over (ε)}( t )= ŷ c ( t )− y ( t ), t=T+ 1 ,T+ 2 ,T+ 3, . . . , n.
[0290] The major differences between the frequency domain MWSA method and time domain methods is that MWSA values are unbiased, and the way in which cycles are represented. In this MWSA frequency domain method, representation of cycles is automatic as they appear in the spectrum. Each cycle is allowed to vary in amplitude and phase. In time domain methods, cycles are modeled by backward shift operators, and each cycle is restricted to a constant amplitude and phase. Even so, specifying them is extremely tedious, even when only a small fraction of the full spectrum of cycles is to be represented.
CONCLUSION, RAMIFICATIONS, AND SCOPE
[0291] Accordingly, the reader will see that the computer powered wire(less) ultra-intelligent real-time monitor of this invention can be used to monitor any data that can be measured by an electronic sensor. It is a full featured, universal and versatile cost-effective device that can be used by anyone
[0292] in a home;
[0293] in a medical establishment;
[0294] in a manufacturing plant;
[0295] in a laboratory;
[0296] or by an auditor.
[0297] As a tool for professional use
[0298] It will provide early rather than late warning of abnormalities and impending failure;
[0299] it will greatly assist quality control engineers in reducing manufacturing cost and raising productivity;
[0300] it will help an auditor detect irregularities that might otherwise go unnoticed;
[0301] it will raise the quality and lower the cost of health care;
[0302] it will focus technician, nurse and physician time and effort on critical conditions and what led up to them;
[0303] it is an instrument that will greatly assist medical professionals in saving lives and making people well.
[0304] Although the description of the invention contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, biological vital sign data in a medical environment can be replaced by speed of a machine or temperature of a chemical bath in a manufacturing environment, or any appropriate data for any other environment in which monitoring is to be performed.
[0305] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | A device ( 1 )( 2 ) and method to monitor, in real time, one or more variables by an at least 2500 hour water proof sensor/transmitter, not requiring recharge, placed at the source where data are automatically collected and transmitted by wire or wireless means ( 2 A)( 2 B) to a battery-free computer-powered ( 2 C) receiver connected to a computer, where software continuously analyzes and charts the data. The software auto and cross correlates the variables, continuously updates and displays the data on simple aggregate charts ( 4 A) or decomposes the data and displays them on newly created common cause charts ( 4 B)( 4 C) of internal systematically related effects and newly created special cause charts ( 4 D)( 4 E) of external random unrelated effects, including summary data, and creates graduated progressive sound, color, print and world wide, fax, email and telephone alarm signals when the chart values exceed user specified limits, either in terms of actual units ( 4 B)( 4 D) or standard deviations ( 4 C)( 4 E), or when any particular pattern occurs. The device helps determine ahead of time, when the source of the monitored variables is functioning abnormally. Advance warning thus obtained, is used to initiate corrective action ( 3 A)( 3 B)( 3 C)( 3 D) so as to prevent failure at the source that is generating the variables. Examples of failure that it helps prevent include but are not limited to, sudden infant death due to sudden infant death syndrome in human babies, heart or respiratory failure in any human being who is either at rest or moving around within a specified area, failure in industrial machines or measuring equipment, manufacturing defects and financial irregularities. | 6 |
BACKGROUND OF THE INVENTION
The invention relates generally to roll apparatus for treating webs of material and, more particularly, to an improved quick release device for separating individual rollers of the apparatus.
A roll apparatus having a quick release device is disclosed in DE-PS 3622398, which shows a calender equipped with a quick release device permitting adjacent rollers to be separated from each other to avoid damaging a "soft" roller should a defect in the paper web, for example, a fold or a tear appear. A "soft" roller, as known in the art, is a roller provided with an elastic covering, such as paper or plastic. At least the bottom roll in such a calender is constructed as hydraulically supported roll in which a hollow cylinder rotates about a stationary crosshead and is supported on the crosshead by a hydraulic supporting device, which produces the line pressure. The crosshead is supported at its distal ends, which project from the hollow cylinder, by hydraulic force exerting devices comprising hydraulic cylinders. During operation, the crosshead bends inside the hollow cylinder under the pressure transmitted to it by the hydraulic supporting device and, consequently, stores a quantity of elastic energy. Thus, at the same time, the crosshead is affected by the simultaneous action of two hydraulic devices, which are independent of each other. If, without the provision of any special measures, the pressure in the hydraulic supporting devices drops suddenly during a quick release action of the bottom roll and the elastic energy of the bent crosshead is released, very powerful strokes, i.e., movement of the crosshead within the cylinder, can occur, which may have a destructive effect upon the roll apparatus.
To counteract this effect, the hydraulic supporting device of DE-PS 3622398 is relieved according to a specific time sequence. The hydraulic supporting device in the hollow cylinder comprises a series of piston-like support elements, which are guided in cylinder bores in the crosshead and are pressed by hydrostatic pressure against the inner circumference of the hollow cylinder. To effect the quick release action, the pressure in the support elements is initially lowered, after which a pressure loss in the hydraulic force exerting devices occurs after an interval determined by a time delay element has passed.
The problem with such an arrangement is that the forces acting on the roller have a direct effect upon the quick release action, while controlling the pressures only has an indirect effect. Thus, even if the pressure in the hydraulic supporting device, i.e., in the individual support elements, has already dropped before quick release occurs, these elements still can transmit considerable forces. This is due to the fact that during a pressure relieving displacement of the support element friction occurs between the individual support elements and the crosshead. Therefore, for a moment, forces still act between the hollow cylinder and the crosshead, which can produce the undesirable and possibly destructive strokes of the crosshead.
SUMMARY OF THE INVENTION
The invention is directed to the problems of providing an improved quick release device in which a more direct control system is employed than heretofore used to relieve the outer hydraulic force exerting devices when the inner hydraulic support devices are relieved.
The invention solves this problem by providing a roll apparatus comprising a first roller having a rotatable hollow cylinder forming a working roll circumference at its outer diameter and a stationary crosshead extending lengthwise through said hollow cylinder to form a surrounding clearance space between an inner circumference of the hollow cylinder and an outer portion of the crosshead. The crosshead has ends projecting from the hollow cylinder and force exerting devices are provided for applying supporting forces to the ends of the crosshead. A hydraulic supporting device is provided in the clearance space for exerting forces against the inner circumference of the hollow cylinder to support same. A second roller is retained in a position above the first roller to form a roll nip therebetween. A quick release device is provided for selectively separating the first and second rollers by allowing movement of the first roller in a downward direction away from the second roller. The quick release device includes means for lowering the pressure of the hydraulic supporting device and a safety device reducing the magnitude of the supporting forces of the force exerting devices only after operation of the quick release device and in response to the load present at the ends of the crosshead being below a predetermined value.
In the apparatus of the invention, the pressure in the support elements no longer is the determining factor. Rather, the load at the end of the crosshead governs operation of the quick release device. This load has a direct effect upon the actual movement of the crosshead at the moment of quick release. When the force exerting devices are relieved and the crosshead no longer transmits any significant forces, undesirable strokes will no longer occur. Normally, such strokes result from remaining residual forces of this type.
In one embodiment of the invention, the safety device comprises a dynamometer disposed between the force exerting device and the corresponding end of the crosshead. As soon as the dynamometer signals a drop in the load at the crosshead end below a predetermined limiting value, the supporting force of the force exerting device is reduced abruptly to permit separation of the rollers. The invention is not restricted to use of hydraulically actuated force exerting devices, but these types of devices are preferred.
In another embodiment of invention the force exerting devices are hydraulically actuated through a valve whose position is controlled in response to signals from position sensors contacting the crosshead. A position sensor for a hollow cylinder is disclosed, per se, in DE-PS 3101429. A position sensor that contacts the crosshead is disclosed in DE-PS 3026865. However, in this document the sensor is employed in a system for controlling the position of the hollow cylinder relative to the crosshead. According to this embodiment of the invention, if the hydraulic supporting device is relieved, which is manifested by a pressure drop in the hydraulic force exerting devices, then, only after the pressure in the force exerting devices falls below a predetermined value, is the pressure in the force exerting devices also lowered. The quick release valve may be a solenoid valve operable upon a limit switch in the central control unit sensing a drop in pressure in the force exerting devices.
In a further embodiment, a sensor is provided for detecting the bending or deflection of the crosshead. The deflection and loading of the crosshead are directly related. For example, when the deflection equals zero, then the load also is zero. Therefore, the principles of the invention also are achieved with use of a control system operable in response to a sensor that detects the deflection of the crosshead. This sensor may comprise a position encoder or a strain gauge arrangement.
Further features, advantages and embodiments of the invention are apparent from consideration of the following detailed description, drawings and appended claims
BRIEF DESCRIPTION OF THE INVENTION
FIG. 1 shows a longitudinal side view of a calender stack in which the bottom roller is illustrated partly in section and the quick release control system of the invention is schematically represented.
FIGS. 2-3 show views similar to FIG. 1 in which further embodiments of the quick release control system of the invention are schematically illustrated.
DETAILED DESCRIPTION
The roll arrangement 100 of FIG. 1 comprises a calender having a bottom roller 1, above which a first top roller 2 and a second top roller 3 are arranged. The axes of the rollers 1, 2, 3 may all lie in a vertical plane. The rollers 1 and 2 form a roll nip 4 therebetween while the rollers 2 and 3 form a roll nip 5. In a calender, "hard" (e.g., having a outer steel surface) and "soft" (e.g., having an elastic covering) rollers generally are alternatinaly provided such that, e.g., if roller 2 were a soft roller, rollers 1 and 3 would be hard rollers. The calender 100 may comprise considerably more than the three rollers depicted. It is equally possible to provide only two cooperating rollers, in place of the depicted three rollers, for instance, as when a glazing calender is required.
All of these roll arrangements require a quick release device to immediately separate the cooperating rollers should a fault be present on the web, which is usually a paper web, to avoid mechanical damage to the soft roller of the roll pair. Such damage could occur if a twisted web were conducted through the nip. The quick release separation also prevents the elastic covering on a soft roller from overheating, which can occur if the web is torn and a heated hard roller directly abuts the soft roller or possibly, the heated hard roller comes to a stop next to the soft roller.
The bottom roller 1 is designed as a hydraulically supported roller having a rotatable hollow cylinder 6, which forms the working roller circumference at its outer diameter, and a stationary crosshead 7 extending through the hollow cylinder 6 to form an annular space between the inner circumference of the cylinder 6 and the outer circumference of the crosshead 7. In the illustrated embodiment, the hollow cylinder 6 is supported on the crosshead 7 at its ends by roller bearings 8. However, this is only one possible type of rotatable support arrangement. The embodiment of FIG. 3 illustrates an alternative support arrangement in which the entire hollow cylinder 6 is displaceable in the working plane relative to the crosshead 7. In FIG. 3, the cylinder 6 is supported, via bearings 9, on a guide ring 10, which is movable in the working plane in a slidable, but nonrotatable manner on the flat portions 11 of the crosshead.
In roll arrangement 100 of FIG. 1, the hydraulic supporting device for the hollow cylinder 6 comprises a sealed, longitudinal pressure chamber 12, which is formed on the side of the roll nip 4 in the annular clearance space between the inner circumference 13 of the hollow cylinder 6 and the top side of the crosshead 7. Chamber 12 is defined by longitudinal seals 14 provided on both sides of the crosshead 7 and transverse end seals 15 arranged near the distal ends of the hollow cylinder 6 at the inner side of the bearings 8. This hydraulic supporting device can be pressurized with hydraulic fluid through a supply duct 16 provided in the center of the crosshead. The fluid exerts a uniform pressure, over the length of the hollow cylinder 6 between the transverse end seals 15, against the inner circumference 13 of the hollow cylinder 6. With respect to the crosshead 7, this pressure produces a downwardly acting load distributed over the length of the crosshead, which causes the crosshead to bend in the middle due to the fixed support arrangement at the protruding ends 7'. Each of the force exerting devices 20 comprises a hydraulic cylinder 17 having a piston 18 and piston rod 19 having a top end bearing against one side of a dynamometer 21. The other side of dynamometer 21 is contacted by a bearing member 22, which receives a respective end 7' of the crosshead 7. The respective end 7' is arranged in a pivot bearing 23 within bearing member 22 to allow for deflection of the crosshead. The bearing members 22 are pressed upwardly until they contact end stops 41, which are fixed to the frame, to carry the roller 1 into its operating position.
The supply duct 16 of the longitudinal chamber 12 is supplied with hydraulic fluid via a conduit 24 from a pump 25 having its output side connected to conduit 24 and its return side drawing fluid from a supply or return tank 26. A bypass conduit 27 has one end connected to the conduit 24 downstream of the pump 25 and another end connected to the supply tank 26. A first quick release valve 28 disposed in conduit 27 is activated by an electromagnet or solenoid 29, which receives its operating signal from a control device (not shown) connected to line 30. Such a device, for example, may be an automatic web monitoring device or a manual switch, which is activated by an operator when an irregularity on the web is observed.
In cylinder 17 below piston 18 pressure chambers 31 of the force exerting devices 20 are connected via a conduit 32 to the output side of a pump 35, which draws fluid from the supply tank 26. Furthermore, a bypass conduit 33, which discharges into the supply tank 26, is connected to the conduit 32 downstream of pump 35. A second quick release valve 34 is disposed in conduit 33 and is activated by an electromagnet 36.
The signals from each dynamometer 21 are input over a respective line 37 into a central control unit 40, which also is connected via line 38 to line 30. Also, the central control unit 40 is connected with the electromagnet 36 of the second quick release valve 34 via line 39. The dynamometer 21, control unit 40 and second quick release valve 34 form the safety device of the roll arrangement 100.
When a signal to relieve the pressure of the hydraulic supporting device, i.e., of the hydraulic fluid in longitudinal chamber 12, is transmitted over the line 30, the first quick release valve 28 opens and the pressure in the longitudinal chamber 12 decreases due to the connection of conduit 27 to tank 26. The signal over line 30 also is provided to the central control unit 40 by the connecting line 38. Central control unit 40 transmits a signal over the line 39 to open the second quick release valve 34, only if the signals from the dynamometers 21 indicate that the loading of the crosshead 7 has fallen below a predetermined value, which value is adjustable by the central control unit 40.
In this manner, when the valve 28 is opened, the entire force provided by the force exerting devices 20 is prevented from suddenly acting upon the bearings 8 or, if the roller is provided with the rotatable support arrangement of FIG. 3, the crosshead 7 is prevented from abruptly shifting inside the hollow cylinder 6.
In the embodiments of FIGS. 2 and 3, corresponding parts are denoted with the same reference numbers. In the roll arrangement 200 of FIG. 2, the end stops 41 are eliminated and the position of the bottom roller 1 is hydraulically controlled. A valve 42, which may be rigidly attached to the force exerting device 20 and, consequently, to the frame of the machine, provides this hydraulic control. The slidable valve member of valve 42 is activated by a schematically shown connection 43, which contacts the crosshead 7 and may provide for mechanical, hydraulic or electric actuation of valve 42. An actuating surface is formed in the valve 42, which is operable to activate the valve to control the equilibrium position of the roller 1. Every time a deviation in the position of the crosshead 7 is detected and relayed through the connection 43 to the actuating surface, the valve 42 is operated to supply hydraulic fluid either to the surge chamber 31 of the force exerting device 20 or to the chamber on the piston rod side as the appropriate case may be. The valves 42 are connected to receive hydraulic fluid via conduit 44, which is connected to the pump 35.
Instead of using dynamometers 21, as provided in the roll arrangement 100, the central control unit 40' in this embodiment is connected by conduits 45 with a respective conduit 46, which is connected to the pressure chamber 31 of the respective force exerting device 20. The control unit 40' may comprise a limit switch arrangement. When a signal is sent over line 30 to operate first quick release valve 28 to relieve the pressure in longitudinal chamber 12, the second quick release valve 34 is activated only if the pressure in the pressure chambers 31, sensed via lines 46, has fallen below a predetermined value. Only then are the pressure chambers 31 relieved by the flow of fluid through the lines 47 and the open, second quick release valve 34 into supply tank 26.
The bottom roller 1' in the roll arrangement 300 of FIG. 3 has a different hydraulic supporting device than that illustrated in the roll arrangements 100 and 200. Namely, piston-like support elements 50 are distributed over the length of the hollow cylinder 6 and arranged in cylinder bores 51 provided on the top side of the crosshead 7. The supporting elements 50 face toward the roll nip 4 and have an appropriately shaped (i.e., curved to match the circumference 13) contact surface abutting against the inner circumference 13 of the hollow cylinder 6. The chambers formed below the support elements 50 and the bottom of cylinder bores 51 are supplied with hydraulic fluid via a supply duct 16 to press the support elements 50 against the inner circumference 13 of the hollow cylinder 6 to support the cylinder. Hydrostatic pressure chambers are formed in the contact surface of the support elements 50, which are supplied with hydraulic fluid from the cylinder chamber 51 through restrictor ducts 52. The support elements 50 may be adjustably pressurized with hydraulic fluid, either individually or in groups, and independently of each other, instead of jointly as illustrated in the bottom roller 1' of FIG. 3. This type of hydraulic support device may be provided in the roll arrangements 100 and 200 instead of the longitudinal pressure chamber 12.
The force exerting devices 20 of FIG. 3 correspond to those described in the roll arrangement 100. However, instead of the dynamometer 21, the roll arrangement 300 has a sensing device 53 to determine the deflection of the crosshead 7 at its ends 7'. Signals from sensor 53 are supplied over lines 54 to the central control unit 40", which, in a manner similar to the other described control units, only opens the second quick release valve 34 after a signal appears on the line 30 and the deflection of the ends 7' falls below a predetermined value.
In FIG. 3, two embodiments of the deflection sensor 53 are shown. In the first embodiment, a holder 55 is provided on the end of the piston rod 19 adjacent the bearing member 22 to project from the piston rod toward the hollow cylinder 6. Holder 55 receives at its end, for example, an inductive position encoder 56, which, along with its sensor pin 57, passes close to the end of the hollow cylinder 6. At some clearance from the piston rod 19 sensor pin 57 contacts the crosshead 7. Upon deflection of ends 7' of the crosshead 7, the point of contact shifts a small amount relative to the crosshead end 7' held in the bearing member 22, whereby the sensor pin 57 also shifts a small amount and generates a corresponding signal for the control unit 40" via stationary position encoder 56. Alternatively, strain gauges 58 may be provided as a deflection sensor. Gauges 58 are fixed to the outer (top) and/or the inner (bottom) bending side of the ends 7' of the crosshead 7. Gauges 58 are connected by a line 54', which may comprise several individual lines, to the control unit 40". In a manner known in the art, the strain gauges 58 form a strain bridge generating signals from which the deflection can be determined.
The control units 40, 40', 40" all are designed such that a releasing signal over the line 39 is not transmitted to the second quick release valve 34 until the signals from both end 7' of the crosshead 7 indicate that the load has been sufficiently removed. | A roll arrangement comprises a hydraulically supported bottom roller having rotating hollow cylinder and a stationary crosshead extending lengthwise through the cylinder to form a clearance space therewith. The end of the crosshead are supported by force exerting devices. The forces producing the line pressure of the roll are transferred through a hydraulic supporting device, such as hydraulic fluid contained within a longitudinal pressure chamber in the crosshead, to the inner circumference of the hollow cylinder. When a quick release action is desired to separate the bottom roller from its counterroll, the pressure in the longitudinal chamber is suddenly lowered by opening a quick release valve connected to a return tank. A corresponding reduction of the pressure in the force exerting devices to permit separation of the rollers occurs only after a sensor, such as a dynamometer, has determined that the load on the crosshead has been substantially removed. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to clock and data recovery systems and, more specifically, to integrator-based front ends and bang-bang phase detectors for clock and data recovery.
[0003] 2. Related Applications
[0004] The subject matter of this application is related to the subject matter of U.S. patent application Ser. No. 09/947,488, filed on Sep. 6, 2001 as attorney docket no. Larsson 25-1 (“Larsson 25-1”), and U.S. patent application Ser. No. 09/955,424, filed on Sep. 18, 2001 as attorney docket no. Larsson 26-13-2 (“Larsson 26-13-2”), the teachings of both of which are incorporated herein by reference.
[0005] 2. Description of the Related Art
[0006] High-speed (e.g., 2.5-3.125 Gb/s) serial links are commonly used for chip-to-chip interconnects in high-speed network systems. For example, synchronous optical network (SONET) OC- 768 applications may utilize 16 channels of 2.5 GB/s to support full duplex I/O of 40 GB/s. Many high-speed communications systems use asynchronous communication, where data is transmitted without a separate clock signal. Since a separate clock signal is not used, at a receiver side of a communications system, clock recovery circuitry is employed to extract intrinsic clock information from incoming data signals. Once extracted, the recovered clock is then used to re-time and regenerate the data originally transmitted. Such a clock and data recovery (CDR) circuit typically includes a voltage-controlled oscillator, a phase-locked loop (PLL), and/or a delay-locked loop (DLL) circuit as part of the clock recovery circuit, as well as deserialization logic as part of the data recovery circuit. Various techniques are used within CDR systems. Many of these are discussed in Sidiropoulos, S., and Horowitz, M., “A Semidigital Dual Delay-Locked Loop,” IEEE Journal of Solid-State Circuits, vol. 32, no. 11, November 1997, incorporated herein by reference.
[0007] Generally, CDR systems suffer from extreme sensitivity to clock skew between clock domains within the CDR circuit. This is because, in these systems, the goal is to generate recovered clock edges which are ideally located to allow registration of the incoming data at a point of maximum signal quality. Given the high-speed nature of these systems and the relatively low noise margin, even minor errors in the alignment of clock edges to data availability may result in erroneous data being captured. Managing this problem in the context of a typical GHz-rate deserializer requires extreme care to be used in matching of the clock paths and balancing of the clock distribution system. In a typical 10 GHz system, the allowable timing uncertainty when the system is set for maximum sensitivity can be as low as 5 ps. Alternatively, accepting a greater timing uncertainty reduces jitter tolerance due to degraded signal-to-noise ratio (SNR).
SUMMARY OF THE INVENTION
[0008] To address the above-discussed deficiencies of the prior art, clock and data recovery circuitry according to one embodiment of the present invention includes a four-way interleaved sampler, where each integrator in the sampler integrates the input data for two unit intervals (UIs) and each integrator is sampled at or near the middle of its two-UI integration cycle. In an exemplary 10-GHz system, the reset cycle of each integrator may begin many tens of picoseconds after the data is sampled. Since the signal is sampled near the center of the integration cycle and is not highly proximate to the time of the integrator reset, the latch signal has a window of uncertainty extending into the length of a data bit cell with little possibility of latching erroneous data. The sensitivity of the clock recovery circuitry may be optimized by centering the latch function over the time of highest signal level, thereby maximizing signal-to-noise ratio.
[0009] In one embodiment, the present invention is a method for recovering data from an input data stream. The method includes integrating the input data stream using multiple independent integrators that are operating out-of-phase relative to one another, wherein at least one integrator has an integration period of more than one unit interval (UI) and processing the output of each integrator to recover the data from the input data stream.
[0010] In one embodiment, the present invention is an apparatus for recovering data from an input data stream. The apparatus includes multiple independent integrators configured to integrate the input data stream, wherein the integrators operate out-of-phase relative to one another, wherein at least one integrator has an integration period of more than one unit interval (UI). It also includes circuitry configured to process the output of each integrator to recover the data from the input data stream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which:
[0012] [0012]FIG. 1 is a block diagram illustrating an asynchronous serializer/deserializer (SerDes) communications system in accordance with one embodiment of the present invention.
[0013] [0013]FIG. 2 is a top-level block diagram illustrating receiver 114 of FIG. 1.
[0014] [0014]FIG. 3 is a block diagram illustrating front-end 202 of FIG. 2.
[0015] [0015]FIG. 4 is a timing diagram of the signals associated with front-end 202 of FIG. 2.
[0016] [0016]FIG. 5 is a block diagram illustrating clock recovery circuit 206 of FIG. 2.
[0017] [0017]FIG. 6 is a block diagram illustrating the logic of phase detector (PD) 502 of FIG. 5.
[0018] [0018]FIG. 7 depicts TABLE 1 , which summarizes the logic of F/S logic gates 602 and 604 of FIG. 6.
DETAILED DESCRIPTION
[0019] Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
[0020] Note that, throughout this text and in the figures, a signal name with lowercase “p” or “n” appended to it, is used to indicate the “positive” or “negative” element, respectively, of a differential pair. Similarly, an uppercase “B” for “bar” appended to a signal name (potentially prior to an appended lowercase “p” or “n”) is used to indicate the inverted copy of that signal. Finally, an uppercase “Q” appended to a signal name indicates that it is the quadrature-phase (i.e., 90-degree) shifted version of that signal. For example CLK2I is the collective name for the differential signal pair consisting of CLK2Ip and CLK2In, CLK2IB is the inverted version of CLK2I, and CLK2QB is an inverted copy of the quadrature-phase shifted version of CLK2I.
[0021] Note also that, in FIGS. 1, 2, 3 , 5 , and 6 , dotted lines are used to represent differential signal pairs. For example, the dotted line labeled “Serial Data In” (SDIN) 112 in FIG. 1, represents, collectively, SDINp and SDINn, the positive and negative elements, respectively, of the differential pair SDIN 112 . Thick lines are used to designate a bus, while thin lines are used to indicate a single signal.
[0022] Serializer/Deserializer Systems
[0023] [0023]FIG. 1 is a block diagram illustrating an asynchronous serializer/deserializer (SerDes) communications system in accordance with one embodiment of the present invention. In FIG. 1, parallel transmit (XMT) data vector 102 is fed to transmitter 104 . Transmitter 104 receives the parallel data along with the differential transmission clock from transmitter-local voltage-controlled oscillator (VCO) and/or phase-locked loop (PLL) 106 . The transmitter loads the parallel data into a shift register and uses the I and Q clocks to generate a transmit clock, which is used to serially “clock-out” the contents of the shift register. The resulting serial data out 108 is output from transmitter 104 and transmitted across transmission medium 110 to receiver 114 . At receiver 114 , serial data in 112 is received, sampled with a local clock that is a function of I and Q clocks from receiver-local VCO/PLL 116 , and deserialized into parallel receive (RCV) data vector 118 , which is output along with RCV clock (PRC) 120 .
[0024] Receiver Overview
[0025] [0025]FIG. 2 is a top-level block diagram illustrating the internals of receiver 114 of FIG. 1. The receiver includes four major circuits: (1) front-end 202 , (2) data recovery circuit 204 , (3) clock recovery circuit 206 , and (4) local clock generator 208 . The receiver performs two major functions: (1) clock recovery and (2) data recovery. The clock recovery function is divided between front-end 202 , clock recovery block 206 , and local clock generator 208 as well as data recovery circuit 204 . The data recovery function is divided between front-end 202 and data recovery circuit 204 .
[0026] Essentially, the clock recovery function serves to generate one or more local sampling clocks that are phase and frequency synchronized with the data transitions of the incoming data. Front-end 202 serves, among other things, to sample the data transitions and integration results of the incoming data and provide this information to a phase detector within clock recovery circuit 206 . A delay-locked loop (DLL), also within clock recovery circuit 206 uses the outputs of the phase detector to create an adjusted version, MIXO, of the local reference I and Q clocks. Local clock generator circuit 208 (which is different from RCVR VCO/PLL 116 of FIG. 1) then uses MIXO to generate quarter-rate local sampling clocks CLK2I, CLK2IB, CLK2Q, and CLK2QB, and finally data recovery circuit 204 is used to divide down and further shift out the local sampling clocks to provide the parallel data receive clock PRC 120 .
[0027] In one possible implementation, front-end 202 and data recovery circuit 204 use these local sampling clocks to sample, synchronize, and demultiplex (i.e., deserialize) the incoming serial data to achieve 16-bit parallel differential receive data vector (PRD) 118 clocked at one-sixteenth the incoming serial data rate. In alternative implementations, PRD 118 may have a different number of bits per vector (e.g., 20 bits), and the output clock rate may be a different fraction of the incoming serial data rate (e.g., one-twentieth). In some implementations, the size and corresponding timing of the output may be configurable between two or more different sets of values (e.g., either 16-bit or 20-bit data).
[0028] Front-End
[0029] [0029]FIG. 3 is a block diagram illustrating front-end 202 of FIG. 2. As illustrated, front-end 202 includes four integration circuits 302 , 304 , 306 , and 308 and two edge samplers 310 and 312 , each of which receives SDIN 112 and one of the four clock signals generated by local clock generator 208 of FIG. 2. In addition, front-end 202 includes six latches 314 , 316 , 318 , 320 , 322 , and 324 , each of which receives a differential signal pair Si from a corresponding integrator or edge sampler, i=1 to 6. Each latch corresponding to an integrator outputs a different bit of 4-bit output data vector OD, and each latch corresponding to an edge sampler outputs a different bit of 2-bit output timing vector OT.
[0030] Integrators
[0031] An integrator functions by integrating an input signal while its clock input is high and holding its output in reset while its clock input is low. In FIG. 3, each of integrators 302 , 304 , 306 , and 308 integrates SDIN 112 corresponding to the period during which each integrator's corresponding integration clock is logic “1” and then holds its output in reset corresponding to the period during which each integrator's integration clock is logic “0.” The integration clocks for integrators 302 - 308 are CLK2I, CLK2Q, CLK2IB, and CLK2QB, respectively.
[0032] For example, INT 1 302 integrates SDIN 112 while the differential clock pair CLK2Ip and CLK2In (collectively represented by CLK2I) corresponds to logic “1.” This occurs when CLK2Ip is positive and CLK2In is negative. During this time, signal S1 reflects the integration of the voltage corresponding to SDIN 112 . When CLK2I corresponds to logic “0,” the output of INT 1 302 is held in reset. During this time, both S1p and S1n are held at, or near, 0 volts differential.
[0033] Since the integration clocks CLK2I, CLK2Q, CLK2IB, and CLK2IB are quarter-rate clocks, the high (and low) period for each integration clock is approximately two unit intervals (UIs). As such, the period of integration (and reset) for each integrator is also about two UIs. Since the integration clocks, by design, are phase aligned to SDN 112 data transitions, the result is that each integrator performs the integration of two sequential bits of SDN 112 at a time. Further, as a result of the relative phasing of the clocks chosen for each integrator, the integration periods for adjacent integrators are overlapped by about one UI. Note that if the integration clocks were only high for only one UI, then no such overlap would occur.
[0034] For example, referring to FIG. 4, SDINp is illustrated as a series 402 of data values {b1, b2, b3, b4, b5, . . .}, where b1 is both the first bit following the rising edge 404 of CLK2Ip as well as the first data bit into front-end 202 of FIG. 3. As illustrated in FIG. 4, when CLK2Ip is positive ( 406 ), INT 1 302 of FIG. 3 integrates the values of b1 and b2, resulting in the bell-shaped segment 408 of S1p, where S1p is seen to first rise to a maximum positive value corresponding to the integration of b1 of value “1,” and then slope back down to “0” corresponding to the integration of b2 of value “0.” Next, when CLK2Ip goes negative ( 410 ) corresponding to CLK2I being logic “0,” S1p is shown to be held in reset ( 412 ).
[0035] Similarly, when CLK2Qp is positive EH, INT 2 304 of FIG. 3 integrates the values of b2 and b3, resulting in the bell-shaped segment 416 of S2p, where S2p is seen to first fall to a maximum negative value corresponding to the integration of b2 of value “0,” and then slope back up to “0” corresponding to the integration of b3 of value “1” S2p is then held in reset when CLK2Qp is negative.
[0036] Similarly, as indicated by S3p in FIG. 4, INT 3 306 of FIG. 3 integrates bits b3 and b4 under control of CLK2IB, and, as indicated by S4p in FIG. 4, INT 4 308 of FIG. 3 integrates bits b4 and b5 under control of CLK2IB.
[0037] As indicated by features 418 and 420 of S3p in FIG. 4, integrating two consecutive “1” bits or two consecutive “0” bits results in saturation of the integrated signal. These maximum and minimum limits of integration correspond to the power supply rails of the integrating devices used in this implementation.
[0038] Only the positive elements of the differential signals are illustrated in FIG. 4. In all cases, it is assumed that the negative elements of the differential signals are substantially inverted copies of the positive elements of those signals.
[0039] Integrator latches
[0040] Each latch utilized in this invention operates by sampling its input on the rising edge of its corresponding input clock, mapping that sample to a logic high or low state, and driving and holding the resulting “registered” state to the latch output until a subsequent rising edge of the input clock causes a transition in the output state. Specifically, for the four latches associated with integrators in FIG. 3, LATCH 1 314 registers S1 on the rising edge of CLK2Q, LATCH 2 316 registers S2 on the rising edge of CLK2IB, LATCH 3 320 registers S3 on the rising edge of CLK2QB, and LATCH 4 320 registers S4 on the rising edge of CLK2I.
[0041] As shown in FIG. 4, registration for each of latches 314 - 320 occurs at or near the mid-point in the integration period of the corresponding integrator. For example, registration for LATCH 1 314 of FIG. 3 is triggered by the rising edge 422 of CLK2Qp, which occurs near the mid-point of segment 408 of the integration period for INT 1 302 of FIG. 3. By registering near the mid-point of each two-UI integration period, as opposed to, for example, registering at the end of a one-UI integration period, the system is more tolerant to skew between the integrator reset control and the corresponding registration clock.
[0042] As illustrated by FIG. 3, the combination of the four integrators and their corresponding latches functions as a 1:4 deserializer for SDIN 112 , from the serial format of SDIN 112 to a 4-bit “pseudo” parallel format, at one fourth the input data rate. As illustrated by FIG. 4, OD1p, OD2p, OD3p, and OD4p are quarter-rate representations of the serial input data SDIN bits b1, b2, b3, and b4. OD1p, OD2p, OD3p, and OD4p are overlapped in time such that a single quarter-rate clock can be used to register them in parallel and drive them onto a quarter-rate bus. As used in these discussions, the term “quarter-rate” is with respect to the data rate of SDIN 112 .
[0043] Edge Samplers and Latches
[0044] Edge samplers 310 and 312 of FIG. 3 register the data stream at certain data transition edges of SDIN 112 . EDGE 1 310 uses the rising edge of CLK2Qp to sample the data at the data transition point corresponding to the mid-point of integration for INT 1 302 , while EDGE 2 312 uses the rising edge of CLK2QBp to sample the data at the data transition point corresponding to the mid-point of integration for INT 3 306 . LATCH 6 322 and LATCH 7 324 use the rising edges of CLK2IB and CLK2I, respectively, to register the respective outputs S5 and S6 of the edge samplers to synchronize them and stabilize them relative to the local clocking system.
[0045] As illustrated in FIG. 4, OT1p is in alignment with OD2p, and OT2p is in alignment with OD4p. In FIG. 4, it is assumed that the edge sampler clocks CLK2Q and CLK2QB are early with respect to the data transition edges of SDIN 112 . The outputs thus reflect the value of data just prior to transition. For example, OT1 is “1” ( 424 ), because b1 is “1” ( 402 ) just prior to the rising edge of CLK2Qp. Similarly, OT2 is “1” ( 426 ), because b3 is “1” ( 428 ) just prior to the rising edge of CLK2QBp. If CLK2Qp had been late with respect to the data transition following b1, OT1 would be “0” corresponding to the value “0” ( 430 ) of b2. However, note that, if CLK2QBp had been late with respect to the data transition following b3, OT2 would still be “1” corresponding to the value “1” ( 432 ) of b4. The significance of these relationships is discussed in more detail in the subsequent section describing the operation of phase detector 502 of FIG. 5.
[0046] Data Recovery
[0047] Referring again to FIG. 2, front-end 202 provides the four-bit parallel signal OD (i.e., bits OD1-4 from latches 314 - 320 of FIG. 3) to data recovery circuit 204 , SYNC circuit 210 performs synchronization to the local sample clocks CLK2I, CLK2IB, CLK2Q, and CLK2QB producing a synchronized version SOC of the clock which will eventually be divided down to produce PRC 120 and a synchronized version SOD of data vector OD. DEMUX circuit 212 is configurable to perform either a further 1:4 deserialization or a 1:5 deserialization, resulting in 16-bit or 20-bit, respectively, parallel RCV data vector (PRD) 118 clocked at one-sixteenth or one-twentieth, respectively, the data rate of SDIN 112 .
[0048] Clock Recovery and Local Clock Generator
[0049] As discussed previously, in addition to processing SDIN 112 to produce 4-bit pseudo parallel output data vector OD, front-end 202 also performs edge sampling on SDIN 112 resulting in 2-bit output timing vector (OT). OD and OT both feed clock recovery circuit 206 . Here OD and OT are used by control logic within clock recovery circuit 206 to adjust the phase and frequency of output MIXO relative to local differential reference I and Q clocks from the local receiver VCO/PLL. MIXO is adjusted so that the local sampling clocks CLK2I, CLK1B, CLK2Q, and CLK2QB, generated by divide-by-two, invert, and quadrature-phase shift circuitry of local clock generator 208 , are substantially aligned with the data transition edges of SDIN 112 at front-end 202 .
[0050] Clock Recovery/DLL Background
[0051] Clock recovery circuit 206 is based on a delay-locked loop (DLL) that performs continuous phase shifting of local differential reference I and Q clocks from the local receiver VCO/PLL, to create local sampling clocks whose phase is aligned with the transition edges of input data SDIN. A voltage-controlled delay element is employed in a DLL circuit to achieve the delay. One specific element used to realize this voltage-controlled delay is an analog quadrature mixer. With such a mixer, a phase-shifted clock signal MIXO can be produced according to the following equation (1):
MIXO=VA·I+VB·Q (1)
[0052] where I and Q are the local in-phase and quadrature-phase input differential clock signals to the DLL, respectively, and VA and VB represent first and second differential voltage control signals, respectively, output from charge pumps that are under the control of a phase detector. The phase of output signal MIXO is thus directly controlled by the relative amplitudes of control signals VA and VB.
[0053] This general DLL technique has been employed in numerous conventional CDR systems including those described in Lee, T. H., Donnelly, K. S., et al., “A 2.5 V CMOS Delay-Locked Loop for an 18 Mbit, 500 Megabyte/s DRAM,” IEEE Journal of Solid-State Circuits (JSSC), vol. 29, no. 12, Dec. 12, 1994, incorporated herein by reference in its entirety.
[0054] Further improvements to allow smooth phase interpolation beyond the first quadrant are set forth in Larsson 25-1, Larsson 26-13-2, and in Yang, F., O'Neill, J., et al., “A 1.5V 86 mW/ch 8-Channel 622-3125 Mb/s/ch CMOS SerDes macrocell with Selectable Mux/Demux Ratio,” ISSCC 2002, Feb. 4, 2002 ( “Yang”), also incorporated herein by reference in its entirety.
[0055] Clock Recovery
[0056] [0056]FIG. 5 shows a block diagram of clock recovery circuit 206 of FIG. 2. As illustrated, circuit 206 includes phase detector (PD) 502 , quadrant controller (Q-CTRL) 504 , amplitude controller (A-CTRL) 506 , charge pumps CPI 508 and CPQ 510 , mixer bias circuit 512 , amplitude detector (A-DETECT) 516 , quadrant detector (Q-DETECT) 518 , and mixer 514 . Each of these elements is described in turn in the following sections.
[0057] Phase Detector
[0058] At a high level, PD 502 uses the information in 4-bit data vector OD and 2-bit timing vector OT to decide (on a clock-by-clock basis) whether the locally generated differential clocks CLK2I, CLK2IB, CLK2Q and CLK2QB, which are functions of the output MIXO of mixer 514 , are running faster or slower than the intrinsic clock implicit in data stream SDIN 112 . If it determines that the local clocks are running fast, the PD 502 asserts a positive pulse on non-differential signal CFAST to quadrant controller (Q-CTRL) 504 . Otherwise, if it determines that the local clocks are running slow, then PD 502 asserts a positive pulse on non-differential signal CSLOW to Q-CTRL 504 .
[0059] [0059]FIG. 6 illustrates the logic of CFAST and CSLOW generation performed by PD 502 of FIG. 5. Each of fast/slow (F/S) logic circuits 602 and 604 implements the logic of TABLE 1 of FIG. 7, where F/S logic circuit 602 is fed by OD1, OT1, and OD2, while F/S logic circuit 604 is fed by OD3, OT2, and OD4.
[0060] F/S logic circuits 602 and 604 independently determine whether the clock is fast or slow according to the logic in TABLE 1 and output their conclusions to OR gates 606 and 608 . F/S logic circuit 602 outputs (a) signal FASTI to FAST gate 606 and (b) signal SLOW1 to SLOW gate 608 . Similarly F/S LOGIC circuit 604 outputs (a) signal FAST2 to FAST gate 606 and (b) signal SLOW2 to SLOW gate 608 . Note that alternatively, the OR gates 606 and 608 could each be replaced with a 2 to 1 multiplexor switched to allow the active signals to pass, or equivalently, each OR gate could be replaced with a “wired OR” arrangement.
[0061] In TABLE 1 , the column headings indicate the input and output ports (and corresponding signals) for F/S logic circuits 602 and 604 of FIG. 6. For F/S logic circuit 602 , n=1 and m=1, while, for F/S logic circuit 604 , n=3 and m=2. In particular, for F/S logic 602 , port A receives OD1, port B receives OT1, port C receives OD2, port D provides FAST1, and port E provides SLOW1. Similarly, for F/S logic 604 , port A receives OD3, port B receives OT2, port C receives OD4, port D provides FAST2, and port E provides SLOW2.
[0062] Rows 1-8 of TABLE 1 correspond to the eight different possible combinations of input values to ports A, B, and C and the associated outputs provided at ports D and E.
[0063] To better understand the logic of TABLE 1 , it is useful to refer back to the signal timing diagram of FIG. 4 and the discussion of front-end 202 of FIG. 2. As illustrated by FIG. 4, and as discussed previously, certain segments, e.g., segments 434 and 436 , of the output signals OD1 and OD2, respectively, convey (in a manner timed appropriately for F/S logic 602 ) the logic states of bits b1 402 and b2 430 , respectively, of SDIN 112 to F/S logic 602 of FIG. 6. Furthermore, segment 424 of output signal OT1 conveys the logic state of SDIN 112 either just before or just after the transition between b1 and b2 to F/S logic 602 .
[0064] Similarly, certain segments, e.g., segments 438 and 440 , of the output signals OD2 and OD3, respectively, convey (in an appropriately timed manner) the logic states of bits b3 ( 428 ) and b4 ( 432 ), respectively, of SDIN 112 to F/S logic 604 of FIG. 6. Furthermore, segment 426 of output signal OT2 conveys the value of SDIN 112 either just before or just after the transition between b3 and b4 to F/S logic 604 .
[0065] If the local sample clocks are early (as indicated, in this case, by the location of rising edge 422 of CLK2Qp, which is used to sample the transition between b1 and b2), then OT1 will reflect the state of SDIN 112 just prior to its transition from b1 to b2, i.e., it will reflect the state of b1. If the local clocks are late, then OT1 will reflect the state of SDIN 112 just after its transition from b1 to b2, i.e., it will reflect the state of b2.
[0066] Similarly, for F/S logic 604 , if the local sample clocks are early (as indicated, in this case, by the location of the rising edge of CLK2QBp, which is used to sample the transition between b3 and b4), then OT2 will reflect the state of SDIN 112 just prior to its transition from b3 to b4, i.e., it will reflect the state of b3. If the local clocks are late, then OT2 will reflect the state of SDIN 112 just after its transition from b3 to b4, i.e., it will reflect the state of b3.
[0067] Thus, when the local clocks are early, the inputs at ports A and B will be equal, and, when the local clocks are late, the inputs at ports B and C will be equal. Referring again to TABLE 1 , rows 2 and 7 correspond to occurrences of early clocks, and rows 4 and 5 correspond to occurrences of late clocks. When the local clocks are early, the output at port D should be high, as indicated in rows 2 and 7, and, when the local clocks are late, the output at port E should be high, as indicated in rows 4 and 5.
[0068] If b1 equals b2, then OT1 is not used to indicate anything about the timing of the local clocks relative to the timing of the transition of SDIN 112 . Similarly, if b3 equals b4, then OT2 is not used to indicate anything about the timing of the local clocks relative to the timing of the transition of SDIN 112 . Thus, as indicated in TABLE 1 , rows 1, 3, 6, and 8, where the entries in columns A and C are equal, are commented with “don't care.” Note that it is possible for CFAST and CSLOW to be both true or both false at a particular point in time given the outputs of F/S logic 602 and 604 , but this does not constitute a violation of the operation of the system.
[0069] Quadrant Controller and Detector
[0070] Referring again to FIG. 5, Q-CTRL 504 receives (a) the CFAST and CSLOW signals from PD 502 and (b) quadrant information related to the current quadrant occupied by the local clock source MIXO from quadrant detector (Q-DETECT) 518 . Using this information, QCTRL 504 generates non-differential control signals UPVA, DNVA, UPVB, and DNVB, which are driven to amplitude controller (A-CTRL) 506 . The outputs provided by Q-CTRL 504 to ACTRL 506 are directed to ultimately control the voltages of four-quadrant mixer 514 subject to the voltage limits imposed by A-CTRL 506 . Q-CTRL 504 is used to update the UPVA, DNVA, UPVB, and DNVB signals so that VA and VB are increased or decreased appropriately, depending on the quadrant in which the output signal vector MIXO is currently located.
[0071] Amplitude Controller, Detector and Charge Pumps
[0072] A-CTRL 506 uses the outputs of Q-CTRL 504 , in addition to information from amplitude detector (A-DETECT) 516 , to determine whether the in-phase and quadrature signal charge pumps, CPI 508 and CPQ 510 , respectively, should be charged or discharged.
[0073] The outputs of charge pumps CPI 508 and CPQ 510 are driven to A-DETECT 516 , which compares these values with locally generated reference voltages VMAX and VMIN to determine the amplitude control to feedback to A-CTRL 506 . Essentially, if the voltage out of CPI 508 exceeds VMAX, then A-DETECT 516 controls A-CTRL 506 to suppress any pulses that would otherwise be asserted on “up charge pump 1” UPCPI. If the voltage out of CPQ 510 exceeds VMAX, then A-DETECT 516 controls A-CTRL 506 to suppress UPCPQ pulses. Similarly, if the either of the voltages out of CPI 508 or CPQ 510 falls below VMIN, then the corresponding “down charge pump” control DNCPI or DNCPQ is suppressed.
[0074] Mixer Bias
[0075] The outputs of charge pumps CPI 508 and CPQ 510 are also driven to mixer bias 512 , where they are converted to fully differential mixer control signals VA and VB, which are driven to mixer 514 and to Q-DETECT 518 .
[0076] Mixer
[0077] Mixer 514 receives differential signals VA and VB from mixer bias 512 along with I and Q components of the local reference clock from the local receiver VCO/PLL 116 of FIG. 1. mixer 514 implements equation (1) and outputs the differential local clock MIXO, which is fed to local clock generator 208 of FIG. 2.
[0078] While this invention has been described with reference to illustrative embodiments, this description should not be construed in a limiting sense.
[0079] For example, although the present invention has been described in the context of a sampler having four integrators, each of which integrates for two unit intervals (UIs), the present invention is not so limited. In other embodiments, the present invention may be implemented using more or fewer integrators. In addition or alternatively, one or more of the integrators may integrate for periods other than two UIs, with different integrators possibly having different integration periods, including some integrators integrating for only a single UI, as long as at least one integrator integrates for at least two UIs. The number of integrators in the front-end will typically be associated with the degree of deserialization provided by the front-end. In general, a front-end having n integrators will produce n-bit deserialized data.
[0080] Other variations on the system include the use of a phase-locked loop as a substitute for circuitry that aligns the phases of the local clocks as a result of information provided by the front-end and phase detectors. Additionally, certain implementations may make use of integration periods that need not be substantially phase-aligned with the incoming data transition edges but instead may overlap those transitions to a greater or lesser extent. Various modifications of the described embodiments, as well as other embodiments of the invention, which are apparent to persons skilled in the art to which the invention pertains are deemed to lie within the principle and scope of the invention as expressed in the following claims.
[0081] The present invention may be implemented as circuit-based processes, including possible implementation on a single integrated circuit. As would be apparent to one skilled in the art, various functions of circuit elements may also be implemented as processing steps in a software program. Such software may be employed in, for example, a digital signal processor, micro-controller, or general-purpose computer.
[0082] Although the steps in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those steps, those steps are not necessarily intended to be limited to being implemented in that particular sequence. | Clock and data recovery circuitry includes an interleaved sampler having multiple integrators, where at least one of the integrators integrates the input data for at least two unit intervals (UIs). One embodiment includes a four-way interleaved sampler, where each integrator in the sampler integrates the input data for two UIs, where each integrator is sampled at or near the middle of its two-UI integration cycle. In an exemplary 10-GHz system, the reset cycle of each integrator may begin many tens of picoseconds after the data is sampled. Since the signal is sampled near the center of the integration cycle and is not highly proximate to the time of the integrator reset, the latch signal has a window of uncertainty extending into the length of a data bit cell with little possibility of latching erroneous data. The sensitivity of the clock recovery circuitry may be optimized by centering the latch function over the time of highest signal level, thereby maximizing signal-to-noise ratio. | 7 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to the technical field of structural design, general design, aerodynamic design and strength design of civil aircrafts, and more specifically to a structural connection form of a pylon with an airfoil and an engine.
BACKGROUND OF THE INVENTION
[0002] A pylon is a connection interface of an aero-engine and an airfoil and mainly functions to mount the engine, transfer engine load, provide a pathway for systems such as a wiring system, environment control system, electrical system and hydraulic system between the engine and the airfoil, and ensure a smooth aerodynamic shape. The design of the pylon structure should take into account various factors such as noise, weight, fuel consumption rate, aerodynamics, system deployment, and engine installation and maintenance.
[0003] As shown in FIG. 1 , a pylon 10 ′ in a conventional configuration is usually designed as a rigid box-shaped structure consisting of an upper beam, a lower beam, a frame having a plurality of vertical stations, and a sidewall which are connected to one another, and assembled with the engine via a front installation joint 20 ′ and a rear installation joint 30 ′. The total load of the engine is transferred via the front installation joint and the rear installation joint, and torque is usually transmitted by virtue of the rear installation joint 30 ′.
[0004] The pylon in the conventional configuration transmits torque via the rear installation joint 30 ′. To have an enough long arm of force to transmit torque, the rear installation joint 30 ′ must have a larger width, which causes the shape of a rear edge of the pylon wider, affecting aerodynamic performance of the aircraft. Besides, the front installation joint 20 ′ is an individual component independent from the pylon but connected to the pylon, and the whole engine installation structure is heavy.
[0005] The conventional pylon is hingedly connected to a nacelle. As shown in FIG. 2 , a pylon sidewall 11 ′ is provided with thrust reverser cowl hinges 12 ′ and fan cowl hinges 13 ′, wherein the thrust reverser cowl hinges 12 ′ are connected with a thrust reverser cowl body (not shown) via a guide rail beam (not shown), and the guide rail beam is provided with a guide rail for guiding the thrust reverser cowl body.
[0006] A conventional aircraft engine duct auxiliary structure for rectifying external ducted airflow is located between a nacelle external duct and a nacelle core cowl body and is connected together with the nacelle core cowl body, and is opened along with the core cowl body upon servicing. It can be seen that the conventional engine duct auxiliary structure is a design integral with the nacelle and turns out to be a component of the nacelle.
SUMMARY OF THE INVENTION
[0007] A first object of the present invention is to provide a novel connection form of connecting a pylon to an airfoil and an engine, which can meet structural needs of small space and achieve weight reduction when an LEAP-X model engine is used.
[0008] A second object of the present invention is to provide a novel connection form of connecting a pylon to an airfoil and an engine, which omits rearward torque transmission and performs forward torque transmission, thereby reducing an engine duct space occupied by the pylon, reasonably solving issue about load transmission of the engine, and thereby achieving reduction of fuel consumption rate, reduction of aerodynamic loss and noise reduction.
[0009] A third object of the present invention is to provide a novel connection form of connecting a pylon to an airfoil and an engine, which solves issue about movement of a rear cowl of a core cowl of an engine nacelle.
[0010] According to one aspect of the present invention, there is provided a pylon structure of an integrated propulsion system, which is adapted to be connected to an aircraft airfoil at one end and connected to an aero-engine at the other end, the pylon structure comprising a pylon box segment consisting of an upper beam, a lower beam, a frame and a sidewall panel, wherein the pylon structure further comprises:
a thrust reverser cowl connection structure disposed on a left wall and a right wall and connected to a nacelle thrust reverser cowl comprising a front fixed cowl and a rear moveable cowl, the thrust reverser cowl connection structure comprising at least one guide rail for guiding the rear moveable cowl to enable the rear moveable cowl to slideably open relative to the pylon box segment.
[0012] In this aspect of the present invention, the engine thrust reverser cowl is directly connected to a sidewall of the pylon box segment, and the thrust reverser cowl is guided to open via the guide rail on the sidewall, thus a guide rail beam is canceled to thereby not only save space and meet the installation requirement of the LEAP-X model engine, but also reduce the weight of the whole propulsion system.
[0013] Preferably, the thrust reverser cowl connection structure comprises an upper guide rail and a lower guide rail for guiding the rear movable cowl, and an intermediate guide rail for guiding a nacelle grid.
[0014] Further preferably, the rear movable cowl is provided with a structure slideably engaged with the upper guide rail and the lower guide rail.
[0015] In an embodiment, the pylon structure further comprises a front installation joint which is disposed on a front wall of the front end frame of the frame and connected to a fan casing of the aero-engine.
[0016] Integrated design of the front installation joint and the pylon may not only save space but also facilitate reduction of the weight of the whole propulsion system.
[0017] Preferably, the front installation joint comprises:
a first lug and a second lug respectively protruding outward from two opposite sides of the front end frame; a first link and a second link respectively connected to the first lug and the second lug at one end, and respectively adapted to be connected to the aero-engine at the other end; wherein the first link and the first lug are pivotally connected at a first connection point, and the second link and the second lug are connected respectively at a second connection point and a third connection point.
[0021] In this aspect of the present invention, the integrated design of the front installation joint and the frame of the pylon can transmit vertical and lateral load as well as torque, overcomes the drawback of the current front installation joint about failure to transmit torque, releases the torque-transmitting function of the rear installation joint so as to reduce the width of the rear installation joint so that the rear installation joint occupies less engine duct space, which facilitates reduction of fuel consumption rate, facilitates retraction of a rear edge of the pylon and achieves reduction of aerodynamic loss. Meanwhile, the integrated design of the front installation joint and the frame of the pylon may effectively reduce the weight of the structure and lower a height of an undercarriage.
[0022] Preferably, connecting bolts running through the first link and the second link respectively at the first connection point, the second connection point and the third connection point are transition-fitted with bushings disposed at these connection points and formed in mounting holes of the first lug and the second lug.
[0023] Further preferably, the first link is further connected to the first lug at a fourth connection point, and the fourth connection point and the second connection point are arranged opposite to each other and respectively located inside, the first connection point and the third connection point, wherein a connecting bolt running through the first link at the fourth connection point is clearance-fitted with the bushing disposed in the mounting hole of the first lug at the fourth connection point.
[0024] The fourth connection point is arranged such that when the front installation joint is connected to the engine via the first link and the second link, the first link is a standby design for possible damages and security purpose.
[0025] Again further preferably, the connecting bolt at the fourth connection point is clearance-fitted with the bushing with a first clearance, and the first clearance is set in a way that when any one of the first connection point, the second connection point and the third connection point fails, the connecting bolt at the fourth connection point partially contacts with the bushing.
[0026] When any one of the first connection point, the second connection point and the third connection point fails, for example, when the second connection point fails, due to the load of the engine, a front end frame of the pylon slightly rotates about the third connection point, and the first clearance at the fourth connection point partially disappears, i.e., the fourth connection point participates in receiving a force.
[0027] Preferably, the front installation joint of the present invention further comprises a third lug protruding outward from a front wall of the front end frame and a third link having one end connected to the third lug at a fifth connection point and the other end adapted to be connected to the engine, and a connecting bolt running through the third link at the fifth connection point is clearance-fitted with a busing disposed in a mounting hole of the third lug at the fifth connection point.
[0028] The fifth connection point is arranged such that when the front installation joint is connected to the engine via the first, second and third links, the third link is a standby design for possible damages and security purpose.
[0029] Further preferably the connecting bolt at the fifth connection point is clearance-fitted with the bushing with a second clearance, and the second clearance is greater than the first clearance and set in a way that when the first link or the second link completely fails, the connecting bolt at the fifth connection point partially contacts with the bushing.
[0030] When the whole first link or the whole second link completely fails, the second clearance at the fifth connection point partially disappears due to the load of the engine, and the third link participates in receiving a force.
[0031] In another embodiment of the present invention, there is included an engine duct auxiliary structure with one end connected to the pylon box segment and the other end adapted to be connected to a nacelle core cowl comprising a core front cowl and a core rear cowl, the engine duct auxiliary structure comprising a front frame hinged with the core front cowl and a rear frame connected with the core rear cowl, the rear frame comprising at least one guide rail for guiding the core rear cowl to enable the core rear cowl to slideably open relative to the pylon box segment.
[0032] The integrated design of the engine duct auxiliary structure and pylon box segment may, on the one hand, meet the need of engine-nacelle-pylon box segment integrated design, and on the other hand, provide a narrower structural shape of the engine duct auxiliary structure to substantially increase the area of an engine external duct flow passageway, reduce the engine fuel consumption rate, improve aircraft economics and present a higher market competitiveness.
[0033] Preferably, the front frame comprises a front beam, a rear beam, an intermediate cross beam and an intermediate slant beam, wherein one end of the front beam is connected to the pylon box segment, and the other end is connected to the core front cowl; wherein the rear beam is located downstream of the front beam, and one end thereof is connected to the pylon box segment and the other end thereof is connected to the core front cowl; wherein both ends of the intermediate cross beam are respectively connected to the front beam and the rear beam; wherein one end of the intermediate slant beam is connected to the intermediate cross beam, and the other end is inclined towards the rear beam and connected to the pylon box segment; wherein the rear frame extends rearward from the rear beam and its upper end is connected to the pylon box segment.
[0034] Further preferably, the rear beam of the front frame is connected to the pylon box segment via a pivoting seat, and the other end of the intermediate slant beam is also connected to the pivoting seat.
[0035] Further preferably, the intermediate cross beam is pivoted with a plurality of hinges, and the other end of the plurality of hinges is connected to the core front cowl so that the core front cowl rotatably opens relative to the pylon box segment.
[0036] Advantageous effects of the present invention are as follow: the engine thrust reverser cowl is directly connected to the sidewall of the pylon box segment, and the thrust reverser cowl is guided to open via the guide rail on the sidewall, thus a guide rail beam is canceled to thereby not only save space and meet the installation requirement of the LEAP-X model engine, but also reduce the weight of the whole propulsion system.
BRIEF DESCRIPTION OF DRAWINGS
[0037] Other features and advantages of the present invention can be made more apparent by the following preferred embodiments described in detail with reference to figures, wherein identical reference numbers denote identical or like parts, wherein
[0038] FIG. 1 is a schematic view of an aircraft pylon in a conventional configuration;
[0039] FIG. 2 is a schematic view of a conventional nacelle connector;
[0040] FIG. 3 illustrates an overall schematic view of a pylon structure of an integrated propulsion system according to a preferred embodiment of the present invention;
[0041] FIG. 4 a illustrates an in-use state of an LEAP-X model engine mounted to a pylon structure of an integrated propulsion system according to a preferred embodiment of the present invention, wherein a thrust reverser structure of the LEAP-X model engine is in a normal deployed position;
[0042] FIG. 4 b is a view similar to FIG. 4 a , but the thrust reverser structure of the LEAP-X model engine is in a maintenance deployment position, and a grid is removed to clearly show the nacelle;
[0043] FIG. 5 illustrates an in-use state in which a front installation joint of FIG. 3 is connected to a fan casing of the engine;
[0044] FIG. 6 a illustrates a schematic view of the front installation joint of the pylon structure of the integrated propulsion system according to a preferred embodiment of the present invention, wherein a fastener for fixing a boomerang link;
[0045] FIG. 6 b is a view similar to FIG. 6 a , wherein the installation joint is assembled with a fastener;
[0046] FIG. 7 is a schematic view showing reception of force of the front installation joint of FIG. 6 a in a normal state;
[0047] FIG. 8 is a schematic view showing reception of force of the front installation joint of FIG. 6 a in a state that a second connection point fails;
[0048] FIG. 9 is a schematic view showing reception of force of the front installation joint of FIG. 6 a , in a state that a second boomerang link fails;
[0049] FIG. 10 illustrates space of the engine duct occupied by a pylon box segment of the pylon structure of the integrated propulsion system according to a preferred embodiment of the present invention;
[0050] FIG. 11 illustrates a mounting position of a fan air valve in the pylon structure of the integrated propulsion system according to a preferred embodiment of the present invention;
[0051] FIG. 12 a illustrates a schematic view in which the pylon structure of the integrated propulsion system according to a preferred embodiment of the present invention is connected with the LEAP-X engine nacelle, wherein a nacelle core cowl is in a normal use state, and a thrust reverser cowl connection structure is removed from a pylon side panel for the sake of clarity;
[0052] FIG. 12 b is similar to FIG. 12 a , but the nacelle core cowl is in a maintenance use position; and
[0053] FIG. 13 illustrates main structures of the engine duct auxiliary structure of FIG. 3 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0054] Embodiments are described in detail below with reference to figures which constitute part of the description. The figures exemplarily exhibit specific embodiments, and the present invention is implemented in these embodiments. The shown embodiments are not intended to exhaust all embodiments according to the present invention. It may be appreciated that other embodiments may be used, and structural or logical changes can be made without departing from the scope of the present invention. Regarding figures, terms indicative of directions such as “outward” and “downward” are used with reference to orientations of the described figures. If the orientations of the figures change, these terms also change accordingly. Since assemblies of the embodiments of the present invention can be implemented in many orientations, these direction terms are used for illustration purpose not for limitation purpose. Hence, the following specific embodiments are not intended to limit the present invention, and the scope of the present invention is defined by the appended claims.
[0055] The internationally advanced LEAP-X engine employs a novel O-DUCT thrust reverser structure, and a thrust reverser body composite material structure cowl body employs integral forming technology. Main advantages are simple maintenance, light weight and easy reduction of noise levels. The fuel consumption of the LEAP-X engine decreases by 116% as compared with that of CFMS6 engine of current B737 and A320, and the noise of the LEAP-X engine decreases by over 10 decibels as compared with the internationally most rigorous fourth-level requirement. It is estimated that the propeller integration technology (namely IPS technology) of the present invention achieves 1.5% fuel consumption reduction and 2-decibel noise reduction.
[0056] Structurally, the engine is connected to the pylon box segment structure via front and rear installation joints, and an engine core cowl IFS structure is connected to the pylon box segment via a MR structure. Additionally, an O-shaped thrust reverser is connected with a sidewall guide rail structure of the pylon box segment, and the whole engine, nacelle and pylon structure wholly bears a force and performs a function of the propulsion system. Therefore, this technology is called propeller integration technology (namely, IPS technology).
[0057] Since the integration technology is a brand-nevi technology, and meanwhile the engine, the thrust reverser structure and pylon structure all are distinct from the conventional form, and the IPS pylon needs to be substantially improved to achieve the design targets such as weight reduction, noise reduction, SFC reduction and aerodynamic loss reduction.
[0058] The following problems need to be solved from perspective of pylon structure:
(1) Reducing the space of engine duct occupied by the pylon; (2) Reasonably solving transfer issue of the engine load; (3) Solving problems related to engine nacelle; (4) Solving the problem about arrangement of systems in the pylon.
[0063] FIG. 3 illustrates an overall schematic view of a pylon structure of an integrated propulsion system according to a preferred embodiment of the present invention. The pylon structure is adapted to be connected to an aircraft airfoil at one end and connected to an aero-engine at the other end, and the pylon structure comprises a pylon box segment 110 consisting of an upper beam, a lower beam, a frame 100 and a sidewall panel 102 ; wherein the pylon structure further comprises a thrust reverser cowl connection structure, a front installation joint 130 and an engine duct auxiliary structure 150 .
[0064] Again as shown in FIG. 3 , the thrust reverser connection structure is disposed on the sidewall panel 102 of the pylon box segment 110 and connected with a nacelle thrust reverser cowl comprising a front fixed cowl 301 , and a rear movable cowl 302 . The thrust reverser connection structure comprises three guide rails: an upper guide rail 121 , an intermediate guide rail 122 and a lower guide rail 123 . The upper guide rail 121 and the lower guide rail 123 are used to guide the rear moveable cowl 302 to allow the rear movable cowl to open relative to the pylon box segment; and the intermediate guide rail 122 is used to guide a nacelle grid 303 . The rear movable cowl 302 is provided with a structure such as a slider that is slideably engaged with the upper guide rail 121 and the lower guide rail 123 . Certainly, if the upper guide rail 121 and lower guide rail 123 are configured as a slider, it is also feasible to provide corresponding guide rails on the rear moveable cowl 302 .
[0065] In the present embodiment, hinges are omitted from the IPS pylon so that the guide rails are directly connected with the pylon. This facilitates reduction of nacelle weight, meanwhile increases nacelle sound absorption area and facilities noise reduction.
[0066] Regarding the structural form of the pylon sidewall, panel and guide rails, as compared with the conventional aircraft structure design, the connection form for connecting the pylon with the thrust reverser is changed from a hinge-hinge beam structure to a guide rail-slider structure. This new connection form is advantageous mainly in reducing the weight of the connection structure, increasing an area of sound-absorbing cells of the nacelle and facilitating noise reduction.
[0067] The guide rail and the sidewall panel 102 of the pylon are manufactured separately, and the connection manner still employs fastener connection. The fastener connection is described as follows: a fastener is directly mounted on the sidewall panel in two forms: one is that the sidewall panel and the guide rail share the fastener, and the other is that the sidewall panel does not share the fastener with the guide rail. First, positions of the sidewall panel not sharing the fastener are mounted first. These positions generally conflict with the positions of the guide rail, so countersunk screws need to be used upon installation. Then the guide rail is mounted on the sidewall panel. At this time, the fastener shared by the sidewall panel and the guide rail is mounted. This form is advantageous in simplifying part processing, not affecting the arrangement of the fastener due to the position of the guide rail, facilitating the mounting of the fastener on the sidewall panel and ensuring the force transmission of the pylon box segment.
[0068] FIG. 4 a illustrates an in-use state of an LEAP-X model engine mounted to a pylon structure of the integrated propulsion system according to a preferred embodiment of the present invention, wherein a thrust reverser structure of the LEAP-X model engine is in a normal deployed position; and FIG. 4 b is a view similar to FIG. 4 a , but the thrust reverser structure of the LEAP-X model engine is in a maintenance deployment position, and a nacelle grid 303 is removed to clearly show the nacelle. Upon maintenance, the rear movable cowl 302 moves backwards away from the front fixed cowl 301 along the upper guide rail 121 and the lower guide rail 123 . It should be appreciated that although there are two guide rails here to guide the rear movable cowl 302 , it is feasible to set only one guide rail or a plurality of guide rails according to needs.
[0069] A main function of the installation joints of the present invention is to connect the engine and transfer the load of the engine to the pylon structure. A conventional engine installation manner is that the engine is connected with the pylon via the front and rear installation joints, and the torque of the engine is transferred to the aircraft pylon via the rear installation joint, while the present invention, by using integrated design of the front installation joint and the pylon frame, can transfer vertical and lateral load, as well as transfer the torque. The present invention may be used to equip the engine on any type of aircraft.
[0070] In the present embodiment, as shown in FIG. 5 , the front installation joint 130 is disposed on a front wall of the front end frame 100 and connected to a first connector 201 , a second connector 203 and a third connector 205 on a fan casing 200 of the aero-engine.
[0071] Introduction is presented for a specific design of the front installation joint 130 in the present embodiment. As shown in FIG. 6 a , the front installation joint 130 is adapted to be integrally formed with the front end frame 100 of the aircraft pylon and comprises a first lug 10 , a second lug 20 , a third lug 30 , a first link 70 , a second link 80 , and a third link 90 . The first lug 10 and the second lug 20 respectively protrude outward from both sides of the front end frame 100 ; and the first link 70 , the second link 80 and the third link 90 are respectively connected to the first lug 10 , the second lug 20 and the third lug 30 at one end, and respectively adapted to be connected to the aero-engine at the other end. In the present embodiment, the first link and the second link are preferably boomerang links and the third link is preferably a straight link, but these links may be links in any other shapes.
[0072] As shown in FIG. 6 b , the first link 70 and the first lug 10 are connected respectively at a first connection point 1 and a fourth connection point 4 , the second link 80 and the second lug 20 are connected respectively at a second connection point 2 and a third connection point 3 , and the third link 90 and the third lug 30 are connected at a fifth connection point 5 . In the present embodiment, the first lug, the second lug and the third lug are preferably a double-lug with a mounting hole which is provided on each lug of the double-lug at the respective connection points. A bushing 50 is mounted in each mounting hole, and a bolt hole is formed on each link at each connection point. One connecting bolt 40 is mounted on a corresponding link respectively at the first through fifth connection points 1 , 2 , 3 , 4 , 5 and runs through the bushing 50 in the mounting hole on the corresponding lugs through these connection points.
[0073] Again as shown in FIG. 5 , the front installation joint of the present embodiment is connected to the first connector 201 , the second connector 203 and the third connector 205 on the engine fan casing 200 via the two boomerang links and one straight link, and the whole front installation joint and the engine have totally three connection point. The fourth connection point 4 on the first link 70 and the third link 90 are standby designs for possible damages and security purpose. That is to say, in normal working conditions, as shown in FIG. 7 and with reference to FIG. 6 a , the three connection points, the first connection point 1 , the second connection point 2 and the third connection point 3 , jointly bear a vertical load (Z direction) and a course torque (X direction) transferred from the engine, and the first connection point 1 and the third connection point 3 bears a lateral load (Y direction). When any one of the first connection point 1 , the second connection point 2 and the third connection point 3 fails, the fourth connection point 4 participates in bearing the vertical load (Z direction) and lateral load (V direction). For example, when the second connection point 2 fails, the first connection point 1 , the fourth connection point 4 and the third connection point 3 jointly bear the vertical load (Z direction), lateral load (Y direction) and course torque (X direction) transferred from the engine. When the whole first link 70 or the Whole second link 80 fails, i.e., both of its connection points fail, for example, when the second link 80 completely fails, the third link 90 will participate in receiving a force, and the first connection point 1 , the fourth connection point 4 and the fifth connection point 5 jointly bear the vertical load (Z direction), the lateral load (V direction) and engine torque transferred from the engine.
[0074] Again as shown in FIG. 7 , in the connection points where the first link 70 and the second link 80 are respectively connected to the first lug 10 and the third lug 30 , the connecting bolt is transition-fitted with the bushing at the first connection point 1 , the second connection point 2 and the third connection point 3 so that under normal working conditions, the three connection points bear all loads and torques.
[0075] To allow the first link 70 and the third link 90 to be standby designs for possible damages and security purpose, and the first link 70 to be a preferable standby design for possible damages and security purpose, i.e., preferably act before the third link 90 acts, the connecting bolt 40 is clearance-fitted with the bushing at the fourth connection point 4 , and the connecting bolt 40 is also clearance-fitted with the bushing at the fifth connection point 5 , but the clearance at the fifth connection point 5 is slightly greater than the clearance at the fourth connection point 4 . Therefore, as shown in FIG. 8 , when any one of the connection points 1 , 2 and 3 fails, for example, when the second connection point 2 fails, due to the load of the engine, the front end frame 100 of the pylon slightly rotates with connecting bolt 40 at the third connection point 3 as a rotation shaft so that the connecting bolt 40 at the fourth connection point 4 partially contacts with the bushing, i.e., the clearance between the connecting bolt 20 and the bushing partially disappears at the fourth connection point 4 , and the fourth connection point 4 begins to participate in receiving the force, and the connection points 1 , 4 and 3 bear the vertical load, lateral load and the course torque. When the whole first link 70 or the whole second link 80 completely fails, for example, when the second link 80 completely fails, as shown in FIG. 8 , due to the load of the engine, the third link 90 is pulled downward so that the connecting bolt 20 at the fifth connection point 5 partially contacts with the bushing, i.e., this partial clearance disappear, such that the third link 90 participates in receiving the force, and the connection points 1 , 4 and 5 bear the vertical load, lateral load and the course torque.
[0076] In the embodiment as shown in FIG. 5 through FIG. 9 , the first connection point 1 , the fourth connection point 4 , the second connection point 2 and the third connection point 3 are preferably arranged in a straight line so that reverse vectors in the straight line direction offset each other. Furthermore, preferably the fourth connection point 4 and the second connection point 2 are arranged opposite to each other and respectively located inside the first connection point 1 and the third connection point 3 . Besides, although in the present embodiment, the fifth connection point 5 is vertically (namely Z direction) located above other connection points 1 , 2 , 3 and 4 and located at an intermediate position of other connection points in a lateral direction (namely, Z direction). It should be appreciated that the fifth connection point 5 may be vertically located below other positions such as connection points 1 , 2 , 3 and 4 so long as the third link 9 does not receive the force after the front installation joint is connected to the engine.
[0077] As compared with the prior art, the front installation joint in the above embodiment has the following advantages:
1) the front installation joint of the engine is integral with the pylon frame, omitting a mounting bracket, namely, omitting a docking form, so that the installation joint is directly connected to the engine fan casing via a link, thereby reducing the weight of a mounting portion of the engine; 2) the installation joint not only bears the load in the vertical direction and horizontal direction, but also bears the engine torque, thereby releasing a torque-bearing function of the rear installation joint; 3) since the front installation joint 130 bears the torque, the width of the shape of the rear installation joint is reduced, and an engine external duct space 304 occupied by the pylon is reduced as shown in FIG. 10 , which facilitates reduction of fuel consumption rate, facilitates retraction of a rear edge 140 of the pylon and achieves reduction of aerodynamic loss; and 4) the design of the first link and the third link enables the whole front installation joint to have a function of standby design for possible damages and security purpose.
[0082] As shown in FIG. 10 , since a duct separation surface is apparently narrower than a conventional pylon, a fan air valve (namely, FAV) 401 is arranged in the engine duct auxiliary structure (namely, BIFI) 150 not in the pylon box segment 110 . Meanwhile, since the BIM is an auxiliary structure, a skin may be made as a detachable skin. As such, it is feasible to take out the FAV without removing the pre-cooler 402 , thereby improving FAV maintenance performance and reducing the maintenance cost.
[0083] As shown in FIG. 12 a and FIG. 12 b , a nacelle core cowl of a nacelle 500 of the LEAP-X engine comprises a core front cowl 501 and a core rear cowl 502 , wherein the core rear cowl 502 needs to be opened by sliding rearward. To meet the need of the core rear cowl 502 , in the present embodiment, BIFI structure no longer serves as part of the nacelle thrust reverser structure as in the conventional BIFI structure, it is integrally arranged with the pylon box segment 110 , i.e. it is suspended below the pylon box segment 110 and provides a guide rail 151 to guide the core rear cowl to slideably open thereon. The BIM is located between an inner surface of the rear moveable cowl 302 of the nacelle thrust reverser structure and the core rear cowl 502 of the nacelle core cowl, and its surface serves as an airflow separation surface of the engine external duct, so it needs to be designed narrower.
[0084] As shown in FIG. 13 and with reference to FIG. 12 a , there is an engine duct auxiliary structure 150 for connecting the nacelle 500 with the pylon box segment 110 , comprising: a front frame 152 comprising a front beam 153 (usually called front end wall), a rear beam 154 , an intermediate cross beam 155 and an intermediate slant beam 156 ; wherein one end of the front beam 153 is connected to the pylon box segment 110 , and the other end is connected to a core front cowl 501 of the nacelle 500 . The rear beam 154 is arranged in the rear of the front beam 153 , and one end thereof is connected to the pylon box segment 110 and the other end thereof is connected to the core front cowl 501 of the nacelle 500 . Both ends of the intermediate cross beam 155 are respectively connected to the front beam 153 and the rear beam 154 . One end of two intermediate slant beams 156 is connected to the intermediate cross beam 155 , and the other end is inclined towards the rear beam 154 and connected to the pylon box segment 110 . A rear frame 157 extends rearward from the rear beam 154 and its upper end is connected to the pylon box segment 110 , and the rear frame 157 is provided with at least one guide rail 151 for guiding the core rear cowl 502 of the nacelle 500 . Those skilled in the art may understand that the number of the guide rail 151 is preferably two.
[0085] Specifically, the rear beam 154 of the front frame 152 is connected to the pylon box segment 110 via a pivoting seat 158 , and the other end of the intermediate slant beam 156 is also connected to the pivoting seat 158 .
[0086] The intermediate cross beam 155 is pivoted to the core front cowl 501 of the nacelle 500 via a plurality of hinges (which are not shown, and may be provided at a connection position 159 as Shown).
[0087] Both sides of the front beam 153 of the engine duct auxiliary structure 150 are connected to the pylon box segment 110 to transfer the course load and the vertical load, and a connecting portion (e.g., a single lug) extending out of the pylon box segment 110 keeps a gap on both sides upon being connected thereto so that it does not transfer lateral load; and an intermediate shear pin leaves a gap in the front and in the rear to allow it to only transfer the lateral load.
[0088] The core front cowl 501 of the nacelle 500 may be connected to the engine duct auxiliary structure 150 via a hinge, which ensures rotatable opening of the core front cowl 501 . The guide rail 151 is used to connect a connection interface of the core rear cowl 502 of the nacelle 500 , which ensures slideable opening of the core rear cowl. Use of the guide rail 151 may ensure that the core rear cowl 502 may be opened rearward, and an O-shaped thrust reverser of the pylon box segment 110 can also be achieved, which facilitates implementation of the pylon box segment 110 . The engine duct auxiliary structure 150 is narrower, which is directly conducive to the saving of the fuel, since the engine duct auxiliary structure 150 is a structure in the engine external duct.
[0089] In the structure shown in FIG. 13 , the front frame 152 of the engine duct auxiliary structure 150 is connected to a main structure of the pylon box segment 110 in a lug-connector connection manner, and the rear frame 157 is connected to the main structure of the pylon box segment 110 in a surface connection manner. However, it may be appreciated that the engine duct auxiliary structure 150 is connected to the main structure of the pylon box segment 110 in a detachable connection manner, e.g., a hinge or a hinged support. The hinged supports of the pylon box segment 110 and the rear frame 157 are pivoted together via two ends of a pivoting rod, and meanwhile, hinges of the pylon box segment 110 and the rear frame 157 may also be pivoted to each other via a pin-shaped fastener. As such, both the front frame 152 and the rear frame 157 are both upwardly pivoted to the pylon box segment 110 , and the front frame 152 is connected to the core rear cowl 501 . That is to say, joints at respective locations are not fixed connections and all are detachable, thereby achieving excellent maintainability.
[0090] The engine duct auxiliary structure 150 is apparently narrower than the conventional pylon, which allows the LEAP-X engine duct to have better aerodynamic properties and reduces engine fuel consumption (about 0.75% as estimated). It is a part of the pylon structure, and the BIFI structure is not a main force-bearing structure but a second-level structure relative to the pylon box segment 110 .
[0091] The technical contents and technical features of specific embodiments of the present invention are already revealed as above. However, it should be appreciated that as guided by the creation idea of the present invention, those skilled in the art can make various modifications and improvements to the above-disclosed various features and combinations of features not explicitly shown here, but these variations and/or combinations all fall within the protection scope of the present invention. The above depictions of embodiments are only exemplary not restrictive.
[0000]
Reference signs:
10′ pylon
11′ pylon sidewall
12′ thrust reverser cowl hinge
13′ fan cowl hinge
20′ front installation joint
30′ rear installation joint
1 first connection point
2 second connection point
3 third connection point
4 fourth connection point
5 fifth connection point
10 first lug
20 second lug
30 third lug
40 connecting bolt
50 bushing
70 first link
80 second link
90 third link
110 pylon box segment
100 front end frame
102 side panel
121 upper guide rail
122 intermediate guide rail
123 lower guide rail
130 front installation joint
140 pylon rear edge
150 engine duct auxiliary structure
151 guide rail
152 front frame
153 front beam
154 rear beam
155 intermediate cross beam
156 intermediate slant beam
157 rear frame
158 pivoting seat
159 connection position
200 engine fan casing
201 first connector
203 second connector
205 third connector
301 front fixed cowl
302 rear moveable cowl
303 nacelle grid
304 engine external duct space
401 fan air valve
402 precooler
500 nacelle
501 core front cowl
502 core rear cowl | An integrated pylon structure for a propulsion system is suitable for one end to be connected to an aircraft wing and the other end to be connected to an aircraft engine. The pylon structure includes a pylon box section ( 110 ) formed from an upper and a lower bean, a frame ( 100 ) and a side wall panel. The pylon structure has a thrust reverser hood connection structure, provided on the side wall and connected with a nacelle thrust reverser hood having a front fixed hood ( 301 ) and a rear movable hood ( 302 ). A guide rail allows the rear movable hood to slide and open relative to the pylon box section. The engine thrust reverser hood is directly connected to the side wall of the pylon box section and a guide rail on the side wall guides the opening of the thrust reverser hood. | 5 |
PRIOR APPLICATION
[0001] Applicant claims priority benefits under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Serial No. 60/384,597 filed May 31, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to a topical drug delivery composition and method. More specifically, this invention relates to topical drug delivery compositions and methods using phosphatidylcholine.
BACKGROUND OF THE INVENTION
[0003] Transdermal drug delivery systems may be designed to act locally at the point of application or to act systemically by entering the body's blood circulation. In these systems, delivery may be achieved by direct topical application of a substance or drug in the form of an ointment or the like, or by adhesion of a patch with a reservoir that holds the drug and releases it to the skin in a time-controlled fashion.
[0004] Transdermal delivery systems for agents such as drugs, pain relieving compounds, vitamins, and skin improving compounds have been in use for a number of years. However, these systems have typically only been useful for transdermal delivery of relatively small molecules. The skin's porous structure permits such small molecules to pass from the epidermis to the dermis via diffusion. These transdermal delivery systems such as creams have been developed for use with analgesics and skin refining compounds. Transdermal systems using a patch have been developed for nicotine and estrogen therapies. Estradiol technologies are described in U.S. Pat. No. 6,521,250 to Meconi, et al.. However, large molecules, such as insulin, are not able to diffuse through the skin. To date there has not been an effective and economical method to transport such molecules through the epidermis to enter the bloodstream via the dermal vasculature.
[0005] It has been proposed that molecules, potentially including larger molecules, can be transported through the skin when such molecules are contained within spherical vesicles, variously called microparticles, microspheres, liposomes, lipid vesicles, transfersomes, formed by hydrating a phospholipid. The resulting vessels are water-insoluble and are dispersed and suspended in a liquid base material which is applied to the skin to deliver the drug. U.S. Pat. No. 6,165,500 to Cevc discloses “transfersomes,” which are vesicles containing both a lipid and surfactant, to achieve transdermal delivery, based on a theory that osmotic pressure will drive the transfersomes through the dermis. Other solutions have been proposed, including the use of ultrasound devices to generating shock waves to enlarge pores, use of electric current to drive substances across skin, and the use of microneedles to pierce skin and deliver drugs into bloodstream. (See More Than the Patch: New Ways to Take Medicine Via Skin , New York Times, Jul. 2, 2002, page F5.
[0006] There remains a need for a transdermal drug delivery system with the improved skin permeability and ability to transport a wider range of substances or drugs. This problem is particularly apparent in the transdermal delivery of substances composed of large molecules, such as polypeptides or proteins, which do not readily pass through the pores of the skin. Absent such a transdermal drug delivery system, the use of injections to deliver these substances will remain the conventional dosage method, despite the pain, complicated administration and general invasiveness involved therein.
SUMMARY OF THE INVENTION
[0007] The present invention relates to compositions and methods of transdermal drug delivery comprising formulating a composition containing the drug in a crystallized phosphatidylcholine carrier and applying the composition to the skin.
DETAILED DESCRIPTION
[0008] Phosphatidylcholine is used as a carrier for the topical drug delivery of macromolecules in the practice of this invention. Phosphatidylcholine is a basic component of cell membrane bilayers and the main phospholipid circulating in the plasma. Phosphatidylcholine is highly absorbable and supplies choline which is needed to facilitate movement of fats and oils across and maintain cell membranes in animals.
[0009] Phosphatidylcholine compositions (herein abbreviated “PC compositions”) of the present invention are formulated to contain macromolecules soluble in PC, which are then applied to skin for transdermal delivery of the macromolecule. PC compositions of the invention are efficacious in the delivery of macromolecular drugs that are conventionally administered intramuscularly, intravenously or orally, including, but not limited to polypeptides such as insulin and somatropin, prostaglandins, glucocorticoids, estrogens, androgens, and the like.
[0010] It is an advantage of the invention that topical delivery is easier and pleasanter as an administration route than injections, particularly for drugs such as insulin that must be given to patients over a period of time, or for a lifetime. Furthermore, unlike oral administration where a substantial amount of the drug can be destroyed in the digestive process, the drugs in a topical application are not wasted. Topical application allows a steady diffusion of the drug to the desired target area without the cyclic dosages typical of orally or parenterally administered drugs.
[0011] Typical phosphatidylcholine compositions of the present invention are nonpolar and contain about 85% phosphatidylcholine. By “phosphatidylcholine” is meant a mixture of stearic, palmitic, and oleic acid diglycerides linked to the choline ester of phosphoric acid, commonly called lecithin. Many commercial lecithin products are available, such as, for example, Lecithol®, Vitellin®, Kelecin®, and Granulestin® because lecithin is widely used in the food industry. Compositions of the invention can contain synthetic or natural lecithin, or mixtures thereof. Natural preparations are preferred because they exhibit desirable physical characteristics and are both economical and nontoxic.
[0012] The macromolecular drugs are mixed with the PC composition under conditions to become entrapped in a phosphatidylcholine bilayer. Phosphatidylcholine forms a bilayer entrapping the macromolecular drug, which may be a polypeptide, contributing to the stability of the active molecule and enhancing penetration. The PC composition therein comprises a carrier-drug combination to be applied topically.
[0013] While not wishing to be bound by any particular theory, it is believed that the following mechanism illustrates how the PC composition acts to efficiently transport the drug across the epidermis, maximizing penetration of the drug. The PC composition, in liquid crystal phase, is loosely arranged in multilamellar fashion, with the drug being bonded and entrapped within the lipid bilayers formed by the PC composition. This forms a loosely arranged, yet stable, PC composition carrier-drug complex. When placed on the epidermis, the carrier-drug complex begins to diffuse through the epidermis. The phosphatidylcholine molecular chain remains loosely linked with the drug molecular chain and the diffusing phosphatidylcholine molecules“drag” the drug molecules along as they pass through the skin layers. Moreover, the phosphatidylcholine molecules may begin to separate from the loosely arranged carrier-drug complex and become integrated into the dermis. As the phosphatidylcholine molecules separate from the crystallized phophoslipid bilayer structure of the carrier-drug complex the drug molecules are released. As these drug molecules are released, they are now within into the dermis and may enter the dermal vasculature so they may act accordingly in the bloodstream. Drug molecules which were once too large to diffuse, by themselves, into the pores of the epidermis, have instead been forced through the epidermis by phosphatidylcholine carriers which naturally enter and integrate into lipid bilayer structures within the cells of the epidermis and/or dermis and resultantly are required to release their bonds to the drug molecules and set them free within the dermis.
[0014] Preferred PC compositions comprise phosphatidylcholine in crystal phase to increase fluidity of the lipid bilayer formed. By reducing rigidity and loosening the phospholipid bilayer of the PC composition, larger molecules may embed therein and penetration of the carrier-drug composition by the cell membrane is facilitated. The skin is more permeable to the fluid, less structured lipid bilayer of the PC/carrier-drug composition applied thereon than to the drug by itself, or entrapped in an organized, arranged vesicle such as a liposome. The loosely packed lipid bilayer of the crystallized carrier-drug composition integrates into the cell membrane, and as a result, has transported the drug so it can enter the bloodstream to act upon the body. The PC composition may be a multilamellar liquid crystal phase or a liquid crystal phase suspension in water which may be converted to multilamellar liquid lipid vesicles.
[0015] In preferred embodiments, nonpolar preparations of phosphatidylcholine are formulated to contain adjunct ingredients, e.g., lipoic acid and ascorbyl palmitate, in addition to the macromolecular drug. The adjunct ingredients act synergistically to help to minimize degradation and thus preserve the integrity of the insulin polypeptide chains, and to enhance transdermal penetration of active insulin so that it can be absorbed by the dermal vasculature.
[0016] Preferred PC compositions of the invention contain some polyenylphosphatidylcholine (herein abbreviated “PPC”) to enhance epidermal penetration. By “polyenylphosphatidylcholine” is meant any phosphatidylcholine bearing two fatty acid substituents, wherein at least one is an unsaturated fatty acid with at least two double bonds such as linoleic acid. Preferred PPCs contain a mixture of substitutents such as those found in natural products such as soybean lecithin, which contains 11.7% palmitic, 4.0% stearic, 8.6% palmitoleic, 9.8% oleic, 55.0% linoleic, and 4.0% linolenic acid substituents and is a by-product of soybean oil manufacture.
[0017] Certain types of soybean lecithin, for example, contain higher levels of polyenylphosphatidylcholine, with dilinoleoylphosphatidylcholine (18:2-18:2 phosphatidylcholine) as the most abundant phosphatidylcholine species, than conventional food grade lecithin, and are useful in formulating phosphatidylcholine insulin compositions of the invention. Alternatively, conventional soybean lecithin is enriched with PPC by adding soybean extracts containing high levels of PPC. As used herein, this type of phosphatidylcholine is called “PPC-enriched” phosphatidylcholine, even where the term encompasses lecithin obtained from natural sources exhibiting PPC levels higher than ordinary soybean varieties. These products are commercially available from American Lecithin, Rhône-Poulenc and other lecithin vendors. American Lecithin markets its products with a “U” designation, indicating high levels of unsaturation; Rhône-Poulenc's product is a soybean extract containing about 42% dilinoleoylphosphatidylcholine and about 24% palmitoyllinoleylphosphatidylcholine (16:0-18:2 PC) as the major PC components.
[0018] PC compositions are used for transdermal polypeptide delivery in some preferred embodiments. Polypeptide drugs that are delivered transdermally using formulations can be small, e.g., ocytocin and vasopressin nonapeptides or large, e.g., insulin, gonadotropin, and somatropin. PC compositions of the invention deliver drugs including, but are not limited to, oxytocin, vasopressin, insulin, somatotropin, calcitonin, chorionic gonadotropin, menotropins, follitropins, somatostatins, progestins, and combinations of any of these. These drugs are readily available from a variety of commercial sources. Insulin, for example, is marketed under the tradenames Humulin®, Novolin®, Humalog®, and Inutral®. Somatotropin is marketed under the tradenames Gentropin®, Humatrope®, Nutropin®, and Serostim®. Some of these products and other polypeptides contain porcine sequences. Preferable compositions of the invention are preferably formulated with recombinant human polypeptides. It is an advantage of the invention that PC insulin compositions are formulated with commercially available ingredients.
[0019] One, non-limiting, example of an insulin topical preparation was formulated by combining 0.75% methyl paraben with a commercial phosphatidylcholine preparation marketed as a solution denoted NAT-8729 (containing PEG-400 at 40% and P.G. at 5%) by mixing for an hour or more to emulsify. To this is slowly added Dow Corning Fluid 200-5 or 10 cst (1% by weight), the formulation is mixed, and then Dow Corning Fluid 190 (1% by weight) is slowly added, and the formulation is further mixed to provide a stock insulin carrier. Prior to topical administration, insulin is added at a level of about 3.8 mg/ml to provide about 100 insulin units per ml.
[0020] Another, non-limiting, example of a pituitary growth hormone (somatotropin) composition was formulated with 85% phosphatidylcholine to which lipoic acid and ascorbyl palmitate was added as antioxidants. Somatotropin readily dispersed in phosphatidylcholine and remained stable in it. Growth hormone appeared to penetrate the skin well when the composition was topically applied.
[0021] It is appreciated that the foregoing is illustrative and not limiting of the invention, and that various changes and modifications to the preferred embodiments described above will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention, and it is therefore intended that such changes and modification be covered by the following claims. | The present invention relates to compositions and methods for transdermal drug delivery comprising formulating a phosphatidylcholine carrier composition containing the drug and applying the composition to the skin. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application No. 60/707,401 filed Aug. 11, 2005, which is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO A SEQUENCE LISTING
[0003] Not Applicable
FIELD OF INVENTION
[0004] The present invention relates to the field of wireless communications, and more specifically to a method and system for maintenance of basestation equipment.
BACKGROUND OF THE INVENTION
[0005] Increased capacity demands are driving Multiple Input Multiple Output (MIMO) antenna technology into the basestation architecture. The cabling requirements for conventional ground based electronics and tower mounted antenna, however, become prohibitive with respect to such implementations. As a result, electronic circuitry and other components are being situated at the top or masthead, of a tower. While tower mounting of the basestation Radio Frequency (RF) hardware resolves the cabling issue, maintaining such equipment is expensive. That is because accessing such equipment typically requires specialized cranes or personnel.
[0006] Therefore there is a need for providing an improved way to maintain basestation equipment mounted on the tower.
BRIEF SUMMARY OF THE INVENTION
[0007] It is an object of the invention to provide a method and system that obviates or mitigates at least one of the disadvantages of existing systems.
[0008] In accordance with an aspect of the present invention, there is provided a system for maintenance of a basestation having a tower and basestation circuitry. The system includes a translator for translating at least a portion of the basestation circuitry between a first position of the tower and a second position of the tower. The first position is different from the second position. The system includes a connection module for detachably connecting to the portion of the basestation circuitry when the portion of the basestation circuitry is at the second position.
[0009] In accordance with a further aspect of the present invention, there is provided a method for a basestation having a tower and basestation circuitry. The method includes the step of translating at least a portion of the basestation circuitry between a first position of the tower and a second position of the tower. The first position is different from the second position. The method includes the step of detachably connecting a connection module to the portion of the basestation circuitry when the portion of the basestation circuitry is at the second position.
[0010] This summary of the invention does not necessarily describe all features of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings wherein:
[0012] FIG. 1 illustrates an example of a basestation system in accordance with an embodiment of the present invention;
[0013] FIG. 2 illustrates an example of the basestation system of FIG. 1 where a basestation radio module is lowered;
[0014] FIG. 3 illustrates an example of the tower mounted equipment, the basestation module platform and the connection plate of FIGS. 1-2 ; and
[0015] FIG. 4 illustrates an example of a plurality of basestation radio modules and mechanism for raising/lowering them and enabling them.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Embodiments of the present invention are described using a basestation having Radio Frequency (RF) equipment placed at the top of a tower when providing a network service. However, the tower mounted equipment may be any equipment other than the RF equipment.
[0017] In the description below, the terms “top”, “tower top” and “masthead” may be used interchangeably. In the description below, the terms “tower” and “mast” may be used interchangeably. In the description below, the terms “tower mounted equipment” and “masthead equipment” may be used interchangeably. In the description below, the terms “top” and “base” are being used in the general sense to depict two positions of the tower, one position being higher than another position.
[0018] In the description below, the terms “couple(ed)” and “connect(ed)” may be used interchangeably. These terms may be used to indicate that two or more elements are directly or indirectly in physical or electrical contact with each other.
[0019] FIG. 1 illustrates an example of a basestation system in accordance with an embodiment of the present invention. The basestation system 2 includes basestation equipment 10 mounted on the top of a tower 4 , hereinafter referred to as tower mounted equipment 10 . The tower mounted equipment 10 may form masthead equipment. The tower 4 may be, but not limited to, a cellular tower. Those of ordinary skill in the art will appreciate that the tower mounted equipment 10 may be located at varying altitudes on the tower. The basestation system 2 may be a basestation tower operating in accordance with, but not limited to, at least one of Wideband Code Division Multiple Access (CDMA), Global System for Mobile (GSM) and Universal Mobile Telecommunications System (UMTS) wireless standards or next generation OFDM based wireless standards.
[0020] The tower mounted equipment 10 includes one or more basestation modules including a basestation radio module 12 and an antenna system 18 . The antenna system 18 is secured to the top of the tower 4 . Those of skill in the art will understand that the representation of the antenna system 18 is schematic only, and the actual configuration of these elements may take on a variety of configurations.
[0021] The basestation system 2 includes mechanism for translating the basestation radio module 12 between the top and base of the tower 4 and enabling the tower mounted equipment 10 to operate when the basestation radio module 12 is located at the tower top.
[0022] The basestation radio module 12 is detachably mounted on a basestation module platform 14 . The basestation radio module 12 may be unloaded from the basestation module platform 14 for maintenance purpose. The antenna system 18 is mounted on a connection plate 16 . The connection plate 16 is secured on the top of the tower 4 .
[0023] The basestation radio module 12 is detachably coupled to the connection plate 16 at the tower top. The tower mounted equipment 10 is operable when the basestation radio module 12 is connected to the antenna system 18 . The basestation radio module 12 is lowered for its maintenance purpose, while the basestation radio module 12 is raised and connected to the antenna system 18 at the tower top to provide a network service.
[0024] In FIG. 1 , the connection plate 16 is formed separately from the antenna system 18 . However, in another example, the connection plate 16 or similar connection mechanism may be formed in the module of the antenna system 18 . In a further example, the connection plate 16 or similar connection mechanism may be formed in any intermediate modules to connect the basestation radio module 12 to the antenna system 18 or any other electronic modules. In a further example, the connection plate 16 or similar connection mechanism may form part of the tower itself. In FIG. 1 , the basestation radio module 12 is connected to the antenna system 18 . However, in another example, the basestation radio module 12 may be connected to any intermediate modules to connect the basestation radio module 12 to the antenna system 18 or any other electronic modules. In FIG. 1 , the basestation radio module 12 is connected to the connection plate 16 . However, in another example, the basestation radio module 12 may be directly connected to the antenna system 18 or any other electronic modules without using the connection plate 16 . Using the connection plate 16 may however provide increased structural support for the components to which the basestation radio module 12 connects.
[0025] In FIG. 1 , one tower mounted equipment 10 is shown. However, the basestation system 2 may include more than tower mounted equipment 10 . Each tower mounted equipment 10 may be located at a different position of the tower 4 . In FIG. 1 , one antenna system 18 is shown. However, the basestation system 2 may include more than one antenna system 18 . The basestation system 2 may include more than one connection plate 16 for more than one antenna system 18 . In FIG. 1 , one basestation radio module 12 is shown. However, the basestation system 2 may include more than one basestation radio module 12 . The basestation system 2 may include more than one basestation module platform 14 for more than one basestation radio module 12 .
[0026] In FIG. 1 , the basestation radio module 12 is located close to the top of the tower 4 . As shown in FIG. 2 , the basestation radio module 12 is locatable at a position lower than that of FIG. 1 . The basestation radio module 12 may be located at the bottom of the tower 4 . However, as described above, it is not required that the basestation radio module 12 be raised or lowered from the absolute bottom or top of the tower respectively.
[0027] Referring to FIGS. 1-2 , a location guide 20 is provided to ensure the proper alignment of the electrical connectors in the tower mounted equipment 10 . In FIGS. 1-2 , the location guide 20 is provided to align the basestation radio module 12 with the connection plate 16 . However, in another example, the location guide 20 may be provided to align the basestation module platform 14 with the connection plate 16 . In a further example, the location guide 20 may be provided to align the basestation radio module 12 or the basestation module platform 14 with a certain position of the tower without using the connection plate 16 . In a further example, the location guide 20 may be provided to align the basestation radio module 12 or the basestation module platform 14 with any electronic modules. In a further example, the basestation system 2 may include more than one tower mounted equipment 10 , and may include more than one location guide 20 for more than one tower mounted equipment 10 .
[0028] A cabling and pulley system having a cable 40 and a pulley 42 is provided to the basestation system 2 . In FIG. 1 , one set of the cable 40 and the pulley 42 is provided to each side of the tower mounted equipment 10 . The pulley 42 is connected to the connection plate 16 . However, in another example, the pulley 42 may be connected to the structure of the tower 4 . The cable 40 is connected to the basestation module platform 14 . The basestation radio module 12 is located by raising or lowering the basestation module platform 14 . However, in another example, the housing of the basestation radio module 12 may be directly raised or lowered by the cabling and pulley system.
[0029] A winch system 44 is provided to wind up the cable 40 . The winch system 44 with the cabling and pulley system enables the basestation radio module 12 to be raised or lowered from the masthead. The winch system 44 may be a manual winch system, an automatic winch system or a combination thereof. The winch system 44 may include a crank to enable manual raising and lowering of the basestation radio module 12 . The winch system 44 may include gear assemblies and may be powered by gas engine, electric motor, hydraulic cylinder, pneumatic, electric, combustion drives, or any other device for providing rotational shaft power. The winch system 44 may include a braking system or ratchet system.
[0030] The power supply to the winch system 44 need not be situated at the base of the tower 4 . For example, an electric motor may be attached to the top of the tower 4 , in which case a controller (not shown) could be used in conjunction therewith (e.g., a hand held controller, key pad, graphical user interface, etc.).
[0031] The winch system 44 may employ a detachable motor that can be temporarily connected to rotate the winch mechanism. Depending on the winch mechanism determined for use the detachable motor may take the form of a compressor in the case of a pneumatic or hydraulic system or a rotational motor as in the case in which a cabling system is used. The specifics of the detachable motor would be readily understood by those skilled in the art.
[0032] Those of skill in the art will understand that the representation of the cable 40 , the pulley 42 and the winch system 44 are schematic only, and the actual configuration of these elements may take on a variety of configurations. Those of skill in the art will understand that mechanism for raising or lowering the basestation radio module 12 may be implemented in various ways other than those shown in FIGS. 1-2 . Wire hawsers, track, hydraulic cylinder, pneumatics, chain or gear driven arrangements (e.g., worm gear/rack) may be used.
[0033] In FIGS. 1-2 , the translating system for translating one basestation module platform 14 is shown. However, in another example, the basestation system 2 may include more than one basestation module platform 14 , and the translating system in the basestation system 2 may translate each basestation module platform 14 . In a further example, the translating system in the basestation system 2 may translate each basestation radio module directly without using the basestation module platform 14 . That is to say, the mechanism for raising and lowering the basestation radio module 12 could be directly connected to the basestation radio module 12 .
[0034] The basestation system 2 includes a ground based base-band processing unit 30 for transmission and reception of low power digital communications data and power to and from the core network and to and from the tower mounted equipment 10 . The basestation system 2 includes a communication cable 32 from the ground based base-band processing unit 30 to the basestation radio module 12 to convey power and base-band data between the ground and the basestation radio module 12 .
[0035] In order to prevent damage to the communication cable 32 connecting the basestation radio module 12 to the network connection, the basestation system 2 uses a plug and socket arrangement such that the communication cable 32 is disconnected from the basestation radio module 12 when the basestation radio module 12 is lowered from the tower top, and is connected to the basestation radio module 12 when the basestation radio module 12 is raised and is positioned at the tower top.
[0036] In FIGS. 1-2 , the communication cable 32 is attached at the top of the tower 4 to the connection plate 16 so that the basestation radio module 12 can be removed from the basestation module platform 14 and replaced or serviced, without having to bending the communication cable 32 when the basestation radio module 12 is lowered from the top of the tower 4 .
[0037] In some radio towers there may be a requirement to service multiple operators' equipment. In such a scenario multiple antenna location plates may be present at various heights along the vertical axis of the mast. In such a scenario each operator's equipment may incorporate a separate winch system for location of the base station equipment. In addition, in the case where the multiple operators use the tower, multiple fixed communication cables may ascend the tower. Those skilled in the art can readily extend the embodiments for maintenance of single basestation to application to multiple platforms at multiple heights to service multiple operators.
[0038] In FIGS. 1-2 , single communication cable 32 is shown. However, in an alternative embodiment, more than one communication cable may be used for providing power, data or a combination thereof to the basestation radio module 12 .
[0039] FIG. 3 illustrates an example of the tower mounted equipment, the basestation module platform and the connection plate of FIGS. 1-2 . The tower mounted equipment 10 of FIG. 3 includes a basestation RF transceiver unit 12 A including elements for transmission and reception of cellular RF signals in a multi-sector environment. The basestation RF transceiver unit 12 A is mounted on the basestation module platform 14 .
[0040] In FIG. 3 , one RF transceiver unit 12 A is shown as an example of the basestation radio module 12 of FIG. 1 . However, more than one basestation radio module may be attached to the basestation module platform 14 and be raised or lowered.
[0041] The tower mounted equipment 10 includes main and diversity antennas 52 that form the antenna system 18 of FIG. 1 or a part of the antenna system 18 . Those of skill in the art will understand that the representation of the main and diversity antennas 52 is schematic only, and the actual configuration of the main and diversity antennas 52 may take on a variety of configurations.
[0042] In FIG. 3 , a connection plate 16 A with blind mate connectors 54 is shown as an example of the connection plate 16 of FIG. 1 . The connection plate 16 A is secured to the tower top. The main and diversity antennas 52 are mounted on the connection plate 16 A. The connection plate 16 A enables connection of the basestation RF transceiver unit 12 A to the main and diversity antenna 52 . The communication cable 32 is attached to the connection plate 16 A. The connection plate 16 A also enables connection of the basestation RF transceiver unit 12 A to the communication cable 32 . The communication cable 32 is not subject to bending associated with it having to follow the basestation RF transceiver unit 12 A down the tower.
[0043] In FIG. 3 , the connection plate 16 A is provided for one basestation RF transceiver unit 12 A. However, the connection plate 16 A may be modified to accommodate multiple RF basestation transceiver units in the case that multiple service providers are connected to the tower.
[0044] The enclosure of the basestation RF transceiver unit 12 A incorporates blind mate connectors 56 into its top surface. The blind mate connectors 56 in the enclosure of the basestation RF transceiver unit 12 A are coupled with the blind mate connectors 54 in the connection plate 16 A. The blind mate connectors 56 may be encompassed by a rubber ‘O’ ring seal to prevent water ingress.
[0045] In FIG. 3 , the blind mate connectors 54 are formed in the connection plate 16 A. However, in another example, the blind mate connectors 54 or any other connection mechanism for connecting the RF transceiver unit 12 A to the antenna 52 may form part of the structure of the tower or may be formed in the housing of any electronic modules. In a further example, the antenna module associated with the antenna 52 may have a connection mechanism and be connected to the RF transceiver unit 12 A without using the connection plate 16 A.
[0046] In FIG. 3 , location guide rods 60 and location alignment holes 62 are shown as an example of the location guide mechanism 20 of FIG. 1 . The location guide rods 60 slide into the location alignment holes 62 . The location alignment holes 62 receive the location guide rods 60 to facilitate blind mate electrical connection of the blind mate connectors 54 and 56 .
[0047] In FIG. 3 , four location guide rods and four location alignment holes are shown. However, the number of the location guide rods and the location alignment holes is not limited to four and it may be varied depending on the design and requirements of the basestation.
[0048] In FIG. 3 , the location guide rods 60 are attached to the connection plate 16 A and the location alignment holes 62 are arranged in the housing of the basestation RF transceiver unit 12 A. However, in another example, the location guide rods 60 may be attached to the housing of the basestation RF transceiver unit 12 A, and the location alignment holes 62 may be arranged in the connection plate 16 A.
[0049] In another example, the location guide rods 60 may be attached to the housing of the antenna system (e.g., 18 of FIGS. 1-2 , 52 of FIG. 3 ) or any other electronic modules. In a further example, the location alignment holes 62 may be formed in the housing of the antenna system (e.g., 18 of FIGS. 1-2 , 52 of FIG. 3 ) or any other electronic modules. In a further example, the location guide rods 60 or the location alignment holes 62 may be formed in the structure of the tower.
[0050] In a further example, the location guide rods 60 or the location alignment holes 62 may be arranged in the housing of any basestation module(s) on the basestation module platform 14 other than the basestation RF transceiver unit 12 A.
[0051] In a further example, the location guide rods 60 and the location alignment holes 62 are arranged such that the location alignment holes 62 are formed in the basestation module platform 14 . This arrangement enables the location alignment holes 52 to be removed from the basestation RF transceiver unit 12 A, and thus it may reduce the size of the basestation RF transceiver unit 12 A.
[0052] in a further embodiment, the communication cable 32 of FIGS. 1-3 may be sufficiently flexible to sustain the mechanical bend radii associated with lowering the basestation module from the tower top.
[0053] In a further embodiment the tower mounted equipment 10 of FIGS. 1-2 may use a waveguide rather than the communication cable 32 .
[0054] Referring to FIG. 4 , there is illustrated a plurality of basestation radio modules to be raised or lowered. Basestation radio modules 70 1 - 70 N (N: integer) are mounted on basestation module platforms 72 1 - 72 N , respectively. Each of the basestation radio modules 70 1 - 70 N may be same or similar to the basestation radio module 12 of FIGS. 1-2 or the basestation radio module 12 A of FIG. 3 . Each of the basestation module platforms 72 1 - 72 N may be same or similar to the basestation module platform 14 of FIGS. 1-2 . Connection modules 74 1 - 74 N are provided to the basestation radio modules 70 1 - 70 N , respectively. Each of the connection modules 74 1 - 74 N may be same or similar to the connection plate 16 of FIGS. 1-2 or the connection plate 16 A of FIG. 3 . The connection modules 74 1 - 74 N may be formed in any electronic modules (e.g., antenna system or any intermediate electronic systems) or form part of the tower. One or more than one communication cable (e.g., 32 of FIGS. 1-3 ) may be located at each connection module.
[0055] Translating systems 76 1 - 76 N are provided to the basestation radio modules 70 1 - 70 N , respectably. Each of the translating systems 76 1 - 76 N may include the cabling and pulley system and the winch system 44 of FIGS. 1-2 or any suitable alternative mechanism for raising or lowering the basestation radio module. The translating systems 76 1 - 76 N raise or lower the basestation module platforms 72 1 - 72 N , respectively. The translating systems 76 1 - 76 N may directly raise or lower the basestation radio modules 70 1 - 70 N , respectively, without using the basestation module platforms 72 1 - 72 N .
[0056] The connection modules 74 1 - 74 N are detachably connected to the basestation radio module 70 1 - 70 N , respectively and enable them to operate, respectively. The connection modules 74 1 - 74 N may be located at different positions of the tower, and thus the basestation radio modules 70 1 - 70 N may be enabled at different positions of the tower. The basestation radio modules 70 1 - 70 N may be lowered for maintenance at different positions of the tower for maintenance. A location guide (e.g., 20 of FIGS. 1-2 , 60 and 62 of FIG. 2 ) may be provided for each basestation radio module 70 1 - 70 N for proper alignment.
[0057] In FIG. 4 , “N” is an integer greater than one. However, “N” may be one. In FIG. 4 , a plurality of translating systems 76 1 - 76 N are shown separately. However, the plurality of translating systems 76 1 - 76 N may share some elements, such as power source.
[0058] There are number of technical advantages to placing RF electronics of a basestation at the tower top. One reason is that a single cable run (e.g., 32 of FIGS. 1-3 ) from the base of the tower to the top can be used to convey both power and data. Additionally, such electronics can be used to minimize the number of cables required for MIMO functionality, for example. This eliminates the up front cost and maintenance of multiple high quality RF cable runs normally required. In addition when receiver equipment is located at the tower base, cable loss directly impacts the receiver noise figure. RF power is also dissipated in the cable runs making the power amplifiers less efficient than those placed at the tower top.
[0059] One issue with tower mounted equipment in conventional systems is the cost to maintain the equipment, as specialized cranes and technicians are typically required to access and service the equipment. Additionally, to avoid such maintenance costs, tower mount electronics component costs are typically increased to realize a higher mean time to breakdown failure rate than ground based equipment. Furthermore, circuit complexity is often increased to provision for redundant circuitry capable of making the tower mounted equipment resilient to circuit component failures.
[0060] By contrast, according to the embodiments of the present invention, on detection of a fault in the tower mounted equipment a single operator (e.g., person or a control signal to the winch system 44 ) may lower the basestation module from the tower top using the translating mechanism. Once lowered the defective component may be replaced or, alternatively, the entire module may be returned to the vendor for repair. The module may be returned to a factory for testing. New or repaired module then will be raised by the single operator to the tower top for service.
[0061] The maintenance arrangement/scheme of the embodiments of the present invention removes the requirement for a crane or specialized service personnel to service tower mounted equipment. The arrangement of the embodiments of the present invention removes the insurance costs associated with sending service personnel up the tower. The arrangement of the embodiments of the present invention reduces costs associated with over-provisioning masthead electronics. For example, Mean Time Between Failure (MTBF) of a ground based equipment may be used for the maintenance of the tower mounted equipment because of low cost service mechanism hence reducing initial design costs and specifications.
[0062] The maintenance arrangement/scheme of the embodiments of the present invention removes the performance degradation in the receiver sensitivity and PA efficiency associated with the cable runs required for ground based radio transceiver modules.
[0063] The maintenance arrangement/scheme of the embodiments of the present invention enables high capacity data services based on, for example, MIMO OFDM, leading to lower cost per bit for the service.
[0064] The single communication cable arrangement (e.g., 32 of FIGS. 1-3 ) is applicable to cable intensive basestation architecture, such as MIMO that normally requires up to 18 cables, and thus increases the viability of the MIMO technology and the design flexibility of radio modules.
[0065] The present invention has been described with regard to one or more embodiments. However, it will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as defined in the claims. | A method and system for maintaining a basestation system is provided. The basestation includes a tower and basestation circuitry placed in the tower. The system includes a translator for translating at least a portion of the basestation circuitry between a first position of the tower and a second position of the tower. The system includes a connection module for detachably connecting to the portion of the basestation circuitry when the portion of the basestation circuitry is at the second position. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to an ionographic imaging system, and in particular, to an ionographic imaging member having a thick dielectric imaging layer and method of imaging with the thick ionographic imaging member.
In electrography, an electrostatic latent image is formed on a dielectric imaging layer (electroreceptor) by various techniques such as by an ion stream (ionography), stylus, shaped electrode, and the like. Development of the electrostatic latent image may be effected by the application of certain electrostatically charged marking particles.
Ion stream electrographic imaging may be accomplished with the aid of ion projection heads. Movement of the ion stream may be assisted by means of a fluid jet introduced into an ion projection head. For example, fluid jet assisted ion projection heads in electrographic marking apparatus for ion projection printing may utilize ions generated in a chamber, entrained in a rapidly moving fluid stream passing into, through and out of the chamber, modulated in an electroded exit zone by being selectively emitted or inhibited therein, and finally deposited in an imagewise pattern on a relatively movable charge receptor (electroceptor). More specifically, the ion projection head may comprise a source of ionizable, pressurized transport fluid, such as air, and an ion generation housing, having a highly efficient entrainment structure and a modulation structure. Within the ion generation housing there is a corona generator comprising a conductive chamber surrounding a wire, and an entrainment structure which comprises an inlet opening for connecting the source of ionizable fluid into the chamber and for directing the fluid through the corona generator, and an outlet opening for removing ion entraining transport fluid from the chamber. The exiting ion laden transport fluid is directed adjacent to the modulation structure for turning "on" and "off" the ion flow to the charge receptor surface. The chamber, the corona generating source, the inlet opening, the outlet opening and the modulation structure each extends in a direction transverse to the direction of relative movement of the electroceptor. The electroceptor may be uniformly charged by suitable means such as a corona charging device, brush charging, induction charging devices and the like, prior to imagewise discharge of the uniformly charged electroceptor by means of a fluid jet assisted ion projection head. In conventional xerography, corona charging is carried out with a device having a high charge output and a large opening such as a corotron so that a high voltage may be deposited on thick photoconductive insulating layers. A thin electroceptor of less than one half mil having a dielectric constant of about 2 or 3 will not charge up to high electric potentials used in conventional xerography on thick photoconductive insulating layers. Thus, if such an electroceptor is employed in an ordinary ion projection electrographic printing system and is uniformly charged with a device having a high charge output and a large opening such as a corotron, it cannot be charged to high electric potentials. In ionographic systems utilizing fluid jet assisted ion projection heads, only a small amount of ions are emitted due to modulation requirements. Therefore, imagewise discharge of a uniformly charged electroceptor by means of a fluid jet assisted ion projection head results in only a slight change in potential and development density of the electrostatic latent image is poor due to low contrast potential. In U.S. Pat. No. 4,524,371 to N. Sheridon et al, issued June 18, 1985, a fluid jet assisted ion projection printing apparatus is described comprising a housing including ion generating and ion modulating regions. The fluid jet dislodges ions from an electrically biased wire and requires high flow rates to achieve higher deposited charge density. Unfortunately, high fluid flow rates cause a high decibel whistling sound due to the blowers and pumps used to move the fluids. High voltage ion beam deposition is also difficult to achieve when utilizing modulation voltage switching. In addition to the whistling noise problem, it is difficult to obtain more charge out of an ion stream imaging device per unit time. This adversely affects the rotational speed of the electroceptor, i.e. a slower speed electroceptor is needed to achieve a higher charge density. Therefore, one of the drawbacks of ionography is the relatively low charge density and low surface potential which can be supplied to an electroceptor surface while simultaneously attempting to achieve adequate image resolution, print density and throughput speed. Thus, the surface charge potential on the electroceptor in ionographic imaging systems has been considered to be too low for typical dry xerographic development. In other words, although one may form an electrostatic latent image on a thin high dielectric constant electroceptor by means of ordinary ion projection printing systems, the voltage achieved is not high enough for development with a dry, conventional xerographic two-component magnetic brush developer utilizing carrier particles having an electrically insulating outer surface. Thin dielectric imaging layers result in less voltage on the surface and fewer toner particles are pulled from the development system for deposition onto the electroceptor imaging surface. This results in low density toner images due to a combination of low charge density and low voltage. It has, therefore, been generally accepted that high resolution, dense image ionography precludes the use of virtually all the standard dry toner development systems because the achievable development fields (or surface potential) falls below the necessary working range. The underlying reason normally given for this is that the electroceptor has to be very thin or have a low electric field from the image charges in order to accept charge without excessive spreading (blooming) of the deposited charge, yet the electroceptor must be thick enough to provide fields strong enough to drive development. The latter was generally not attainable without also having fields high enough to cause excessive blooming. So the remaining choice was to focus on high charge density and seek a development system which could develop weak fields (e.g. development with liquid ink or single component conductive magnetic brushes containing marking particles having an average particle size of between about 0.1 micrometer and about 15 micrometers). It was believed that the resolution and blooming characteristics were only related to surface charge and field (or surface potential) which were only a function of the dielectric thickness (physical thickness/dielectric constant). For example, in U.S. Pat. No. 4,410,584 to Ando et al issued Aug. 24, 1976, a dielectric imaging member is disclosed having a thickness of about 1 mil (25.4 micrometers). Other patents such as U.S. Pat. No. 4,463,363 to Gundlach et al, U.S. Pat. No. 4,524,371 to Sheridan et al, U.S. Pat. No. 4,644,373 to Sheridan et al, and U.S. Pat. No. 4,584,592 to Tuan et al merely mention a dielectric imaging member but do not appear to provide any dimensions. Some prior art systems have employed low charge modulating ion sources depositing charges of, for example, 17 to 20 nanocoulombs per cm 2 . These low charges were too low to be operable with conventional two component development systems utilizing thin, low dielectric constant electroceptors. Further, thin electroceptor or dielectric imaging layer thicknesses are expensive and difficult to process because greater absolute uniformity is necessary to maintain the variance to a small set fraction of the total imaging layer thickness. Thickness variation in an ion stream electrographic imaging system is directly related to the uniformity of the image voltage which is directly related to the developed image quality.
Thus, the prior art ionographic imaging systems utilize low potential charge generating devices, emit an irritating whistling noise at high fluid jet rates and are generally unsuitable for development with standard dry two-component xerographic developers.
Other electrographic systems using dielectric materials such as aluminum oxide materials in the electroceptor exhibit low charge acceptance, high charge decay rates and lateral conduction under ordinary operating conditions. Since aluminum oxide materials are hygroscopic, the electroceptor must be run hot in order to avoid the adverse effects of large variations in ambient humidity [e.g. above 50 percent RH and 23.9° C. (75° F.)] such as image blurring and image retention after erase (ghosting). This electroceptor has too small a dielectric thickness for use in ionographic imaging systems utilizing low potential charge generating devices and standard two component dry xerographic toner development systems.
A stylus, instead of fluid jet ion projection, may be used to charge an electroceptor. Although a stylus is capable of charging dielectric imaging members to high potentials, the stylus itself and/or the imaging member can wear rapidly, produces undersirable fumes and can puncture the electroceptor.
Some prior art xerographic photoreceptors having a thickness of at least about 25 micrometers (1 mil) have been charged to relatively high voltages because of an unlimited power source such as a corotron which are not charge limited. Unfortunately, xeographic photoreceptors require expensive special shipping and storage treatment for protection from temperature extremes of fluctuations, exposure to sun light, contact with reactive fumes and the like. Moreover, special shutter systems, particularly automatic shutter systems, are required in xerographic machines to protect the photoreceptor when it is in use or when it is not in use. Further, photoreceptors are usually sensitive to heat and must be located a safe distance from fusers thereby limiting flexibility in machine architecture design. Also, photoreceptors are sensitive to toner filming. In addition, the coefficient of friction, surface energy and the like of photoreceptors materials, particularly the surface, cannot be readily tailored to accommodate different machine components such as blade cleaning systems. Moreover, cycle up and cycle down problems are a common characteristic of photoreceptors.
INFORMATION DISCLOSURE STATEMENT
In U.S. Pat. No. 4,524,371 to N. Sheridon et al, issued June 18, 1985, a fluid jet assisted ion projection printing apparatus is disclosed comprising a housing including ion generation and ion modulating regions. Image resolution was limited by the number of spots per inch in the printing apparatus and density is a function of the use of a development electrode.
In U.S. Pat. No. 3,725,951 to McCurry, issued Apr. 3, 1973--a method of forming electrostatic images on a dielectric surface is disclosed by controlling the relative ion concentration in a gas stream moving through a channel and directed upon the dielectric surface. Relative ion concentration in the gas stream is controlled by selective application of electric fields to an array of channels. A -15 volt DC supply is employed for the electric fields. A dielectric medium may be precharged to a desired potential with a polarity opposite the ion polarity so that subsequent controlled application of ions forms a latent image on the precharged dielectric surface. The latent image passes through a developer and fixer, "both of which are well known in the art".
In U.S. Pat. No. 3,742,516 to Cavanaugh et al, issued June 26, 1973--a printing head is disclosed for forming electrostatic images on a dielectric surface by using selective application of low voltage electric fields to control the relative ion concentration in a gas stream moving through a slot and directed upon the dielectric surface. A -15 volt DC supply is employed for the electric fields. A dielectric medium may be precharged with a desired potential with a polarity opposite the ion polarity so that subsequent controlled application of ions forms a latent image on the precharged dielectric surface. The latent image passes through a developer and fixer, "both of which are well known in the art".
In U.S. Pat. No. 4,593,994 to Tamura et al, issued June 10, 1986--An ion flow modulator used in a photocopy machine is described. The ion flow modulator includes an insulating substrate, a common electrode formed on a major surface of the insulating substrate, a plurality of ion flow control electrodes, a photoconductive layer and various other components. Positively charged ions from the modulator form an electrostatic latent image on a dielectric drum which was previously charged with a uniform negative charge. Toner supplied from a toner hopper is attracted to the latent image and the resulting toner image is transferred to a copy sheet and fixed thereto. A specific dielectric drum is disclosed comprising a polyethylene terephthalate layer having a thickness of approximately 20 micrometers.
In U.S. Pat. No. 4,168,974 to Ando et al, issued Sept. 25, 1979--An electrophotographic process is disclosed in which an image is formed using a photosensitive screen having a plurality of tiny openings. Image exposure of the uniformly charged screen forms a primary electrostatic latent image on the screen that is employed to modulate ions moving through the screen between a corona ion flow source and screen whereby a secondary electrostatic latent image is formed on a recording member that was previously uniformly charged to a predetermined potential. An insulated recording drum is disclosed comprising a conductive substrate coated with an insulating layer. The electrostatic latent image on the recording drum may be developed by wet type or dry type developing means. The resulting toner image may be transferred to a copy sheet and fixed thereto. An insulating layer thickness of 25 micrometers and dielectricity K of 3 are specifically mentioned.
In U.S. Pat. No. 3,976,484 to Ando et al, issued Aug. 24, 1976--An electrophotographic process is disclosed in which an image is formed using a photosensitive screen having a plurality of fine openings. Image exposure of the uniformly charged screen forms a primary electrostatic latent image on the screen that is employed to modulate ions moving through the screen under an applied electric field between an ion flow source and screen whereby a secondary electrostatic latent image is formed on a chargeable recording member consisting of a conductive base and a thin chargeable layer of, for example, a thin layer of polyethylene terephthalate or sufficiently dried conventional paper. The secondary image may be formed on the recording member while it is on a supporting conductive roller applied with a bias voltage. The latent image is developed by a developer and fixed. Development systems employed appear to include liquid and magnetic brush developers.
In U.S. Pat. No. 4,137,537 to Takahashi et al, issued Jan. 30, 1979--Electrostatic transfer process and apparatus are disclosed. An insulating surface of a latent image forming material is uniformly charged with an electrostatic charge and the charge in the image forming areas of the insulating surface are subsequently erased by electric discharge from closely spaced pin electrodes. The resulting electrostatic latent image, in the presence of a development electrode, is developed with a developer having a charge of the same polarity as the voltage applied to the development electrode. A magnetic brush development method is disclosed as preferred using a developing bias voltage. The developed image is transferred to a paper sheet. The latent image forming material may comprise a conductive substrate, an undercoat layer of a first dielectric and a recording layer of a second dielectric. In one embodiment, the undercoat layer may have a low electric capacity (C 2 =50-100 pF/cm 2 ) and medium electric resistivity (ρ 2 =10 6 -10 9 Ω-cm), and having a thickness of 30 to 80 micrometers. The recording layers have a high electric capacity (C 1 =200-500 pF/cm 2 ), medium electric resistivity (ρ 1 =10 12 -10 15 Ω-cm), and a thickness of 15 to 50 micrometers. The specific inductivity (εr 2 ) of the undercoat layer was about 4.0 and the specific inductivity of the recording layer was about 0.7. Carbon or metal oxide may be incorporated in an acrylic, epoxy or melamine resin to obtain the above electric resistivity and specific inductivity for the undercoat Titanium oxide or the like can be incorporated in an acrylic, epoxy or melamine resin to increase electric capacity to obtain the above electric resistivity and specific inductivity for the recording layer.
In U.S. Pat. No. 4,410,584 to Toba et al, issued Oct. 18, 1983, an electrostatic recording member is disclosed comprising a recording layer, an electrically conductive layer and a support, wherein the electrically conductive layer is composed of electrically conductive micro-fine powder dispersed in a polymer binder. The recording layer may comprise various organic and inorganic dielectric materials listed, for example in column 4, lines 13-29, and may have a thickness of at 1 to 20 micrometers.
In U.S. Pat. No. 3,967,959 to Goffe et al, issued July 6, 1976--a migration imaging system is disclosed in which a migration imaging member comprises a substrate, a softenable layer migration marking material, and an overlayer comprising various materials such as polystyrene, silicone resins, acrylic or cellulosic resins and many other materials, listed for example, in the paragraph bridging columns 6 and 7. The overcoating layer may have a thickness up to about 75 micrometers (if not electrically conductive). The surface of the migration imaging member may be electrically charged in imagewise configuration by various modes including charging or sensitizing through a mask or stencil, shaped electrodes, electron beam and numerous other techniques.
In U.S. Pat. No. 4,143,965 to Ando et al, issued Mar. 13, 1979--An electrophotographic process is disclosed in which an image is formed using a photosensitive screen having a plurality of tiny openings. Image exposure of the uniformly charged screen forms a primary electrostatic latent image on the screen that is employed to modulate ions moving through the screen between a corona ion flow source and screen whereby a secondary electrostatic latent image is formed on a chargeable recording member. An acceleration field is applied between the screen and the chargeable recording member. An insulative recording drum is disclosed comprising an aluminum drum coated with a 15 micrometer thick layer of insulating polycarbonate. The electrostatic latent image on the recording drum may be toner developed by a developing device and the resulting toner image may be transferred to paper and fused thereto.
In U.S. Pat. No. 4,284,697 to Ando et al, issued Aug. 18, 1981--An electrophotographic process is disclosed in which an image is formed using an arcuate photosensitive screen having a plurality of tiny openings. Image exposure of the uniformly charged screen forms a primary electrostatic latent image on the screen that is employed to modulate ions moving through the screen between a corona ion flow source and screen whereby a secondary electrostatic latent image is formed on a flat or arcuate recording member. The screen or recording member having the greater radius is rotated or moved at a higher velocity than the other. An insulated recording medium is disclosed such as recording paper or a drum comprising an aluminum substrate coated with a 15 μm thick layer of insulative material such as resin or the like provided by coating or adhesion. The electrostatic latent image on the recording drum may be developed by a developing means. The resulting toner image may be transferred to copy paper and fixed thereto. An insulating layer thickness of 25 micrometers and dielectricity K of 3 are specifically mentioned.
In U.S. Pat. No. 4,535,345 to Wilcox et al, issued Aug. 13, 1985--An ion projection apparatus is disclosed including sequentially, an imagewise charging station, a developing station and a fusing station for forming images on a charge receptor sheet. A backing electrode serves to accelerate charge deposition upon the receptor and to provide a counter charge to the latent image ion charge. The backing electrode extends from the ion projection region through the fusing region. The charge receptor sheet is preferably ordinary paper. A magnetic brush roller rotates through a sump of magnetic toner particles where it picks up toner and brushes it over the paper surface. As tendrils of linked toner particles extending from the roller are swept over the paper, a negative charge is induced on the particles and some are attracted to the positive surface charges of the established dipoles and adhere to the paper.
In GB 2 164 000 A to Xerox Corporation, published Mar. 12, 1986--A fluid assisted ion projection electrographic copier is disclosed comprising a modulation assembly having a photoconductive layer for controlling the flow of ions along an exit channel in accordance with a raster pattern projected from an original to be copied. Ions allowed to exit the modulation assembly are deposited on a receptor sheet, such as plain or dielectric paper, on a backing electrode. A preferred receptor of ordinary paper is preheated to 150°-160° C. to drive out moisture and render the paper less conductive so that it can retain a charge. A sheet resistivity of on the order of 10 15 ohm/sq is mentioned. Development is accomplished at a development station comprising a trough containing a magnetic monocomponent toner and a magentic brush roller. Toner is attracted from the brush roller to the ion image. The resulting toner image is fused.
In U.S. Pat. No. 4,463,363 to Gundlach et al, issued July 31, 1984--A fluid jet assisted electrographic marking apparatus for ion projection printing is disclosed wherein ions are generated in a chamber, entrained in a rapidly moving fluid stream, modulated in an electroded exit zone and deposited in an imagewise pattern on a relatively movable charge receptor. A discussion of the prior art describes an ion projection system using a controlled ionized fluid stream for discharging precharged areas on a charge receiving surface. A large field of opposite polarity to the ionic species is maintained between an accelerating electrode and a ion projector housing to attract the ions to a receiving surface of a receptor sheet.
In U.S. Pat. No. 4,538,163 to Sheridon, issued Aug. 27, 1985--A fluid jet assisted ion projection printing apparatus is disclosed wherein substantially equal numbers of positive and negative ions are generated simultaneously during a series of RF breakdowns which take place within a fluid transport channel. A discussion of the prior art describes an ion projection system using a controlled ionized fluid stream for discharging precharged areas on a charge receiving surface. A charge receptor such as ordinary paper collects ions from the fluid stream in image configuration. The charge receptor overlies a biased conductive accelerating electrode plate. Oppositely charged marking particles are attracted to the ion patterns at a development zone.
In U.S. Pat. No. 4,524,371 to Sheridon et al, issued June 18, 1985--A fluid jet assisted ion projection printing apparatus is disclosed having a housing including ion generation and ion modulation regions. The ions are deposited on a charge receptor on a backing electrode which may be connected to a high potential source of a sign opposite to that of the corona source.
In U.S. Pat. No. 4,644,373 to Sheridan et al, issued Feb. 17, 1987--A fluid assisted ion projection printing head is disclosed having a U-shaped cavity mated to a planar, conductive member which forms a closure for a major portion of the cavity opening and defines and ion generation chamber and a cavity exit region that is electrically conductive. Ions allowed to exit the printing head are deposited on a dielectric layer coated on an electrically conductive acceleration electrode. A high electric potential of a sign opposite the corona potential of the printing head is connected to the acceleration electrode.
In U.S. Pat. No. 4,584,592 to Tuuan et al, issued Apr. 22, 1986--A fluid jet assisted ion projection marking apparatus is disclosed including a marking head having integrally fabricated thereon, an array of modulating electrodes, address bus lines, data bus lines and thin film switches. A charge receptor collects ions from the fluid stream in image configuration. The charge receptor overlies a biased conductive accelerating back electrode. The charge receptor may be an insulating intermediate surface such as a dielectric drum.
In U.S. Pat. No. 4,410,584 to Toba et al, issued Oct. 18, 1983--An electrostatic recording member is disclosed comprising a recording layer, an electrically conductive layer and a support, wherein the electrically conductive layer is composed of micro-fine powder dispersed in an organic binder and has a surface resistivity of 10 6 to 10 8 ohms. The support may be of various shapes and various metallic or polymer materials. The recording layer is dielectric and has a volume resistivity of at least 10 12 ohm.cm preferably at least 10 14 ohm.cm. Dielectric materials such as organic dielectric substances such as polyesters, polycarbonates, polyamides, polyurethanes, (meth)acrylic-type resins, styrene-type resins, polypropylene, etc. or mixtures of inorganic powders, e.g. TiO 2 , Al 2 O 3 , MgO, etc., and organic dielectric substances are disclosed. A recording layer thickness of at least 1 μm, and preferably up to 20 μm, especially 2 to 6 μm are disclosed. Electrostatic latent images are formed on the recording member by needle electrodes. The electrostatic latent image may be developed and the resulting developed image may be transferred to ordinary paper.
In U.S. Pat. No. 4,435,066 to Tarumi et al, issued Mar. 6, 1984--An electrostatic reproducing apparatus is disclosed in which the ion flow passing through an ion modulating member is increased by strengthening the electric field between the electrode of the ion modulating electrode and the reproducing member. A dielectric drum and a developing device are also disclosed as employed in the prior art.
In U.S. Pat. No. 4,491,855 to Fuji et al, issued Jan. 1, 1985--A method and apparatus are disclosed utilizing a controller having a plurality of openings or slit-like openings to control the passage of charged particles and to record a visible image by charged particles directly on an image receiving member. The charged particles are supported on a supporting member and an alternating field is applied between the supporting member and a control electrode. The image receiving member may, for example, be paper on an electrode.
In U.S. Pat. No. 4,474,850 to Burwasser, issued Oct. 2, 1984--An ink jet recording transparency is disclosed comprising a transparent resinous support having a 2-15 micrometer thick coating of a carboxylated, high molecular weight polymer or copolymer, or salts thereof, and optionally, a particulate pigment. Various specific pigments and substituents for the polymer are also disclosed.
In U.S. Pat. No. 4,481,244 to Haruta et al, issued Nov. 6, 1984--A material for writing or printing is disclosed comprising a substrate and a coating layer containing a polymer having both hydrophilic and hydrophobic segments. The coating may comprise various polymers prepared from monomers of, for example, styrene, acrylonitrile, vinyl acetate, vinyl chloride, acrylamide, vinylidene chloride, and many other specific materials. A porous inorganic powder, such as zeolites, silica and synthetic mica, may also be incorporated into the coating.
In U.S. Pat. No. 4,503,111 to Jaeger et al, issued Mar. 5, 1985--A recording material is disclosed comprising a hydrophobic substrate material with a polymeric coating. The polymeric coating may comprises a mixture of polyvinylpyrrolidone and a compatible matrix forming polymer. Specific coating thicknesses disclosed include 10.16 micrometers (0.40 mil) and 12.7 micrometers (0.5 mil). A final coating of at least 5 micrometers (0.005 mm) is also mentioned.
Thus, while systems utilizing the above-described known approaches may be suitable for their intended purposes, there continues to be a need for the development of an improved ionographic imaging system.
OBJECTS OF THE INVENTION
It is an object of this invention to provide a novel ionographic imaging system which overcomes the above-noted disadvantages.
It is another object of this invention to provide a thicker electroceptor capable of accepting high electrostatic potentials.
It is still another object of this invention to provide an electroceptor that allows lower flow rates of fluids through ionographic imaging heads thereby avoiding loud whistling noises from expensive blowers and pumps used to move the fluids.
It is another object of this invention to provide a system for creating high charge density or surface potential on an electroceptor surface.
It is still another object of this invention to provide a system for achieving high resolution images on an electroceptor surface.
It is another object of this invention to provide a system for forming strong fields for xerographic development with dry two-component developers.
It is still another object of this invention to provide a system for achieving a combination of both line and solid area images at the same time.
It is another object of this invention to provide a system for achieving higher charge density at higher electroceptor speeds.
It is still another object of this invention to provide a system that minimizes dielectric imaging layer wear.
It is still another object of this invention to provide a system that avoids production of undesirable fumes.
It is still another object of this invention to provide a system that utilizes a simple and inexpensive imaging member.
It is still another object of this invention to provide a system that utilizes a stable and durable imaging member.
It is still another object of this invention to provide a system that is reusable in a multi pass system without distortion.
It is still another object of this invention is to provide a higher latitude for the manufacture of the imaging member.
SUMMARY OF THE INVENTION
The foregoing objects and others are accomplished in accordance with this invention by providing an ionographic imaging member comprising a conductive layer and a uniform and continuous dielectric imaging layerfree of voids, the imaging layer having a dielectric constant of from about 1.5 to about 40 and a thickness of at least about 45 micrometers, the thickness divided by the dielectric constant having a value of from about 30 to about 60 micrometers.
Also included within the scope of this invention is an imaging process comprising providing an ionographic imaging member comprising a conductive layer and a dielectric imaging layer comprising a film forming polymer, the imaging layer having an imaging surface, a dielectric constant of from about 1.5 to about 40 and a thickness of at least about 45 micrometers, the thickness divided by the dielectric constant having a value of from about 30 to about 60; selectively directing a low current ion stream on the imaging surface to form an electrostatic latent image on the imaging surface; and contacting the imaging surface with electrostatically attractable marking particles whereby the marking particles deposit on the imaging surface in image configuration. The deposited marking particles may be transfered to a receiving member and the imaging surface may thereafter be cleaned and cycled through additional latent image forming, marking particle contact, marking particle transfer and cleaning steps.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and further features and advantages of this invention will be apparent from the following description considered with the accompanying drawings, wherein:
FIG. 1 is a partial sectional elevation view showing a printing apparatus utilizing a fluid assisted ion projection printing head; and
FIG. 2 is a sectional elevation view showing details of the ion projection printing head.
With particular reference to the drawings, there is illustrated in FIG. 1 a printing system 10 comprising an electrographic imaging member 12 comprising an electrically conductive drum 14 bearing a dielectric imaging layer 16. Arranged around the outer periphery of electrographic imaging member 12 is a charging station 18 for applying a uniform electrostatic charge to dielectric imaging layer 16; a fluid flow assisted ion projection printing head 20 (e.g. of the type described in U.S. Pat. Nos. 4,463,363, 4,524,371 or 4,644,373) for selectively discharging the uniformly charged dielectric imaging layer 16 to form an electrostatic latent image; a development station 22 (e.g. a magnetic brush applicator) for contacting the electrostatic latent image with two-component developer to form a toner image in conformance with the electrostatic latent image; a sheet feeding station 24 to feed receiving sheets (shown as a dashed line 26) to dielectric imaging layer 16; a transfer station 28 to transfer the toner image to receiving sheets 26; a sheet transport station 30 to transport receiving sheets 26 bearing the transferred toner image to a fusing station 32 for fixing the toner image to receiving sheets 26; and cleaning station 33 for removing any residual toner remaining on the imaging layer 16. An adjustable biasing power supply 34 connected to development station 22 permits changes to image development conditions relative to the latent image potential. By introducing a reverse bias, of the same polarity as the ions forming the latent image, and applying the bias between the conductive drum 14 and the development station 22, non-uniformities in the non-image areas of the latent image can be kept more free of unwanted toner particles. Except for an opening at the bottom, cassette housing 36 surrounds and supports electrographic imaging member 12, charging station 18, printing head 20, development station 22, and cleaning station 33. The bottom of cassette housing 36 is open to allow imaging layer 16 to contact receiving sheets. Rails 38 and 40 are secured to the sides of and support cassette housing 36 and are adapted to be slideably mounted in horizontal tracks 42 and 44, repectively, which are, in turn, secured to frame members of the printing device. A suitable latching means (not shown) temporarily retains the cassette in place relative to the path of the receiving sheets. This arrangement facilitates rapid replacement of the major components of the electrographic printing engine. If desired, one or more of the processing stations may be positioned outside of cassette housing 36 and mounted to the frame members of the printing device because replacement is unnecessary at the time the electrographic imaging member 12 is replaced. The entire disclosures of U.S. Pat. Nos. 4,463,363, 4,524,371 and 4,644,373 are incorporated herein by reference.
Referring to FIG. 2, there is illustrated, by way of example, an ion projection head 50 comprising an upper casting 51 of electrically conductive material. Upper casting 51 is cast of stainless steel but it should be understood that any other suitable conductive material will be satisfactory, as long as it will not be affected by extended exposure to the chemistry of the corona discharge. Upper casting 51 of projection head 50 is connected to a plenum chamber (not shown) to which is secured a source of fluid (not shown). An entrance channel 52 receives low pressure fluid (preferably air) from the plenum chamber and delivers it to ion generation cavity 54. The entrance channel 52 should have a large enough cross-sectional area to ensure that the pressure drop therethrough will be small. Cavity 54 has a generally U-shaped cross section, with its three sides surrounding a corona wire 56. Suitable wire mounting supports (not shown) are provided at opposite ends of the cavity 54 for mounting wire 56 at a predetermined location within the cavity. By mounting the wire ends on eccentric support (not shown), relative to the housing of projection head 50, some limited adjustment of the wire location is made possible. It should be apparent that although an ion projection head 50 of this construction is illustrated, other suitable ion projection head configurations may be substituted for the head illustrated. A conductive plate 58, insulating layer 60, and thin film element layer 63 are supported on a planar substrate 64, typically about 1,016 micrometers (40 mils) thick. A pair of extensions on each side of planar substrate 64 form wiping shoes (not shown) which ride upon the outboard edges of the dielectric image layer 66 supported on electrically grounded metal drum 67 so that the proper spacing is established between ion projection head 50 and the imaging surface of dielectric image layer 66.
When properly positioned on upper casting 51 of ion projection head 50, by means of suitable locating lugs (not shown), conductive plate 58 and planar substrate 64 are each cantilever mounted so that they define, in conjunction with upper casting 51, an exit channel 68 including the cavity exit region 70 [about 250 micrometers (10 mils) long] and an ion modulation region 71 [about 508 micrometers (20 mils) long]. Conductive plate 58, typically about 305 micrometers (12 mils) thick, closes the major portion of U-shaped cavity 54, forming an ion generation chamber within cavity 54 and leaving cavity exit region 70 between the end of conductive plate 58 and adjacent cavity wall 62. Preferably planar substrate 64 is a large area marking chip comprising a glass plate upon which are integrally fabricated thin film modulating electrodes, conductive traces and transistors. This large area chip is fully described in U.S. Pat. No. 4,584,592 to Hsing C. Tuan et al., the entire disclosure thereof being incorporated herein by reference. All the thin film elements are represented by thin film element layer 63. Insulating layer 60 overcoats thin film element layer 63 to electrically isolate it from the conductive plate 58.
Placement of corona wire 56 is preferably about the same distance from cavity wall 62 and from conductive plate 58, and closer to these chamber walls than to the remaining cavity walls. Such an orientation will yield higher corona output currents than with other cylindrical ion generation chamber of comparable size. The width across the cavity 54 is about 3175 micrometers (125 mils) but corona wire 56 is spaced only about 635 micrometers (25 mils) from each of the cavity walls 62 (i.e., less than half the distance between the wire and the walls of a conventional cylindrical chamber). It should be understood that it would be possible to fabricate upper casting 51 of an insulating material, as long as the cavity wall 62 is made conductive and is suitably connected to a reference potential (such as ground). If upper casting 51 is made insulating, the ion flow to the remote cavity walls will accumulate thereon. However, by spacing corona wire 56 much closer to the conductive walls than to the insulating walls, relatively few ions will flow to the insulating walls, charge build-up is minimized, and arcing to those walls is prevented.
Air flow enters ion projection head 50 through entrance channel 52, flows through cavity 54 (ion generation chamber) and out of the ion generation chamber through exit channel 68. In order to ionize the air (or other ionizable fluid) around corona wire 56 for generating a uniform corona around each linear increment of the wire in the space between the wire and cavity walls 62, well known technology is applied. For example, a high potential source 72 (on the order of about several thousand volts) may be applied to corona wire 56 through a suitable resistance element 74 (typically one megohm) and through an inductive element 75 (typically 2700 microhenries and placed as close as possible to the ion projection head) used to prevent radiative coupling from the corona wire to other system electronics during startup and a reference potential 76 (on the order of about a thousand volts or, alternatively, electrical ground) may be applied to cavity wall 62. Some of the ions, thus generated, will be attracted to cavity wall 62 where they will recombine into uncharged air molecules. Once the remainder of the ions have been swept into the exit channel 68 with the air flow, it becomes necessary to render the escaping ion laden airstream intelligible. This is accomplished in ion modulation region 71 by individually switchable modulation electrodes (not shown) in thin film element layer 63, each connected to a low voltage source 78 (on the order of about thirty volts) through a switch 80. In actual construction, the modulation electronics driving the individually switchable modulation electrodes in thin film element layer 63 may comprise standard multiplex circuitry whereby groups of electrodes are ganged and suitable backing electrodes are present on the opposite wall 62 or, alternatively each electrode may be individually driven by a known, series in/parallel out, shift register. Each electrode controls a narrow "beam" of ions in the curtain-like air stream that exits from ion modulation region 71. For example, in an array of 200 control electrodes per inch, the conductive electrodes could be about 89 micrometers (3.5 mils) wide each separated from the next by 38 micrometers (1.5 mils). It is expected that more compact arrays, having narrower electrodes and narrower insulating barriers, is well within the realm of the possible. Optimally, the distance between the thin film element layer 63 and cavity wall 62 at the closest point is between about 76 micrometers (3 mils) and about 127 micrometers (5 mils) from the standpoint of resolution and power consumption requirements. For the channel widths of this magnitude, laminar flow conditions will prevail with the air velocities of interest, e.g. about 1×10 4 cm/sec. The ions allowed to exit from ion modulation region 68 come under the influence of electrically grounded metal drum 67 which functions as an acceleration electrode that attracts the ions in order that they may be deposited upon the surface of dielectric imaging layer 66. A high potential electrical source (not shown) on the order of several thousand volts DC, of a sign opposite to that of the ions exiting from the ion projection head, may be applied to metal drum 67 in lieu of grounding. Alternatively, the surface of the dielectric imaging layer 66 may be charged by charging station 18 (see FIG. 1) to a high electric potential (on the order of a thousand volts) opposite in sign to that of the ions from the ion projection head. One benefit of precharging the receiver to a high potential of either sign is to avoid problems associated with lower potentials being created on the receiver surface by triboelectrification against components such as the cleaning blade and developer which are in contact with the surface of the electroreceptor. Triboelectric charging levels on the dielectric imaging layer 66 may reach levels 600 V above ground in either polarity depending on the receiver thickness and on the materials chosen for the contacting subsystems. By choosing the precharge level higher than the highest triboelectric charge level, all image areas and triboelectric charged areas will be precharged to a uniform level by the precharging device.
The conductive layer underlying the dielectric imaging layer may be an electrically conductive supporting substrate or an electrically conductive layer on a supporting substrate. In the latter embodiment, the supporting substrate may be either electrically insulating or electrically conductive. The conductive layer as a supporting substrate or as an electrically conductive layer on a supporting substrate may be in any suitable form including a web, foil, laminate or the like, strip, sheet, coil, cylinder, drum, endless belt, circular disc or other suitable shape. Any suitable electrically conductive material may be employed in the conductive layer. The conductive layer may be, for example, a thin vacuum deposited metal or metal oxide coating, a metal foil, electrically conductive particles dispersed in a binder and the like, or gasses which produce conductive coatings when plasma deposited. Typical metals and metal oxides include aluminum, indium, gold, tin oxide, indium tin oxide, silver, nickel, and the like. Typical electrically conductive supporting substrates include metal tubes, metalized polymers such as polyesters and other polymeric and cellulosic materials, film coated with opaque or transparent conductive polymers or the like. Typical insulating supporting substrates include organic and inorganic polymers, ceramics, cellulosic materials, salts, and blends.
Any suitable adhesive material may be employed in the optional adhesive layer of the ionographic imaging member of this invention. The optional adhesive layer may be substantially electrically insulating, or have any other suitable properties. Typical adhesive materials include polyesters (e.g. Vitel PE-100 and PE-200, available from Goodyear Chemicals Division of the Goodyear Tire and Rubber Company and DuPont 4900, available from E. I. du Pont de Nemours & Co.); styrene copolymers (e.g. various Pliolite polymers available from Goodyear Chemicals Division of the Goodyear Tire and Rubber Company); Versalan 1138 and Macromelt 6238, available from Henkel Corp.; acrylic polymers (e.g. DuPont 68070 and 68080 acrylic adhesives, available from E. I. du Pont de Nemours & Co.); polyurethane resins (e.g. Estane 5707, 5715, available from B. F. Goodrich Chemical Company, Division of B. F. Goodrich Co.) and the like and mixtures thereof. Where the adhesive layer is electrically insulating, it is preferably continuous and has a thickness up to about 10 micrometers, although thicker adhesive layers may be suitable and desirable in some embodiments. Where the adhesive is not conductive, the dielectric thickness of the adhesive layer should be added to the dielectric thickness of the imaging layer. If the adhesive layer is electrically conductive, there are virtually no limitations on thickness, except for the practical ones of handling and economics. Adhesive layers of between about 0.5 micrometer and about 2.0 micrometers are preferred for more uniform coatings of dielectric imaging layer material when applied by spray coating.
The dielectric imaging layer of this invention comprises a material capable of forming an integral, uniform and continuous layer free of voids and may comprise a film forming polymer, inorganic materials or mixtures thereof with or without other additives. The dielectric imaging layer as a whole should have a dielectric constant of from about 1.5 to about 40 and a thickness of at least about 45 micrometers, the thickness divided by the dielectric constant having a value of from about 30 to about 60. It has been found that some electroreceptors having these properties have produced images with at least about 600 spots/inch resolution and at least about 0.8 image density in ionographic imaging systems utilizing fluid jet assisted ion projection heads and two component developers containing insulating carrier particles as well as single component and liquid development systems. The dielectric imaging layer may be made from any suitable organic or inorganic material. The dielectric imaging layer may be homogeneous or heterogeneous. Typical homogeneous layers include organic film forming polymers having a dielectric constant of between about 1.5 to about 40 such as those listed in Table I below.
TABLE I______________________________________Dielectric Constant DIELECTRIC IMAGING LAYER(@ 10.sup.6 cps. or Hz) POLYMERS______________________________________4 to 6 Polyurethane3 to 4.5 Polyesters2 to 3 Polytetrafluoroethylene and other fluorocarbon polymers2.8 to 3.2 Polycarbonate3.1 to 3.7 Polyarylether3.1 Polysulfone2.5 to 3.4 Polybutadiene and Copolymers with Stryene, vinyl/toluene, acrylates3.5 Polyethersulfone2.2 to 2.6 Polyethylene and Polypropylene3.5 Polyimide4.0 Poly(amide-imide)3.1 Polyetherimide2.12 Polyethylpentene3.2 Polyphenylene Sulfide2.5 to 3.4 Polystyrene and Acrylonitrile Copolymers3.3-4.5 Polyvinylchloride and Polyvinyl acetate copolymers and terpolymers2.6 to 3.3 Silicones2.1 to 3.5 Acrylics and Copolymers2.8 to 4.1 Alkyd3.0-5.0 Amino2.8 to 4.0 Cellulosic resins and polymers3.3 to 4.0 Epoxy resins and esters3.3 to 4.5 Nylon and Other polyamides4.5 to 5.0 Phenolic2.6 to 3.0 Phenylene oxide6.4 to 10.0 Polyvinylidene fluoride7.0 to 9.0 Polyvinyl fluoride3.8 Phenoxy3.7 Polyaryl Sulfone______________________________________
Typical organic film forming polymers include, for example, polycarbonate co-polyesters (e.g. XP73036.00 and XP73038.00, available from Dow Chemical Co.), polyethylene terephthalate, co-poly(1,4-cyclohexylenedimethylene/ethylene) terephthalate, polysulfone and the like. Of special interest are the various urethanes, epoxies, acrylates, and silane materials which could be deposited as monomeric coatings and cured on the conductive layer by UV, e-beam or heat to form tough abrasion resistant polymeric coatings. Polymeric dielectric imaging layer materials such as polyurethane (Imron enamel available from E. I. du Pont Nemours and Co.) polycarbonate (e.g. Makralon 5745, available from BASF Corp.), polycarbonate co-esters (e.g. XP73010.00, available from Dow Chemical Co. Corp.), polysulfone, copoly (1,4-cyclohexylene-dimethylene/ethylene) terephthalate (PETG co-polyester 6763, available from Eastman Kodak Co.), polyvinyl fluoride, polyvinylidene fluoride, perfluoroalkoxy tetrafluoroethylene, and in mixtures thereof are particularly preferred because they readily accept charge, exhibit low charge decay, good humidity stability, and are easy to clean. The dielectric imaging layer may comprise a blend of a film forming polymer and an adhesive such as the adhesive materials described above with reference to the optional adhesive layer. For example, excellent results have been achieved with blends of 80 percent by weight polycarbonate (Lexan 4701, available from General Electric Co.) with 20 percent by weight polyester (Vitel PE-100, available from Goodyear Tire and Rubber Co.) or 20 percent by weight polyester (Vitel PE-200, available from Goodyear Tire and Rubber Co.). These blends adhere particularly well to metallic surfaces and eliminate the need for a special adhesive layer.
If desired, any suitable inorganic material may be employed in a homogeneous dielectric imaging layer. Typical inorganic materials include ceramics, aluminum oxide, titanium dioxide, zinc oxide, barium oxide, glasses, magnesium oxide and the like.
The dielectric imaging layer may also contain any suitable dissolved or dispersed materials. These dissolved or dispersed materials may include, for example, inorganic materials such as barium titanate, transition metal oxides of iron, titanium, vanadium, manganase, or nickel, phosphate glass particles and the like. One specific class of dispersed materials is obtained from the transition metal oxides by making use of their property of multiple valency. Transition metal phosphate glasses may be obtained by mixing and subsequently melting sufficient quantities of the transition metal oxides with phosphorous pentoxide. This process creates a glass with predetermined dielectric properties in which a desired composite material dielectric constant can be obtained in a predictable manner. One example of such a glass is 4.5 TiO 2-x .2P 2 O 5 , where `x` determines the ratio of the two valence states of the Ti--the larger the `x` the more Ti 3 + ion is present. The ratio of Ti 3 + to Ti 4 + determines the dielectric properties of the glass. Thus, the smaller the value of `x`, the smaller the value of the DC dielectric constant. Such a glass may be produced by first obtaining an appropriate TiO 2 --P 2 O 5 mixture by heating a calculated mix of powdered TiO 2 and (NH 4 ) 2 HPO 4 in an argon atmosphere. This mixture is doped as required with Ti 2 O 3 . After thorough mixing, the resultant powder is heated in an argon atmosphere until it melts. It is maintained in a molten state for a period of about 1 hour and then cast by pouring directly from the melt. Alternatively, the glass may be shotted by conventional means. A value of x=0.05 yields a static dielectric constant of about 20 and a high frequency dielectric constant of about 6. Values in this range are easily achieved with all the transition metal oxides; values as high as 100 can be obtained for the static dielectric constant. Once formed, the glass is ground or otherwise processed into fine particles for combination in the manner described herein to create the electroceptor of a desired dielectric constant. In preparing the transition metal phosphate glasses other transition metals such as V, Mn, Ni, Fe and the like may be substituted for Ti in the above formula. The values in front of the oxide and the pentoxide may also be varied. Thus, with the pentoxide value fixed, the other value may be varied from 2.5 to 6 to still achieve a glass. These materials are are humidity insensitive, tough, vary in transparency from clear at `x`=0 to smoky for x=0.1, and are nontoxic in that they are inert in this form. Alternatively, or in addition to the inorganic materials, organic materials maybe dissolved or dispersed in the electroceptor layer. Typical organic materials include charge transport molecules, waxes, stearates, light and thermal stabilizers, dyes, antioxidants, plasticizers, and the like and mixtures thereof. Preferably, the dielectric imaging layer contains from about 20 percent by weight to about 100 percent by weight film forming polymer and from about 0 percent by weight to about 80 percent by weight of dispersed material, based on the total weight of the dielectric imaging layer. Typical heterogeneous layers include organic polymers containing dissolved or dispersed materials such as barium titanate dispersed in polypropylene, or transition metal (Fe, Ti, V, Mn, Ni) oxide or phosphate glass particles dispersed in a polymer such as polycarbonate, polyester, polyethylene, polysulfone, polyvinyl, polyurethane, nylon, and the like. The dielectric imaging layer may also contain various compounds dissolved or dispersed throughout which could aid in improving electrical charge retention such as various charge transport molecules. Also, for example, additives could be employed to increase or decrease the dielectric constant of the dielectric imaging layer. By selection of suitable dielectric imaging layer materials, the electroceptor surface may be utilized for triboelectric charging of toner or developers. Moreover, release agents may be incorporated in the imaging layer to promote toner transfer or removal, e.g. zinc stearate may be added for cleaning. Further, powder fillers may be added to increase compressive strength for transfix properties.
It should also be appreciated that a host of other dielectric materials are listed in the Handbook of Chemistry and Physics, 66th Ed. 1985-1986, CRC Press, Inc., Section E, pages 49-59 and elsewhere which are potentially useful in dielectric imaging layers (electroceptors), and their selection is obvious once the desired conditions stated above are recognized.
If desired, the dielectric imaging layer may comprise multiple layers of the same or different dielectric materials. Generally, the composite of the multiple layers, as a whole, should have a dielectric constant of from about 1.5 to about 40 and a thickness of at least about 45 micrometers, the thickness divided by the dielectric constant having a value of from about 30 to about 60. The uppermost layer may have different properties than the underlying layers. For example, a Teflon upper layer having a thickness of about 2 micrometers may be selected for its low dielectric constant property, its excellent stability to wear resistance, and its low surface energy characteristics for improved transfer and cleaning processes. The underlying dielectric layer could be another dielectric material such as a polyimide (Kapton type F, available from E. I. Du Pont de Nemours & Co.) having thickness of about 43 to 75 micrometers and a dielectric constant of 3.7.
The thickness of the deposited dielectric imaging layer or layers after any drying or curing step is preferably at least about 75 micrometers to obtain high resolution and image density. When the dry thickness of the dielectric imaging layer is less than about 45 micrometers, the image density from a given ion projection head and two component development system is low, although resolution is acceptable. Optimum results are achieved with a total dielectric imaging layer thickness of between about 75 micrometers and about 400 micrometers.
The dielectric imaging layer and/or the optional adhesive layer may be applied to an underlying layer by any suitable coating process. Typical coating processes include conventional draw bar, air assisted, atomized, or rotary spraying, extrusion, dip, gravure roll, wire wound rod, air knife coating, sputtering, powder coating, and the like.
If desired, any suitable solvent may be employed with the film forming polymer material to facilitate application of the dielectric imaging layer to the electrically conductive layer or to the optional adhesive layer. For those materials which form films during the coating process, the solvent should dissolve the film forming polymer. Typical combinations of film forming polymer materials and solvents or combinations of solvents include polycarbonate (e.g. Lexan 4701 available from General Electric Co.) and dichloromethane/1,1,2-trichloroethane; polycarbonate (e.g. Makrolon 5705, available from BASF Corp.) and 1,12 trichloroethane; polysulfone (e.g. P-3500, available from Union Carbide Corp.), methylene chloride and 1,1,2 trichloroethane; Merlon M-39 (available from Mobay Chemical Co.), dichloromethane, 1,1,2 trichloroethane, Lexan 145 (available from General Electric Co.) and 1,1,2 trichloroethane; Lexan 3250 (available from General Electric Co.), dichloromethane and 1,1,2 trichloroethane; Dow XP73038 (available from Dow Chemical Co.), dichloroethane and 1,1,2 trichloroethane; XP 73010.0 (available from Dow Chemical Co.) and 1,1,2 trichloroethane; Lexan 145 (available from General Electric Co.), dichloroethane and 1,1,2 trichloroethane; and Dow Polycarbonate Copolymer XP73036.00 (available from Dow Chemical Co.), dichloromethane and 1,1,2 trichloroethane and the like. Coatings applied from solutions may be solidified by any suitable technique to dry or cure the coating. Typical drying techniques include oven drying, infra-red lamp drying, vacuum chamber drying, and the like. Drying is preferably conducted at a rate which minimizes the formation of bubbles and stress in the coating. For example, programmed heating rates conducted with incremental increases in temperature for predetermined periods of time may be utilized to form layers substantially free of bubbles, stress cracks and other voids. Polymers may also be held in suspension, emulsion, or dispersion during the coating process and later formed into films during drying, coalescence, or curing processes in which latent solvents are employed.
It is generally desired to achieve between about 75 and about 600 volts for good development of the latent image on a dielectric imaging layer utilizing electrophoretic, conductive magnetic brush, or single component development and between about 250 and about 1000 volts for good development of the latent image on a dielectric imaging layer utilizing two component development with insulating carriers.
The dielectric constant of the dielectric imaging layer affects the blooming factor. Charge spreading occurs when the incoming ions are repelled by the field emanating from the receptor towards the ion head created by ions already deposited on the receptor. Field strength in the region above the electroreceptor is determined by the ratio of the dielectric thickness of the region between the ion projection head and the receptor and the dielectric thickness of the receptor. For the same thickness of receiver, the lower dielectric constant causes more spreading. Generally, satisfactory results may be achieved with dielectric imaging layers having a dielectric constant between about 1.5 and about 40 with thicknesses of at least 45 microns which give dielectric thicknesses of between 30 and 60 microns. The lower boundry of 1.5 for dielectric constant is currently a material availability boundry. Coating uniformity for the thin layers needed to utilize low dielectric constant materials becomes more difficult to achieve because of a tighter requirement on absolute thickness. Voids such as pinholes and other coating defects are also more problematic for thinner coatings. The upper limit of about 40 on the dielectric constant of a film forming polymer is determined by the effects of the dopant used to raise the dielectric constant. The mechanical integrity of the layer is adversely affected by the addition of bulk dopants and adhesive properties of the polymer to the dopant and of the mixture to the substrate. Some high dielectric constant materials are very sensitive to factors such as charge trapping and charge injection. These factors are difficult to control in high dielectric constant materials created by bulk doping of polymers. Moreover, the interface with the substrate becomes more sensitive to charge injection creating the possible need for charge blocking layers. In addition, high dielectric constant materials require greater thicknesses which increase cost and manufacturing difficulty. A dielectric constant of between about 2 and about 12 is preferred. Optimum results are achieved with a dielectric constant of between about 2 and about 8.
The dielectric imaging layer should also have a bulk resistivity of at least about 10 10 ohm cm at between about 5 percent to about 80 percent relative humidity and between about 16° C. (60° F.) and about 50° C. (122° F.) because charge movement on the surface of the imaging layer after imagewise discharge results in image blooming. Bulk resistivity below this level also causes charge decay through the dielectric imaging layer decreasing the available image charge level for development.
In regard to thickness of the dielectric imaging layer, thinner dielectric imaging layers can accept charge without excessive spreading, but are more adversely affected by pin holes, impurities and the like. Moreover, less voltage can be impressed on it so that adequate development with two component magnetic brush development with insulating carrier particles is not possible. Also, the uniformity of coating and the tolerances of the substrate surface become more critical with thinner dielectric imaging layers. For example, a 0.25 micrometer thickness variation in a thick 203 micrometer (8 mil) dielectric imaging layer presents less variation of uniformity than a 0.25 micrometer thickness variation in a thin 25 micrometer (1 mil) dielectric imaging layer. A satisfactory lower thickness limit is about 45 micrometers with a dielectric constant of 1.5 because variation in thicknesses of less than about 5% can be achieved by conventional coating techniques and films without pinholes and other coating defects can be cost effectively produced. A preferred thickness is about 76 micrometers (3 mils) for a dielectric constant of 2 to about 360 micrometers for a dielectric constant of 12 and an optimum at lower dielectric imaging layer thicknesses is about 127 micrometers (5 mils) where the dielectric constant of the dielectric imaging layer is about 3. For a dielectric imaging layer having a dielectric constant of about 7, the lower thickness limit is about 210 micrometers (8.3 mils). The satisfactory upper limit is about 2400 micrometers for materials having a dielectric constants of about 40.
The thickness divided by the dielectric constant should be between about 30 and about 60 with optimum being about 35 to 54. For materials having a thickness approaching the upper limit of 2400 micrometers, costs become considerable because the dielectric constant has to be raised with special compounds such as barium titanate. The use of additives can affect batch to batch uniformity of the dielectric imaging layer. For example, a small percentage change in additive content can cause a much greater percentage change in dielectric constant beyond 30 percent loading, because the dielectric constant is a superlinear function of loading.
As previously described, a preferred imaging process of this invention comprises providing an ionographic imaging member comprising a conductive layer and a dielectric imaging layer comprising a film forming polymer, the imaging layer having an imaging surface, a dielectric constant of from about 1.5 to about 40 and a thickness of at least about 45 micrometers, the thickness divided by the dielectric constant having a value of from about 30 to about 60; uniformly depositing on the imaging surface an electrostatic charge of a first polarity, directing a stream of ions of a polarity opposite the charge of a first polarity from a head electrically biased to the same polarity as the ions to discharge in image configuration the uniformly deposited charge of a first polarity thereby forming an electrostatic latent image on the imaging surface, and depositing electrostatically attractable marking particles on the imaging surface in conformance with the electrostatic latent image while simultaneously applying an electrical bias of the first polarity across the thickness of the dielectric layer and marking particle developer system.
Generally, the uniform charging of the ionographic imaging member is accomplished to achieve a potential between the ion projection head and the conductive layer of the ionographic imaging member of between about 1000 volts and about 4000 volts. The uniform charge on the dielectric member may account for between 5 percent and 100 percent of the potential. The dielectric imaging member may be uniformly charged by any suitable means. A typical charging means is a conventional corona charging element extensively utilized in xerographic imaging systems. Generally, satisfactory results may be achieved by uniformly charging the dielectric imaging layer to between about -50 volts and about -2000 volts. When the dielectric imaging layer is charged to less than about -50 volts, the charging systems are less able to provide a uniform charge level or to effectively erase the previous imagewise charge pattern. If the dielectric imaging layer is charged to more than about 100 volts per micrometer of thickness or exceeds its dielectric strength electrical breakdown may occur. If the voltage difference between the head and receptor exceeds the Paschen limit for the spacing between them, electrical breakdown can also occur.
Imagewise discharging of the uniformly charged imaging surface starting at a satisfactory level of about -1500 V with an ion stream should reduce the charge potential on the imaging surface to between about -1425 volts and about -500 volts to form an electrostatic latent image on the imaging surface having a difference in potential between background areas and image areas of between about 75 volts and about 1000 volts. Selection of surface potential depends on the biasing of suitable developer subsystems, with about 75 to about 600 volts for good development of the latent image on a dielectric imaging layer utilizing electrophoretic, conductive magnetic brush, or single component development and with about 250 to about 1000 volts for good development of the latent image on a dielectric imaging layer utilizing two component development with insulating carriers. Any suitable non-fluid assisted or fluid assisted ion projection printing head may be utilized to imagewise discharge the uniformly charged dielectric imaging layer. Ion projection printing heads are well known in the art. Typical non-fluid assisted ion projection printing heads are described, for example, in U.S. Pat. Nos. 3,976,484, 4,143,965, 4,137,537, 4,168,974, and 4,494,129, the entire disclosures of these patents being incorporated herein by reference. Typical fluid assisted ion projection heads are described, for example, in U.S. Pat. No. 4,644,373 to N. Sheridon and G. Sander, U.S. Pat. No. 4,463,363 to R. Gundlach and R. Bergen and U.S. Pat. No. 4,524,371 to N. Sheridon and M. Berkovitz, the entire disclosures of these patents being incorporated herein by reference. Fluid assisted ion projection printing heads are preferred because they do not come into physical contact with the electroreceptor which can cause wear and damage as stylus systems can. Further, fluid assisted ion projection is more efficient and can produce higher resolution images because non fluid assisted systems utilize screens or apertures which restrict ion flow to certain regions of the receptor. As previously described, in a typical fluid assisted ion projection printing head, pressurized air is moved through an ion generation chamber for entraining ions generated in the ion generation chamber and for transporting them through an exit channel or slit including an ion modulation region for subsequent deposition upon the uniformly charged dielectric imaging layer. Generally, the pressurized air is under a pressure of between about 1 inch of water and about 10 inches of water, and preferably between about 3.5 to about 7 inches of water prior to introduction into the ion generation chamber. A corona wire is mounted in the ion generation chamber and high electrical fields are established between the mounted corona wire, maintained at from about 2000 volts to about 6000 volts DC, and the conductive walls of the ion generation chamber. Because the voltage on the corona wire needed to maintain the corona is dependent on the spacing and geometry of the wire and the ion generation chamber, the preferred embodiment is to maintain this voltage by applying a comstant current source of about from 0.8 to 2.0 miliamps to the wire. A bias potential of from 0 volts to about 1500 volts DC may be applied to the conductive walls of the ion generation chamber, the polarity of the reference voltage being the same as that of the polarity of the potential applied to the corona wire. As the ions are swept into the exit slit the ion stream is modulated by individually switchable modulation electrodes in thin film element layer, each connected to a voltage source of from about 10 volts to about 400 volts DC, the polarity of the applied potential being chosen to deflect the ions toward or away from the modulation electrodes. The distance between the thin film element layer and cavity wall at the closest point is between about 76 micrometers (3 mils) and about 203 micrometers (8 mils) to provide satisfactory resolution at a reasonable rate of power consumption. Since image resolution depends upon the spots per inch of charge projected to the receiver to produce the electrostatic latent image, the ion streams should be controlled and modulated to less than the spot width. For example, 2700 volts is employed for a 635 micrometer (0.025 inch) exit slit gap to prevent charge spreading as ions traverse the space between the fluid assisted ion projection printing head and the receiver surface. For the channel widths of this magnitude, laminar flow conditions will prevail with the air velocities between about 0.3 CFM and about 3 CFM and preferably between about 1 CFM to about 2.1 CFM. A high potential electrical source between about 0 volts to about 1500 volts DC of a sign opposite to that of the corona potential may be applied to metal layer underlying the dielectric imaging layer. Generally, the fluid assisted ion projection printing head should be spaced from about 150 micrometers and about 1500 micrometers from the imaging surface of the dielectric imaging layer. If the head is too close to the imaging surface, Paschen breakdown occurs and the imaging surface discharges. Although one polarity of charging and discharging has been described here, this invention may equally well be used with all polarities reversed, and/or with development systems utilizing charged or discharged area development with well known choices of development bias and materials.
The electrostatic latent image is then developed with electrostatically attractable marking particles to form a marking particle image corresponding to the electrostatic latent image. The developing (toning) step may be identical to that conventionally used in xerographic imaging. The electrostatically attractable marking particles may be applied, for example, to the electrostatic latent image on a receiver precharged to about -1500 V and imaged to about -650 V with a developer applicator while supplying a bias potential to the developer applicator of between about -1450 volts and about -1300 volts whereby the marking particles deposit on the imaging surface in image configuration to form a marking particle image. Generally, the minimum surface voltage of the image to be developed should be at least about 250 volts when insulating two-component developers are employed and about 75 volts when conductive two-component developers or when single component development systems are used. Conductive single or two-component developers as mentioned here are systems which tend to develop until the electric field above the toned latent image is neutralized while insulating two-component developers systems tend to develop less than 50 percent of the electric field above the latent image.
Any suitable conventional xerographic dry or liquid developer containing electrostatically attractable marking particles may be employed to develop the electrostatic latent image on the electroreceptor of this invention. This invention is particularly effective for development with suitable dry two-component developers containing electrically insulating carrier particles. Two-component developers comprise marking (toner) particles and carrier particles. Typical toner particles may be of any composition suitable for development of electrostatic latent images, such as those comprising a resin and a colorant. Typical toner resins include polyesters, polyamides, epoxies, polyurethanes, diolefins, vinyl resins and polymeric esterification products of a dicarboxylic acid and a diol comprising a diphenol. Examples of vinyl monomers include styrene, p-chlorostyrene, vinyl naphthalene, unsaturated mono-olefins such as ethylene, propylene, butylene, isobutylene and the like; vinyl halides such as vinyl chloride, vinyl bromide, vinyl fluoride, vinyl acetate, vinyl propionate, vinyl benzoate, and vinyl butyrate; vinyl esters such as esters of monocarboxylic acids, including methyl acrylate, ethyl acrylate, n-butylacrylate, isobutyl acrylate, dodecyl acrylate, n-octyl acrylate, 2-chloroethyl acrylate, phenyl acrylate, methylalpha-chloroacrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, and the like; acrylonitrile, methacrylonitrile, acrylamide, vinyl ethers, including vinyl methyl ether, vinyl isobutyl ether, and vinyl ethyl ether; vinyl ketones such as vinyl methyl ketone, vinyl hexyl ketone, and methyl isopropenyl ketone; N-vinyl indole and N-vinyl pyrrolidene; styrene butadienes; mixtures of these monomers; and the like. The resins are generally present in an amount of from about 30 to about 99 percent by weight of the toner composition, although they may be present in greater or lesser amounts, provided that the objectives of the invention are achieved.
Any suitable pigment or dyes may be employed in the toner particles. Typical pigments or dyes include carbon black, nigrosine dye, aniline blue, magnetites, and mixtures thereof, with carbon black being the preferred colorant. The pigment is preferably present in an amount sufficient to render the toner composition highly colored to permit the formation of a clearly visible image on a recording member. Generally, the pigment particles are present in amounts of from about 1 percent by weight to about 20 percent by weight based on the total weight of the toner composition; however, lesser or greater amounts of pigment particles may be present provided that the objectives of the present invention are achieved.
Other colored toner pigments include red, green, blue, brown, magenta, cyan, and yellow particles, as well as mixtures thereof. Illustrative examples of suitable magenta pigments include 2,9-dimethyl-substituted quinacridone and anthraquinone dye, identified in the color index as CI 60710, CI Dispersed Red 15, a diazo dye identified in the color index as CI 26050, CI Solvent Red 19, and the like. Illustrative examples of suitable cyan pigments include copper tetra-4-(octadecyl sulfonamido) phthalocyanine, X-copper phthalocyanine pigment, listed in the color index as CI 74160, CI Pigment Blue, and Anthradanthrene Blue, identified in the color index as CI 69810, Special Blue X-2137, and the like. Illustrative examples of yellow pigments that may be selected include diarylide yellow 3,3-dichlorobenzidene acetoacetanilides, a monoazo pigment identified in the color index as CI 12700, CI Solvent Yellow 16, a nitrophenyl amine sulfonamide identified in the color index as Foron Yellow SE/GLN, CI Dispersed Yellow 33, 2,5-dimethoxy-4-sulfonanilide phenylazo-4'-chloro-2,5-dimethoxy aceto-acetanilide, Permanent Yellow FGL, and the like. These color pigments are generally present in an amount of from about 15 weight percent to about 20.5 weight percent based on the weight of the toner resin particles, although lesser or greater amounts may be present provided that the objectives of the present invention are met.
When the pigment particles are magnetites, which comprise a mixture of iron oxides (Fe 3 O 4 ) such as those commercially available as Mapico Black from Columbian Division, Cities Services, Inc., Akron, Ohio, these pigments are present in the toner composition in an amount of from about 10 percent by weight to about 70 percent by weight, and preferably in an amount of from about 20 percent by weight to about 50 percent by weight, although they may be present in greater or lesser amounts, provided that the objectives of the invention are achieved.
The toner compositions may be prepared by any suitable method. For example, the components of the dry toner particles may be mixed in a ball mill, to which steel beads for agitation are added in an amount of approximately five times the weight of the toner. The ball mill may be operated at about 120 feet per minute for about 30 minutes, after which time the steel beads are removed. Dry toner particles for two-component developers generally have an average particle size between about 8 micrometers and about 15 micrometers. Typical dry toners for two-component developers are disclosed, for example, in U.S. Pat. Nos. 2,788,288, 3,079,342 and Re. 25,136, the disclosures of which are incorporated herein in their entirety. Dry toner particles for single component developers generally have an average particle size of between about 6 micrometers and 25 micrometers. Typical toners for single toner developers include, for example, Xerox 1012 Toner for the Xerox 1012 machine and Canon NP 3000 Toner or Canon universal toner for the Canon NP-210, NP-300, NP-400 , and NP-500 machines.
Any suitable external additives may also be utilized with the dry toner particles. The amounts of external additives are measured in terms of percentage by weight of the toner composition, but are not themselves included when calculating the percentage composition of the toner. For example, a toner composition containing a resin, a pigment, and an external additive may comprise 80 percent by weight resin and 20 percent by weight pigment; the amount of external additive present is reported in terms of its percent by weight of the combined resin and pigment. External additives may include any additives suitable for use in electrostatographic toners, including straight silica, colloidal silica (e.g. Aerosil R972®, available from Degussa, Inc.), ferric oxide, unilin, polypropylene waxes, polymethylmethacrylate, zinc stearate, chromium oxide, aluminum oxide, stearic acid, polyvinylidene flouride (e.g. Kynar®, available from Pennwalt Chemicals Corporation), and the like. External additives may be present in any suitable amount, provided that the objectives of the present invention are achieved.
Any suitable carrier particles may be employed with the toner particles. Typical carrier particles include granular zircon, steel, nickel, iron ferrites, and the like. Other typical carrier particles include nickel berry carriers as disclosed in U.S. Pat. No. 3,847,604, the entire disclosure of which is incorporated herein by reference. These carriers comprise nodular carrier beads of nickel characterized by surfaces of reoccurring recesses and protrusions that provide the particles with a relatively large external area. The diameters of the carrier particles may vary, but are generally from about 50 microns to about 1,000 microns, thus allowing the particles to possess sufficient density and inertia to avoid adherence to the electrostatic images during the development process. Carrier particles may possess coated surfaces. Typical coating materials include polymers and terpolymers, including, for example, fluoropolymers such as polyvinylidene fluorides as disclosed in U.S. Pat. Nos. 3,526,533; 3,849,186; and 3,942,979, the entire disclosures of which are incorporated herein by reference. The toner may be present, for example, in the two-component developer in an amount equal to about 1 to about 5 percent by weight of the carrier, and preferably is equal to about 3 percent by weight of the carrier. The carrier, either coated or uncoated, may have an electrically insulating or electrically conductive outer surface. The expression "electrically insulating" as employed herein is defined as having a bulk resistivity of at least about 10 12 ohm cm. Heretofore, as indicated above, electrostatic latent images formed by directing a stream of ions onto a dielectric layer could not form dense, high resolution images when developed with two-component developer containing carrier particles having an electrically insulating outer surface.
If desired development may be effected with any suitable liquid developer. Liquid developers are disclosed, for example, in U.S. Pat. Nos. 2,890,174 and 2,899,335, the disclosures of these patents being incorporated herein in their entirety. Typical liquid developers may comprise aqueous based or oil based inks. This includes both inks containing a water or oil soluble dye substance and pigmented inks. Typical dye substances include Methylene Blue, commercially available from Eastman Kodak Company, Brilliant Yellow, commercially available from the Harlaco Chemical Co., potassium permanganate, ferric chloride and Methylene Violet, Rose Bengal and Quinoline Yellow, the latter three available from Allied Chemical Company, and the like. Typical pigments are carbon black, graphite, lamp black, bone black, charcoal, titanium dioxide, white lead, zinc oxide, zinc sulfide, iron oxide, chromium oxide, lead chromate, zinc chromate, cadmium yellow, cadmium red, red lead, antimony dioxide, magnesium silicate, calcium carbonate, calcium silicate, phthalocyanines, benzidines, naphthols, toluidines, and the like. The liquid developer composition may comprise a finely divided opaque powder, a high resistance liquid and an ingredient to prevent agglomeration. Typical high resistance liquids include organic dielectric liquids such as Isopar, carbon tetrachloride, kerosene, benzene, trichloroethylene, and the like. Other liquid developer components or additives include vinyl resins, such as carboxy vinyl polymers, polyvinylpyrrolidones, methylvinylether maleic anhydride interpolymers, polyvinyl alcohols; cellulosics such as sodium carboxy-ethylcellulose, hydroxypropylmethyl cellulose, hydroxyethyl cellulose, methyl cellulose, cellulose derivatives such as esters and ethers thereof; alkali soluble proteins, casein, gelatin; acrylate salts such as ammonium polyacrylate, sodium polyacrylate; and the like.
Any suitable conventional xerographic development technique may be utilized to deposit toner particles on the electrostatic latent image on the imaging surface of the dielectric imaging members of this invention. Well known xerographic development techniques include, magnetic brush, cascade, powder cloud, liquid and the like development processes. Magnetic brush development is more fully described, for example, in U.S. Pat. No. 2,791,949, cascade development is more fully described, for example, in U.S. Pat. Nos. 2,618,551 and 2,618,552, powder cloud development is more fully described, for example, in U.S. Pat. Nos. 2,725,305 and 2,918,910, and 3,015,305, and liquid development is more fully described, for example, in U.S. Pat. No. 3,084,043. All of these toner, developer and development technique patents are incorporated herein in their entirety.
When a magnetic brush developer applicator is employed for development, the development subsystem employed to apply the developer to the imaging surface of this invention is preferably run at a greater speed than one utilized for high charge xerographic systems. Thus, the direction of rotation of developer applicator rolls is preferably concurrent with the electroceptor direction and the surface speed is about 3 to about 6 times the speed of the electroreceptor with optimum between about 4 and about 5 times the electroreceptor speed. This compares to a surface speed for developer applicator rolls of 2 to 3 times that of a photoreceptor in common usage for nominal charge light and lens xerographic systems. The higher ratio compensates for the lower charge density in the latent image from the ion projection head and provides more toner per unit time in the development zone. Although developability is equivalent in both cases of with and against development roll directions for these higher speed ratios, some bead loss and scavenging can occur if the developer roll is run in the direction counter to the electroceptor direction. When it is desired that the developed image comprise an image developed corresponding to the areas of charge, it is generally preferred to pass in contact therewith a developer which is triboelectrically charged to a polarity opposite to the retained charge of the latent image whereby the developer is attracted and adheres to the charged areas of the insulative image pattern. However, when it is preferred that a developed image corresponding to the uncharged (discharged) areas be reproduced, it is the general practice to employ developer charged to the same polarity as the image charge pattern. The developer will then be repelled by the charges of the latent image and will deposit on the non-charged (discharged) areas of the imaging member with the charged areas remaining absent of developer.
Image density is enhanced by the use of a development electrode. Development electrodes are widely used in the field of electrophotography. Depending upon the particular development technique employed, the development electrode may exist as part of the developer applicator or as a separate electrode closely spaced from the imaging surface of the dielectric imaging layer. For example, the development electrode may be a cylindrical applicator for applying two-component magnetic developer to the electrostatic latent image on the imaging surface of the dielectric imaging layer. The development electrode may be of any suitable shape. Typical development electrode shapes include cylinders, flat and arcuate plates, segmented flat and arcuate plates, and the like. Satisfactory results may be achieved with a development electrode to dielectric imaging layer surface distance of between about 250 and about 2500 micrometers for dry two-component developers and of between 75 and 1000 micrometers for single component development systems. The lower limit for dry two-component developers is limited by the bead size and the magnetic brush rigidity. The upper limit is determined by the ratio of the dielectric thicknesses of the development zone and the electroreceptor such that the electrode is effective in bringing the field into the region between the development electrode and the surface of the receptor. For single component development systems, the separation limits are set by the size of the toner for contact systems and by the height of the projected toner for jumping and cloud type systems. A high potential electrical source of between about 40 volts DC and about 300 volts DC of a sign opposite to that of the corona potential, may be applied to the development electrode to achieve satisfactory image density. The lower limit of the developer bias is set by the tendency of some development systems to deposit toner in the background areas of the images when the reverse or cleaning field is below about 40 V above the background voltage. The upper limit is determined by the loss of developability caused by decreasing the contrast voltage available.
In a typical example, the charge attained from an ionographic imaging system utilizing a fluid jet assisted ion projection head can be about 17 to about 20 nanocoulombs/cm 2 at a 2 in/sec imaging layer surface speed. For a desired contrast voltage of about 850 volts, a polycarbonate dielectric imaging layer material having a thickness of about 125 micrometers (5 mils) and a dielectric constant of 3.1 can be used. The dielectric constant can range from about 1.5 to about 12 or even higher. The thickness divided by the dielectric constant can be about 40 to 54 optimum, but 30 to 60 has been found to be the range for satisfactory results in this material and in other materials with dielectric constants ranging from about 1.5 to about 12 or even higher for development with dry two-component developer containing carrier particles having an electrically insulating outer surface. If, for example, the dielectric constant as 7 as for polyvinyl fluoride (Tedlar, available from E. I. du Pont de Nemours & Co.), then the optimum thickness range is from about 280 micrometers (11 mils) to about 378 micrometers (15 mils) or about 11 to 15 times greater than the 25 micrometer (1 mil) thickness described in U.S. Pat. No. 4,410,584. The foregoing calculations were performed for optimum parameters based on a fluid jet assisted ion projection head that deposits a charge ranging from about 15 to about 30 nanocoulombs per cm 2 .
Any suitable means may be used to transfer the developed image from the surface of the imaging member to the transfer or copy sheet representing the final copy. A particularly useful and generally preferred method of carrying out the transfer operation comprises an electrostatic transfer technique wherein a transfer sheet is placed in contact with the image bearing surface and an electric charge applied to the reverse side of the transfer sheet by, for example, an adjacent ion source such as a corona discharge electrode or other similar device placed in juxtaposition to the transfer member. Such an ion source may be similar to the source employed during a charging step of a conventional xerographic imaging process and is maintained at a high electrical potential with respect to the image bearing imaging member. Corona discharge results in the deposition on the transfer sheet of ionized particles which serve to charge the sheet. The transfer sheet will be charged to a polarity opposite to that of the developed image and such charge is strong enough to overcome the potential initially applied to the surface of the imaging member. A single wire corotron having applied thereto a potential of between about 3000 and about 7000 volts provides satisfactory transfer. Adhesive pick off is another form of image transfer that may be used. The electrostatic transfer process is preferred in order to obtain maximum image transfer while retaining high image resolution. When liquid developers are employed a more generally preferred method of image transfer is that of applying contact pressure when the transfer sheet is brought into surface contact with the developed image.
Any suitable material may be used as the transfer or receiving sheet for the developed image during the imaging process. The copy material may be insulating in nature or partially conductive. Typical materials are polyethylene, polyvinylchloride, polyvinyl fluoride, polypropylene, polyethylene terephthalate, ordinary bond paper, and the like.
The image transferred to the surface of the transfer or receiving sheet may be fixed to its support by any suitable means such as vapor fusing, heated roll fusing, flash fusing, oven fusing, lamination and the like. It is preferred to use the heat fixing technique in conjunction with toner developed images inasmuch as it allows for a high degree of control of the fixing phase of the process. When liquid developers are used, fixing is achieved by allowing for the evaporation of the relatively volatile carrier fluids utilized. Thus, the fixing step may be identical to that conventionally used in xerographic imaging.
The imaging member may optionally be erased by any suitable technique such as exposing the imaging surface to AC corona discharge to neutralize any residual charge on the imaging member. Typical potentials applied to an AC corona erasing device range from plus and minus about 3000 volts and about 6000 volts.
If desired, the imaging surface of the imaging member may be cleaned. Any suitable cleaning step that is conventionally used in xerographic imaging may be employed for cleaning the imaging member of this invention. Typical, well known xerographic cleaning techniques include brush cleaning, web cleaning, blade cleaning, and the like.
After transfer of the deposited toner image from the imaging member to a receiving member, the imaging member may, with or without erase and cleaning steps, be cycled through additional electrostatic latent image forming, development and transfer steps to prepare additional imaged receiving members.
Although formation of an electrostatic latent image by utilization of a fluid assisted ion stream system for imagewise discharge of uniformly precharged electroceptors of this invention is particularly preferred to achieve surface voltages and high energy fields suitable for development with any kind of developer, including standard, dry two-component developers to achieve image densities of at least about 0.7, satisfactory results may be achieved with other types of developers, such as liquid or single component conductive developers, where the electrostatic latent image is formed on an electroceptor by an ion stream with or without any prior uniform charging step.
Unlike prior art ion stream ionographic systems, the ion stream latent image forming system of this invention utilizes thick dielectric imaging layers to provide images having excellent density and resolution. In addition, when a dielectric imaging layer is applied to a substrate there is a variation in the thickness which is inherent in the coating method employed, e.g. spray coating. This variation is a small percentage of the total thickness when the dielectric imaging layer is thick as compared to the percentage of the total thickness when the dielectric imaging layer is thin. Therefore, thicker dielectric layers are, relatively speaking, more uniform and therefore provide more uniform imaging. Although direct ion stream charging of a thin high dielectric constant electroceptor without a precharge step will not deposit sufficient charge for adequate development with a dry two-component xerographic developer containing insulating carrier particles, the high charge density and voltage employed in the system of this invention facilitate development with two-component developers and does not limit development to liquid or conductive developer development. In other words, thin prior art dielectric coatings leads to fewer toner particles being pulled from the dry two-component, insulating carrier development systems for deposition onto the electroceptor imaging surface thereby resulting in low density images due to inadequate charge density and voltage. The toner images formed from two-component developer on the imaging members of this invention are readily electrostatically transferred or pressure transfixed to a receiving member. Moreover, ion stream imaging may be conducted at lower ion stream flow rates to minimize undesirable whistling noises from the pumps, blowers, and fluid jet assisted ion projection head. Because higher latent image voltages may be obtained from thicker electroreceptors while utilizing low modulation voltage switching and lower ion stream rates, higher image density may be achieved at higher electroceptor speeds. Also, unlike prior art photoreceptors, the dielectric imaging layer of this invention is simpler and less expensive to fabricate. Characters, pictoral images, and print fonts formed in bit mapped images and impressed onto the electroreceptor by fluid assisted ion projection heads have the further advantage that each pixel imaged can be varied in density and their width and height can be varied to form a combination of both line and solid area images at the same time with the system of this invention. Such combinations of both line and solid area images are not achievable when thin electroceptors of the prior art are utilized. A further advantage over scanned laser bit mapped images is that the ion stream of this invention can be imaged continuously in both process and cross process directions while the scanned laser images are overlayed dot images (non-continuous) in the process direction. The thicker electroceptor or dielectric layer reduces expense, is easier to process and achieves greater uniformity because any tolerance variance is a small fraction of the total thickness. Also, unlike stylus imaging, the system of this invention does not form fumes and minimizes wear on the electroceptor. This invention avoids the problems of unduly low fields in thin electroceptors for driving development and excessive spreading of charge exhibited with thick electroceptors.
An electroceptor need not be photosensitive and therefore does not require special shipping and storage treatment required for photoreceptors. In addition, compared to photoreceptors, the cost and complexity necessary for protection from temperature extremes or fluctuations, exposure to sun light and like are avoided. Further, special shutter systems required in xerographic machines to protect the photoreceptor when it is in use or when it is not in use, particularly automatic shutter systems, are unnecessary in electroceptor systems. Further, non-photoconductive dielectric receiver electroceptors are less sensitive to heat and may be located closer to fusers to provide greater flexibility in machine architecture design. Also, the electroceptor is less sensitive than photoreceptors to toner filming. In addition, the materials of an electroceptor may be tailored, particularly the surface, coefficient of friction, surface energy, and the like to accommodate different machine components such as the cleaning system. Thus, materials for different combinations of electroreceptors and cleaning blades can be chosen to reduce friction between the two components, reduce noise caused by contact during motion, and/or increase cleaning efficiency. Since the imaging head can ride directly on an electroceptor imaging surface at a spacing fixed by the supports, critical spacing requirements are readily accommodated even for electroreceptors which exhibit runout. Because of the greater durability of electroceptor materials, one may utilize higher cleaning blade pressures. Developer spacing is also facilitated because the developer applicator may also ride on the surface of the electroceptor. In systems utilizing the spacing of critical components from the electroreceptor by riding these components on the more durable surface of the electroreceptor, costs of maintaining roundness in the receptor can also be reduced. Moreover, cycle up and cycle down problems characteristic of photoreceptors are avoided with non-photoconductive electroceptors.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described in detail with reference to specific preferred embodiments thereof, it being understood that these examples are intended to be illustrative only. The invention is not intended to be limited to the materials, conditions, or process parameters recited herein. All parts and percentages are by weight unless otherwise indicated.
Representative dielectric imaging layer materials and process conditions for forming the layers to produce continuous films without pin holes for electroceptors are described in Examples I to XIX. A Binks spray booth Model BF-4 was used in conjunction with a Binks model 21 automatic spray gun and a type 42753 reciprocator to apply coating compositions to a cylindrical mandrel in the following Examples. This equipment is available from Binks Company, Franklin Park, Ill. The Model 21 gun was equipped with various fluid nozzles and air atomization nozzles. The coating composition to be sprayed was placed in a pressure pot and about 10 psi air pressure was applied to the pot to force the coating composition through a hose to the spray gun. The spray gun was operated in an automatic mode in conjunction with the motion of the reciprocator. The electrically conductive drum substrate to be sprayed was mounted on a turntable in the booth and rotated at a predetermined rate. The drum for Examples I to XVII were of aluminum having a length of about 24.5 cm, an outside diameter of about 84 mm and a thickness of about 4 mm. The spray gun traversed the length of the drum and spraying occured from top to bottom in a vertical direction. The spray cycle was repeated to obtain the desired thickness.
EXAMPLE I
A primer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the primer coating on a plurality of aluminum drums were as follows:
______________________________________Materials: 0.1 percent volume solids solution made from 1.0 gms polyester resin (DuPont 49,000, available from E. I. duPont de Nemours & Co.)Solvent: 522 gms methylene chloride and 600 gms 1,1,2 trichloroethaneTemperature: 21° C. (70° F.)Relative Humidity: 48 percentDrum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 4Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.0Gun Model: 21______________________________________
After drying at room temperature (22° C.) for about 2 hours, the deposited primer coating had a thickness of about 1 micrometer and a dielectric constant of about 3.28 (10 6 cps or Hz). The dried coating was carefully examined and found to be uniform, continuous and free of pin holes.
EXAMPLE II
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polycarbonate resin (Makrolon 5705, available from BASF Corporation)Solvent: 1100 gms 1,1,2 trichloroethaneTemperature: 21° C. (70° F.)Relative Humidity: 42 percentDrum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 45Fluid Nozzle: 63CAir Nozzle: 63PENeedle Setting: 1.2Gun Model: 21______________________________________
Each spray pass deposited on the average about 2.8 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness variations. Drying was effected by oven heating under the following conditions which were determined to be sufficient for defect free coatings, but not optimized for efficient drying or for minimum manufacturing costs:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 126 micrometers (5 mils), a dielectric constant of about 2.93 (10 6 cps or Hz), and a surface and bulk resistivity greater than about 10 10 ohm cm. The dried coating was carefully examined and found to be uniform, continuous and free of pin holes.
EXAMPLE III
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polysulfone (P-3500, available from Union Carbide Corporation)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 21° C. (70° F.)Relative Humidity: 48%Drum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 45Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.25Gun Model: 21______________________________________
Each spray pass deposited on the average about 2.8 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 127 micrometers (5 mils), a dielectric constant of about 3.1 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coating was carefully examined and found to be uniform, continuous and free of pin holes.
EXAMPLE IV
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 5.6 percent by volume solids solution made from 56 gms polysulfone (P-3500, available from Union Carbide Corporation)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 23° C. (74° F.)Relative Humidity: 42%Drum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 9 for 1 milFluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.25Gun Model: 21______________________________________
Each spray pass deposited on the average about 2.8 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 25 micrometers (1 mil), a dielectric constant of about 3.1 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coating was carefully examined and found to be continuous and free of pin holes, but coating thickness varied by about 10 percent.
EXAMPLE V
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I (except for rotation speed being twice as fast) were as follows:
______________________________________Materials: 5.6 percent volume solids solution made from 56 gms polycarbonate- polyester resin blend (Lexan 4501, available from General Electric Co.)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 16° C. (60° F.)Relative Humidity: <58 percentDrum Rotation Speed: 300 rpmGun to Drum Distance: 23 cm (9 in)Number of Passes: 16Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.2Gun Model: 21______________________________________
Each spray pass deposited on the average about 4.7 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
The dried layer had a thickness of about 75 micrometers, a dielectric constant of about 2.93 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coating was carefully examined and found to be smooth, continuous and free of pin holes, but coating thickness varied by about 10 percent.
EXAMPLE VI
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 35 gms polycarbonate resin (Makrolon 5705, available from BASF Corporation)Solvent: 1100 gms 1,1,2 trichloroethaneTemperature: 23° C. (74° F.)Relative Humidity: 65 percentDrum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 33Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.5Gun Model: 21______________________________________
Each spray pass deposited on the average about 2.3 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 76 micrometers (3 mils), a dielectric constant of about 2.93 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm.
EXAMPLE VII
A series of dielectric imaging layer coatings were prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layers on a primer coated aluminum drum (prepared as described in Example I) were as follows:
______________________________________Materials: 224 gms Polycarbonate (Lexan 145, available from General Electric Co.)Solvent: 4400 gms 1,1,2 trichloroethaneTemperature: 21° C. (70° F.)Relative Humidity: <58 percentDrum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.6Gun Model: 21______________________________________ Dry Film thicknessCoating No. Number of Spray Passes mils (μm)______________________________________VII-A 5 0.5 (12.7)VII-B 10 1 (25.0)VII-C 20 2 (51.8)VII-D 41 4 (102.6)VII-E 51 5 (127)VII-F 61 6 (152)VII-G 81 8 (203)______________________________________
Each spray pass deposited on the average about 2.5 μm dry polymer coating. The drum was rotated about 1 minute between spray passes to allow excess solvent to evaporate for those coatings of up to about 4 mils thick and for about 2 minutes between spray passes for the thicker layers thereby preventing coating sag and orange peel defects which in turn cause uneven coatings. Drying was effected by oven heating using the conditions discussed in Example II. After drying, the deposited dielectric imaging layer coatings had a thickness as described in the Table above, a dielectric constant of about 2.93 (10 6 cps or Hz) and a surface and bulk resisitivity of greater than about 10 10 ohm cm. The coatings were carefully examined and found to be uniform, continuous and free of pin holes except for coatings VII A, B and C in which coating thickness varied from about 15 percent for VII A to about 10 percent for VII B and C.
EXAMPLE VIII
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polycarbonate coester (Lexan 3250, available from General Electric Co.)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 20° C. (68° F.)Relative Humidity: 45 percentDrum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 29Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.6Gun Model: 21______________________________________
Each spray pass deposited on the average about 2.6 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 76 micrometers (3 mils), a dielectric constant of about 3.1 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coatings were carefully examined and found to be uniform, continuous, free of pin holes, but coating thickness varied about 10 percent.
EXAMPLE IX
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 147 gms polycarbonate coester (Lexan 4701, available from General Electric Co.)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 20° C. (68° F.)Relative Humidity: 45 percentDrum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 42Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.6Gun Model: 21______________________________________
Each spray pass deposited on the average about 3.3 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 138 micrometers (5.5 mils), a dielectric constant of about 3.1 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coatings were carefully examined and found to be uniform, continuous, free of pin holes and bubble defects.
EXAMPLE X
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polycarbonate resin (XP73010.00, available from Dow Chemical Co.)Solvent: 1100 gms 1,1,2 trichloroethaneTemperature: 20° C. (68° F.)Relative Humidity: 45%Drum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 36Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.3Gun Model: 21______________________________________
Each spray pass deposited on the average about 2.8 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 100 micrometers (4 mils), a dielectric constant of about 2.93 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coating was carefully examined and found to be uniform, continuous and free of pin holes.
EXAMPLE XI
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polycarbonate resin (Lexan 145, available from General Electric Co.)Solvent: 522 gms. methylene chloride 600 gms. 1,1,2 trichloroethaneTemperature: 20° C. (68° F.)Relative Humidity: 47%Drum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 50Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.6Gun Model: 21______________________________________
Each spray pass deposited on the average about 2.3 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 125 micrometers (5 mils), a dielectric constant of about 2.93 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coating was carefully examined and found to be uniform, continuous and free of pin holes.
EXAMPLE XII
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polycarbonate coester (XP73036.00, available from Dow Chemical Co.)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 20° C. (68° F.)Relative Humidity: 60%Drum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 36Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.5Gun Model: 21______________________________________
Each spray pass deposited about 2.8 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 100 micrometers (4 mils), a dielectric constant of about 2.93 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm. The dried coating was carefully examined and found to be uniform, continuous and free of pin holes.
EXAMPLE XIII
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polyetherimide resin (Ultem 1000, available from General Electric Co.)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 20° C. (68° F.)Relative Humidity: 47 percentDrum Rotation Speed: 185 rpm ± 10 percent [TC-200]Gun to Drum Distance: 23 cm (9 in)Number of Passes: 39Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.5Gun Model: 21______________________________________
Each spray pass deposited about 2.6 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 102 micrometers (4 mils), a dielectric constant of about 3.1 and a resistivity of about 10 10 ohm cm. The dried coating was carefully examined and found to be uniform, continuous and free of pin holes. EXAMPLE XIV
A dielectric imaging layer was prepared by dissolving a film forming polymer and a primer adhesive together in a blend comprising 56 gms polycarbonate coester (Lexan 4701, available from General Electric Co.) and 2 gms of polyester resin (DuPont 49,000, available from E. I. duPont de Nemours & Co.) in a solvent blend of 522 gms methylene chloride and 1,1,2 trichloroethane. The polymer blend solution was coated using the spray and drying conditions of Example VIII on a non-primed aluminum drum which was previously vapor degreased. After drying, the deposited dielectric imaging layer coating had a thickness of about 125 micrometers (5 mils), a dielectric constant of about 3.1 and a surface resistivity of greater than 10 10 ohm cm. The dried coating was carefully examined and found to be firmly adhering to the aluminum substrate, uniform, continuous and free of pin holes.
EXAMPLE XV
A dielectric imaging layer was prepared by mixing 3 volumes of Imron 500S clear enamel with 1 volume of Imron 192S activator polyurethane composition and the viscosity adjusted with 8485S solvent to a DuPont viscosity cup of 18-22 seconds. The Imron enamel, activator and diluent were obtained from E. I. du Pont de Nemours & Co. The polyurethane was applied to a vapor degreased aluminum roll by spray coating and then air dried for 8 hours at 60° C. followed by heating for 2 hours at 100° C. to achieve a dry coating thickness of 200 micrometers (8 mils). The dielectric imaging layer was continuous, free of pinholes, had a dielectric constant of about 4, and exhibited a surface resistivity of greater than 10 10 ohm-cm. The coating firmly adhered to the substrate and had a uniform thickness of ±2.5% end to end and ±5% around the roll. When the roll was corona charged to about 1500 volts with a negative potential, the voltage variation on the coating around the drum was <50 v.
EXAMPLE XVI
A dielectric imaging layer was prepared as described in Example XIV except that 56 gms of a copolyester polymer (PETG 6763, available from Eastman Chemical Products, Inc. a subsidiary of Eastman Kodak Co.) composed of copoly (1,4-cyclohexylendimethylene/ethylene) terephthalate) was used in place of the Lexan 4701. After drying, the deposited dielectric imaging layer had a thickness of about 150 micrometers (6 mils), a dielectric constant of about 3.5 and a surface resistivity of greater than 10 10 ohm-cm. The dried coating was uniform in thickness and free of pinholes.
EXAMPLE XVII
A dielectric imaging layer was prepared by dissolving Lexan 3250 polycarbonate polymer in a solvent blend of methylene chloride and 1,1,2-trichloroethane as described in Example VIII in which 60 weight percent of BaTiO 3 (available from Ferro Corporation), based on the weight of the polymer, was dispersed by roll milling with glass beads to obtain a uniform dispersion. The composition was diluted with additional solvent to obtain a spray coatable consistency. The composition was applied to a primer coated aluminum drum (prepared as described in Example 1) and dried for 24 hours at 60° C., 90° C. for 24 hours, and 120° C. for 3 hours. The deposited dielectric imaging layer coating had a thickness of about 288 micrometers (11.5 mils), a dielectric constant of about 6.8 and a surface resistivity of greater than 10 10 ohm-cm. The layer was white, continuous, uniform and free of pinholes.
EXAMPLE XVIII
Nickel drums having a length of about 245 mm, an outside diameter of about 84 mm and a thickness of about 0.2 mm were coated with a polyvinyl fluoride polymer (Tedlar, available from E. I. DuPont de Nemours & Co.) dispersion. The coating dispersion were applied to the drums using a doctor metering process which was capable of forming a coating having a thickness (after drying) up to about 500 micrometers by adjusting a gap between a doctor blade and an adjacent drum wall. The rheology of the coating dispersion was controlled by adjusting the resin solids, milling process conditions, and additives such as described in U.S. Pat. No. 4,698,382 (duPont) and in a paper entitled "Poly(Vinyl Fluoride) Properties and Coating Technology" by J. J. Dietrick, T. E. Hedge, and M. E. Kiecsma, presented at the 8th Annual Symposium on New Coatings and New Coatings Raw Materials, sponsored by the North Dakota State University Polymer and Coatings Department, May 30, 1966, so that sagging, orange peel and other coating thickness variations were minimized. The coatings were coalesced at 200° C. for 10 minutes and then dried for 20 minutes at 200° C. Coatings were produced with thickness from about 100 micrometers (4 mils) up to about 500 micrometers (20 mils), in increments of 50 micrometers (2 mils), a dielectric constant of about 7.9 (depending on the coating additives employed), and a surface resistivity of greater than 10 10 ohm-cm. The coatings were continuous, uniform and free of pinholes. Coating thicknesses from end to end were ±2.5 percent and ±5 percent around the drums. Generally, those drum coatings having a thickness of from 225 micrometers (9 mils) and a dielectric constant of 7 up to coatings having a thickness of 450 micrometers (18 mils) and a dielectric constant of 9 were found to produce good test prints when employed in the device described in Example XX below.
EXAMPLE XIX
A dielectric imaging layer coating solution was prepared by dissolving a film forming polymer in a solvent. The specific conditions for applying the imaging layer coating on a primer coated aluminum drum prepared as described in Example I were as follows:
______________________________________Materials: 56 gms polycarbonate coester (XP73038.00, available from Dow Chemical Co.)Solvent: 522 gms methylene chloride 600 gms 1,1,2 trichloroethaneTemperature: 20° C. (68° F.)Relative Humidity: 60%Drum Rotation Speed: 185 rpm ± 10 percentGun to Drum Distance: 23 cm (9 in)Number of Passes: 27Fluid Nozzle: 63BAir Nozzle: 63PENeedle Setting: 1.5Gun Model: 21______________________________________
Each spray pass deposited about 2.8 μm of dry polymer coating. The drum was rotated about 1 minute in between spray passes to allow excess solvent to evaporate thereby preventing coating sag and orange peel defects which, in turn cause coating thickness non-uniformities. Drying was effected by oven heating under the following conditions:
22° C. for about 64 hours
60° C. for about 24 hours
90° C. for about 24 hours
120° C. for about 3 hours
22° C. for about 64 hours
After drying, the deposited dielectric imaging layer coating had a thickness of about 76 micrometers (3 mils), a dielectric constant of about 2.93 (10 6 cps or Hz), and a surface and bulk resistivity of greater than about 10 10 ohm cm.
EXAMPLE XX
The electrographic drums of Examples II through XIX were substituted for the xerographic drum in a modified Xerox 2830 xerographic copier which utilizes biased magnetic brush development. The Xerox 2830 xerographic copier, prior to modification, comprised an electrophotographic drum around the periphery of which are mounted a charging station to deposit a uniform electrostatic charge, an exposure station, a magnetic brush development station, a paper sheet feeding station, an electrostatic toner image transfer station, a toner image fusing station, and a blade cleaning station. The Xerox 2830 xerographic copier was modified to substitute a fluid jet assisted ion projection head similar to the head illustrated in FIG. 2 for the exposure station of the copier. The magnetic brush developer employed comprised toner particles having an average particle size of about 12 micrometers and comprising a styrene copolymer pigmented with about 10 percent carbon black and carrier particles having an average size between about 50 and about 100 micrometers comprising uncoated, insulating ferrite particles. The magnetic brush developer also contained minor amounts of an external additive comprising zinc stearate and colloidal silica particles. The adjustable biasing power supply connected to the magnetic brush developing station allowed testing of the samples under various image development conditions of from 0 to 40% of the latent image potential. By introducing this reverse bias, of the same polarity as the ions forming the latent image, and applying the bias between the conductive layer of the electrographic drums and the development roll, non-uniformities in the non-image areas of the latent image can be kept more free of unwanted toner particles. Referring to the fluid jet assisted ion projection head illustrated in FIG. 2 for the type of head substituted for the exposure system, the upper casting 51 was cast of stainless steel. The conductive plate 58, insulating layer 60, and thin film element layer 63 were supported on a planar substrate 64 having a thickness of about 1,016 micrometers. A pair of extensions on each side of planar substrate 64 form wiping shoes which rode upon the outboard edges of the dielectric image layer 66 spaced the ion projection head 50 about 760 micrometers from the imaging surface of dielectric image layer 66. The exit channel 68 included an cavity exit region 70 about 250 micrometers (10 mils) long and an ion modulation region 71 about 508 micrometers (20 mils) long. A planar substrate 64 was employed comprising a large area marking chip comprising a glass plate upon which was integrally fabricated thin film modulating electrodes, conductive traces and transistors. The width across the cavity 54 was about 3175 micrometers (125 mils) and corona wire 56 was spaced about 635 micrometers (25 mils) from the cavity wall 62 nearest the cavity exit. A high potential source 72 of about +3,600 volts was applied to corona wire 56 through a one megohm resistance element 74 and a reference potential 76+1,200 volts applied to cavity walls 62. The individually switchable thin film element layer 63 (an array of 300 control electrodes per inch not shown) were each connected through standard multiplex circuitry (represented by two position switch 80) to a low voltage source 78 of +1,220 volts or +1,230 volts, 10 to 20 volts above the reference potential. Each electrode controlled a narrow "beam" of ions in the curtain-like air stream that exited from ion modulation region 71. The conductive electrodes were about 89 micrometers (3.5 mils) wide each separated from the next by 38 micrometers (1.5 mils). The distance between the thin film element layer 63 and cavity wall 62 at the closest point was about 75 micrometers (3 mils). Laminar flow conditions prevailed at air velocities of about 1.2 cubic feet per minute. The metal drum of each of the tested samples were electrically grounded. In operation, the imaging surface on the dielectric imaging layer on each electrographic drum was uniformly charged to about -1500 volts at the charging station, imagewise discharged to -750 volts with the ion stream exiting from the fluid jet assisted ion projection head to form an electrostatic latent image having a difference in potential between background areas and the image areas of about 150 volts, and developed with toner particles deposited from the two-component magnetic brush developer applied at the magnetic brush development station.
The dielectric imaging layers of Examples II, III, VII D, VII E, VII F, IX, X, XI, XII, XIII, XIV, XV, XVI, XVII, and XVIII all repeatedly produced print images having about 1.2 density units, resolution up to 300 lines or spots per inch, no discernable image spread or blooming and clean background in tests of several hundred print cycles. The dielectric image layers of Examples IV, V, VI, VII A, VII B, VII C, VIII, and XIX produced print densities of less than about 0.6, but image resolution was good and print background was low. Dielectric imaging layer VII G produced the highest image density at about 1.3, but the images were broader or had bloomed to dimensions greater than that of the original input.
The developer housing of the modified Xerox 2830 Machine was purged of the two component developer material and loaded with a developer consisting of single component toner particles. The toner particles comprised a styrene copolymer pigmented with carbon black and magnetite and had an average particle size of about 12 micrometers. The developer housing was spaced about 10 mils (254 micrometers) from the dielectric imaging surface. An electrostatic latent image was formed on the dielectric imaging layer of Example XV as described above and developed with the single component developer. The images produced had a density of about 1.0, resolution of 300 spots per inch, clean background and no discernable image blooming.
EXAMPLE XXI
Polyimide film (Kapton, available from E. I. du Pont de Nemours & Co.) having a length of about 990 mm a width of about 305 mm and a thickness of about 75 micrometers was coated on both sides with a coating of fluorocarbon resin (Teflon FEP, available from E. I. du Pont de Nemours & Co.) having a thickness about 25 micrometers on each surface to yield a composite sheet having a thickness of about 125 micrometers. This composite sheet was spray coated on one of the fluorocarbon resin surfaces with a carbon black pigment dispersion in an olefinic binder (LE 12644, available from Red Spot Paint and Varnish Co. Inc.). The resulting conductive carbon black coating was about 10 micrometers thick after drying. Since the dielectric constants of the Kapton film and FEP fluoropolymer were 3.7 and 2.1, respectively, the composite sheet had an effective dielectric constant of about 2.7 for the combined layers. The ends of the coated sheet were overlapped and forced together for 20 seconds using a jaw sealer device operating at about 350° C. and 20 psi to form an endless belt. The belt was cycled in a test fixture equipped with a belt drive and fitted with a fluid jet assisted ion projection head similar to the head illustrated in FIG. 2, a developer applicator station, paper transport station, image transfer station, toner fusing station and cleaning station. The images produced under the charging conditions described in Example XX had a resolution of 300 spots per inch and achieved a print density to about 1.1.
EXAMPLE XXII
Dielectric imaging layers were prepared using an electrostatic coating technique. The substrates coated were aluminum drums having a 65 mm diameter, 266 mm length, 2.5 mm wall thickness (nominal) and surface roughness of about 0.4 μm, (16μ inch). The substrates were cleaned by ultrasonic immersion cleaning in detergent followed by a freon vapor degrease, and a final isopropanol hand wipe with a lint free cloth. A Nordson Model #NPE CC8 with a Nordson Model #NPE-2A automatic gun was used to electrostatically apply coating powder to the drums while the drums were rotated at 100-150 RPM, (horizontal). The electrostatic gun horizontally traversed the drums at 0.5 to 1.0 inches/sec. Nitrogen gas was used for powder delivery and atomization. Typical powder delivery settings were:
______________________________________Atomization 12 to 20 PSIDelivery 8 to 20 PSI______________________________________
The powder coating materials and conditions for coating and curing were as follows:
______________________________________(a) Perfluoroalkoxy Teflon (PFA, available from E.I.duPont de Nemours & Co.)Dielectric constant 2.1(10.sup.6 cps or Hz)Surface & Bulk Resistivity >10.sup.10 ohm cmGun voltage 70 kvDry Thickness 0.0035 in (88.9 μm), 3 coats/bakesThickness/Dielectric constant 42 μmCure temp./time 740° F.(393° C.), 20 minutes(b) Co-polymer of ethylene and tetrafluoroethylene(Tefzel, available from E.I. duPont de Nemours & Co.)Dielectric constant 2.6(10.sup.6 cps or Hz)Surface & Bulk Resistivity >10.sup.10 ohm cmGun voltage 70 kDry Thickness 0.0045 in (114.3 μm), 4 coats/bakeThickness/Dielectric constant 44 μmCure temp./time 575° F.(302° C.), 30 minutes(c) Acrylic Resin (Pulvalure 154 series, available fromGlidden Coating and Resins)Dielectric constant 3.3(10.sup.6 cps or Hz)Surface & Bulk Resistivity >10.sup.10 ohm cmGun voltage 40-50 kvDry Thickness 0.0055 in (139.7 μm), 3 coats/bakesThickness/Dielectric constant 42 μmCure temp./time 350° F.(177° C.), 15 minutes(d) Clear polyurethane resin (Vedoc, available fromFerro Corp.)Dielectric constant 4.0(10.sup.6 cps or Hz)Surface & Bulk Resistivity >10.sup.10 ohm cmGun voltage 55-70 kvDry Thickness 0.006 in (152.4 μm), 3 coats/bakesThickness/Dielectric constant 38 μmCure temp./time 290° F.(143° C.), 25 minutes(e) Crystal clear polyester (Oxyplast, glycidyl polyester,available from Fuller O'Brien Paint Co.)Dielectric constant 4.0(10.sup.6 cps or Hz)Surface & Bulk Resistivity >10.sup.10 ohm cmGun voltage 70-90 kvDry Thickness 0.006 inch (152.4 μm), 3 coats/bakesThickness/Dielectric constant 38 μmCure temp./time 400° F.(204° C.), 20 minutes(f) Clear Epoxy (Vedoc VE 101-A, available from,Ferro Corp.)Dielectric constant 3.5(10.sup.6 cps or Hz)Surface & Bulk Resistivity >10.sup.10 ohm cmGun voltage 55-70 kvDry Thickness 6 mils (152.4 μm), 3 coats/bakesThickness/Dielectric constant 44 μmCure temp./time 350° F.(177° C.), 30 minutes______________________________________
The Xerox 2830 xerographic copier modified as described in Example XX was again modified so that the aluminum drums of Example XXII could be substituted in the place of the drums of Examples II to XIX. The fluid jet assisted ion projection head had an array of 600 control electrodes per inch. The magnetic brush developer, the cleaning subsystem, paper sheet feeding system, fusing system and charging corotron were repositioned so that the spacing, charging and motion relationships were maintained as in Example XX. The dielectric imaging layers all produced excellent prints of about 1.1 density units, resolution of 600 lines or spots per inch, sharp well defined character edges and corners, and clean background free of toner deposits. The dielectric imaging layer of XXII a) was exceptionally easy to clean using a polyurethane wiper blade material.
Although the invention has been described with reference to specific preferred embodiments, it is not intended to be limited thereto, rather those skilled in the art will recognize that variations and modifications may be made therein which are within the spirit of the invention and within the scope of the claims. | An ionographic imaging member containing a conductive layer and a uniform and continuous dielectric imaging layer free of voids, the imaging layer having a dielectric constant of from about 1.5 to about 40 and a thickness of at least about 45 micrometers, the thickness divided by the dielectric constant having a value of from about 30 to about 60 micrometers. This member may be used in an ionographic imaging process. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and hereby claims priority to International Application No. PCT/EP2009/060957 filed on Aug. 26, 2009 and German Application No. 10 2008 049 198.5 filed on Sep. 26, 2008, the contents of which are hereby incorporated by reference.
BACKGROUND
[0002] The invention relates to a coil system and to a method for the contactless navigation of a magnetic body in a work space.
[0003] Coil systems for the contactless magnetic navigation of a magnetic body use a plurality of coils to produce a magnetic field which interacts with the magnetic body, whereby magnetic forces and torques are generated which cause the movement of the magnetic body. The magnetic force and the magnetic torque, which act on the magnetic body, can be suitably adjusted by way of the corresponding currents into the individual coils of the coil system.
[0004] Coil systems of the above type are used in particular in the medical field. Here a patient is examined in the work space of the coil system using the magnetic body. The work space is accessible from the outside and in this space the magnetic forces of the coil system have an adequate effect on the magnetic body. To carry out the examination the magnetic body, which is located in the patient, and the part of the patient's body to be examined are introduced into the work space of the coil system. The magnetic body is a probe with which measurements on—in particular images of—a patient's internal organs can be taken.
[0005] A coil system with magnetic probe is used, for example, in gastroenterology, in particular gastroscopy, see WO 2007/077922 A1. During the endoscopic examination the patient's stomach is partially filled with water and the patient swallows an appropriate probe which contains a permanent magnet and a camera.
[0006] Here the patient's stomach is located in the work space of the coil system or is introduced into the work space after the probe has been swallowed. By using the magnetic forces and torques generated by the coil system the probe is moved in such a way that images of the areas of the patient's gastric mucosa to be examined are produced. It is necessary in this connection for it to be possible by way of suitably energizing the coils to generate an inhomogeneous magnetic field such that the probe is appropriately positioned and is kept in this position by the interaction of this magnetic field with the permanent magnet in the probe.
[0007] Various approaches are known from the related art for appropriately positioning a magnetic body relative to a coil system. A coil system is known from WO 2006/014011 A1 in which, during the examination, the patient to be examined is moved in relation to the coil system. The coil system is constructed in such a way that a single spatial point exists which is fixed in relation to the coil system. If no external forces act on the magnetic body the body moves toward this spatial point as a result of the magnetic forces and torques exerted. When the magnetic body has reached this spatial point it remains there provided no forces are exerted from the outside. It has proven disadvantageous in this connection that either the coil system or the patient or both have to be mechanically moved in order to move the magnetic body. This is a problem in particular in applications in which rapid movement of the magnetic body toward a predetermined position is required.
[0008] Systems are also known from the related art in which the coil system is replaced by one or more permanent magnet(s) in order to move a magnetic body, see for example U.S. Pat. No. 7,019,610 B2. The movement toward a predetermined position is achieved by a mechanical movement of the patient or the permanent magnet or patient and permanent magnet in this system as well.
[0009] Coil systems are also known from the related art in which, without mechanical movement, by appropriate adjustment of the magnetic fields and field gradients, to the position of the magnetic body a movement of the magnetic body is achieved that is caused merely by the currents in the coil system (see for example WO 2006/092421 A1). However, it is necessary here for the position and orientation of the magnetic body to be known, and this in turn means that the position of the magnetic body also has to be measured.
SUMMARY
[0010] One possible object is to avoid the drawbacks of the related art described above and to create a coil system and a method with which a magnetic body can easily be contactlessly navigated.
[0011] The inventors propose a coil system having a plurality of coils and a current controller for controlling the respective currents in the plurality of coils. In order to navigate a magnetic body to a variably predeterminable position in the work space of the coil system, the current controller is designed such that the currents in the plurality of coils are adjusted in such a way that the magnetic forces generated by the currents and acting upon the magnetic body at multiple positions at the edge of a convex environment around the predeterminable position are directed into the environment. “Variably predeterminable” is here taken to mean that the position in the work space is not fixed, but may be variably adjusted by the current controller. The magnetic body is designed in particular such that it has a predetermined magnetic dipole moment in a specified direction.
[0012] Such control of the currents ensures that, independently of the current position of the magnetic body in the work space, a movement of the body toward the predeterminable position is always ensured. The predeterminable position can be adjusted for example by the user by way of a user interface. A convex environment is taken to mean an environment which does not have any regions that are inwardly curved. The convex environment must be located in the work space of the coil system in this case. The environment is preferably located in the vicinity of the predeterminable position. Vicinity denotes in particular that the maximum spacing of the edge of the environment is 10% or less from the largest extent of the coil system. For medical applications environments whose edge has a maximal spacing between 0.005 m and 0.1 m, preferably of 0.01 m, from the predeterminable position in particular have proven to be practicable.
[0013] The coil system has the advantage that a magnetic field maximum (“peak”) can be created with substantially forces directed toward the predeterminable position merely by an appropriate current controller. It is not necessary for the coil system to be mechanically moved here, and the current position of the magnetic body in the work space is known. Determination of this current position may therefore be omitted.
[0014] In a preferred embodiment the environment around the predeterminable position is a polygon and/or a polyhedron, for example a triangle, square or other quadrilateral. A polygon is particularly expedient if the movement of the magnetic body has less than three translational degrees of freedom. The plurality of positions, on which the magnetic forces act at the edge of the environment for a magnetic body positioned there, are preferably located at one or more of the corner(s) of the polygon and/or polyhedron, in particular at all corners of the polygon and/or polyhedron.
[0015] In a preferred embodiment of the coil system the current controller is designed in such a way that the currents are calculated for the predeterminable position by the current controller during operation of the coil system. The currents suitable for a certain position are therefore determined in real time. It is likewise possible for the currents to be adjusted for a large number of predeterminable positions to be stored in a memory of the current controller. If a spatial position toward which the magnetic body should move, is fixed for example by way of a user interface, the corresponding currents to be adjusted are then read out of this memory.
[0016] In a particularly preferred embodiment the currents to be adjusted in order to navigate the magnetic body to the predeterminable position represent the solution to an optimization problem with the boundary condition that the magnetic forces generated by the currents and acting upon the magnetic body at multiple positions at the edge of the convex environment around the predeterminable position are directed into the environment. In a preferred embodiment the optimization problem is a linear program and/or a quadratic program which can be reliably solved in a short calculating time using known standard optimization methods.
[0017] In a preferred embodiment the optimization problem is the minimization of the value, or the 2-norm (i.e. the Euclidean norm) of the vector of the currents in the plurality of coils while taking account of the additional boundary condition that the magnetic forces generated by the currents and acting upon the magnetic body at multiple positions at the edge of the convex environment around the predeterminable position exceed a predetermined value respectively.
[0018] In a further embodiment of the coil system the currents are weighted differently when solving the optimization problem. Instead of the 2-norm of the vector of the coil currents, the 2-norm of a weighted vector of the coil currents is minimized for example, with each individual coil current being weighted with the square root of the ohmic resistance of the coils. The ohmic total power loss is minimized in the plurality of coils as a result.
[0019] Alternatively or additionally the optimization problem can also be defined in such a way that the magnetic forces generated by the currents and acting upon the magnetic body at multiple positions at the edge of the convex environment around the predeterminable position are maximized. It is taken into account as an additional boundary condition that the value of currents of the plurality of coils is below a respective maximum value.
[0020] In a particularly preferred embodiment it is taken into account when solving the optimization problem described above as an additional boundary condition that the magnetic field generated by the currents at the predeterminable position is substantially directed in a predetermined direction and has a value which exceeds a predetermined value. This ensures that the magnetic body also has a specified orientation toward the predeterminable position.
[0021] In a further embodiment of the coil system the current controller takes account of a movement of the magnetic body with two translational degrees of freedom or less.
[0022] The coil system is preferably used in a medical device which is designed in such a way that a patient can be positioned in the coil system and a magnetic body in the form of a probe for examining the organs in the patient can be navigated to predeterminable positions inside the patient's body by the current controller.
[0023] The inventors also propose a method for the contactless magnetic navigation of a magnetic body in a work space using an coil system. In order to navigate the magnetic body to a predeterminable position in the work space, the currents in the plurality of coils of the coil system are adjusted by the current controller of the coil system in such a way that the magnetic forces generated by the currents and acting upon the magnetic body at multiple positions at the edge of a convex environment around the predeterminable position are directed into the environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
[0025] FIG. 1 shows a schematic diagram of a magnetic body in the form of a capsule for medical applications;
[0026] FIG. 2 shows a schematic diagram of the configuration of the magnetic forces for the movement of a capsule to a spatial position according to an embodiment of the inventors' proposals;
[0027] FIG. 3 shows a schematic diagram of the optimization problem of the invention for the movement of a capsule with two translational degrees of freedom; and
[0028] FIG. 4 shows a schematic diagram of the optimization problem for the movement of a capsule with three translational degrees of freedom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0030] Proposed systems will be described below with reference to a medical device for the endoscopic examination of organs in a patient. The medical device comprises a coil system which is analogously constructed in particular to the coil system in document WO 2006/092421 A1, which is incorporated herein by reference. This coil system comprises 14 individually controllable coils for generating corresponding magnetic fields. The individual coils are designed in such a way that the magnetic field or the field gradient of the respective coils are not concentrated on one or more spatial position(s) in the work space specified by the coils. Other coil systems may optionally be used, wherein eight coils should be used as a minimum in order to be able to control the magnetic degrees of freedom independently of one another. Despite the same construction as the coil system in document WO 2006/092421 A1 the coil system used in the embodiment described hereinafter differs in the control of the currents of the individual coils.
[0031] In the embodiment described here a magnetic capsule 1 is moved by the coil system, and this is schematically reproduced in FIG. 1 . The capsule is an endoscopic probe which is swallowed by the patient in order to perform corresponding examinations in the patient's gastro-intestinal tract. The capsule is a magnetic body having a magnetic dipole moment m. When a magnetic field is applied, which is schematically indicated in FIG. 1 by the field lines M, a torque is generated on the capsule 1 which aligns the magnetic dipole moment of the capsule in the direction of the magnetic field.
[0032] The capsule 1 contains a camera (not shown) and is swallowed by the patient before the endoscopic examination. The patient is positioned in the work space of the coil system in the process or thereafter. The capsule can then be moved in the coil system by appropriate adjustment of the currents, and in particular can also be aligned in a desired direction of orientation. Gastroenterological examinations by way of example can be carried out using the capsule. The patient drinks a sufficient quantity of water before and optionally also during the examination, so during the examination the capsule is moved in the water or on the surface of the water. By suitably adjusting the currents in the coils the capsule can then be moved and oriented on the surface of the water to the regions of the stomach to be examined, and close-up views, in which the capsule is completely located in the water below the surface thereof, are also possible. The capsule has a high-frequency transmitter with which the recorded images are emitted and are received outside the patient by a corresponding receiver. This receiver is, for example, integrated in a belt which the patient wears during the examination.
[0033] In the embodiment described below the movement of the capsule in a space with five degrees of freedom comprising two translational and all three rotational degrees of freedom is considered. This corresponds, for example, to the above-described movement of the capsule on the surface of the water in a patient's stomach with three rotational and only two translational degrees of freedom. The aim of the control of the currents in the coils described below is accordingly to adjust the currents in the work space of the coil system in such a way that the coils generate a magnetic field maximum at a predetermined spatial position, so the capsule moves toward this spatial position and remains there. The spatial position can be suitably adjusted and changed by an operator, i.e. the medical staff, by way of a user interface in order to perform corresponding examinations of the relevant organs in the patient.
[0034] The three-dimensional magnetic dipole moment vector of the capsule 1 will be designated {right arrow over (m)} hereinafter and a coil system with n coils coils will be considered. The magnetic dipole moment of the capsule is generated inside the capsule by a suitable magnetic element. The specific three-dimensional spatial position, to which the capsule should move, is designated P, moreover. The magnetic field generated by the current flow in the coils is represented by the three-dimensional magnetic field vector {right arrow over (B)}(P). The force generated by the magnetic field as a function of the magnetic dipole moment of the capsule and the spatial position P is reproduced by the three-dimensional force vector {right arrow over (R)}(P, {right arrow over (m)}). The currents in the individual coils are represented by a vector I with n coils entries, with each entry reflecting the current flow in a single coil. The following relationship exists between the current vector I and the magnetic field generated therefrom and the force generated therefrom at spatial position P:
[0000]
[
B
→
F
→
]
=
A
(
P
,
m
→
)
I
[0035] Here A(P, {right arrow over (m)}) is a 6×n coils matrix. The matrix A(P, {right arrow over (m)}) is the product of two matrices U({right arrow over (m)}) and v(P), i.e. the following applies:
[0000] A ( P,{right arrow over (m)} )= U ( {right arrow over (m)} ) V ( P )
[0036] The matrix V(P) is a 8×n coils matrix which depends on the geometry of the coil system in addition to the specific spatial position P. The matrix is specified or can be determined without problems for any spatial position from the specific geometry of the coil system according to the biot-savart law. The additional matrix U({right arrow over (m)}) is a 6×8 matrix which reads as follows:
[0000]
U
(
m
→
)
=
[
1
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
m
x
m
y
m
z
0
0
0
0
0
0
m
x
0
m
z
m
y
0
0
0
-
m
z
0
m
x
m
y
-
m
z
]
[0037] Here m x , m y , m z represent the x, y and z components of the magnetic dipole moment vector {right arrow over (m)}.
[0038] To calculate the matrix U({right arrow over (m)}) the magnetic dipole moment {right arrow over (m)}, i.e. the orientation of the capsule, has to be known. As already stated, a scenario is being considered in which the capsule can move in space with five degrees of freedom, comprising all three rotational degrees of freedom. The consequence of this is that the magnetic dipole moment of the capsule is substantially (i.e. with negligible errors) aligned in the direction of the magnetic field {right arrow over (B)} of the coil system acting on the capsule. To ensure this it is specified as a boundary condition hereinafter that the value of the magnetic field is greater than a minimal value, i.e. the following applies:
[0000] ∥{right arrow over (B)}∥≧B min
[0039] Here B min is a suitably chosen scalar value which is chosen to be so large that the largest possible disturbing torque that can act on the capsule, divided by the product of B min and the value of {right arrow over (m)} is less than the sine of the maximal admissible solid angle between {right arrow over (B)} and {right arrow over (m)}.
[0040] The magnetic dipole moment {right arrow over (m)} of the capsule is known. Therefore the relationship between the magnetic field and/or the exerted force and the current vector on the specific spatial position P can be described as follows:
[0000]
[
B
→
F
→
]
=
A
(
P
)
I
[0041] As already stated, the currents in the coil system should accordingly be adjusted in such a way that a magnetic field with a maximum is generated at point P. This occurs by way of the solution of a convex optimization problem, taking account of the boundary condition that the magnetic forces align in relation to the specific spatial position, as indicated in FIG. 2 . FIG. 2 shows the specific spatial position P and a predetermined environment Ω around the spatial position. For reasons of clarity a two-dimensional environment is reproduced. The optimization can, however, optionally also be applied to three-dimensional environments. The alignment of the forces on the closed edge of this environment is indicated by a large number of arrows, one of the arrows, by way of example, being designated F. The alignment of the forces at the corresponding positions at the edge of the environment (which tally with the respective origins of the arrows) must be such that every force that is exerted on the magnetic body at the respective edge position is directed into the environment Ω. This criterion is taken into account in the optimization problem described below as a necessary boundary condition.
[0042] The optimization problems formulated below are convex optimization problems which can be reliably and efficiently solved using convex optimization methods that are sufficiently known from the related art. In the scenario described here of the magnetic navigation of a magnetic capsule the optimization problem can also be solved in real time. In other words, the current controller of the coil system contains a computing unit which solves a corresponding optimization problem, independently of the selected orientation and position to which the capsule should move, and adjusts the current values that result therefrom. It is optionally also possible to determine in advance for a large number of orientations and positions in the work space of the coil space the currents that are to be adjusted accordingly and to store them in a memory in the current controller of the coil system.
[0043] The optimization problem to be solved will be described hereinafter on the basis of a movement of the capsule in which no forces act on the capsule in the y direction and the capsule cannot experience a translational movement in the y direction either. This corresponds to the above movement with two translational degrees of freedom, wherein only one translational movement of the capsule is possible in the x and z directions. In addition the capsule can rotate as desired, i.e. all three possible degrees of freedom exist for rotation.
[0044] The relationship between the current vector and the magnetic field and the exerted magnetic force can be written as follows:
[0000] B x ( P )= A 1 ( P ) I
[0000] B y ( P )= A 2 ( P ) I
[0000] B z ( P )= A 3 ( P ) I
[0000] F x ( P )= A 4 ( P ) I
[0000] F y ( P )= A 5 ( P ) I
[0000] F z ( P )= A 6 ( P ) I
[0045] Here A i designates the rows i of the above matrix A(P).
[0046] The desired orientation {right arrow over (m)} desired of the magnetic dipole and therefore the desired orientation of the magnetic field is suitably fixedly chosen in advance and is arbitrary in the exemplary embodiment described here. There is always the possibility of (x, y, z) coordinate systems being aligned in such a way that the vector {right arrow over (m)} desired is aligned in the x axis of the coordinate system. The scenario will therefore be considered hereinafter, without limiting the generality, that only the x component B x of the magnetic field is given as not being equal to zero, whereas the y component B y and the z component B Z are substantially zero.
[0047] Two vectors {right arrow over (T)} x =[d peak width , 0, 0] T and {right arrow over (T)} z =[0, 0, d peak width ] T will be considered hereinafter, where d peak width is a positive scalar distance value, typically in a range between 0.01 and 0.1 m. Four points P 1 , P 2 , P 3 , P 4 in the working volume of the coil systems are defined by the above vectors {right arrow over (T)} x and {right arrow over (T)} z as follows:
[0000]
P
1
=P−{right arrow over (T)}
z
[0000]
P
2
=P+{right arrow over (T)}
x
[0000]
P
3
=P+{right arrow over (T)}
z
[0000]
P
4
=P−{right arrow over (T)}
x
[0048] These points are illustrated by way of example in FIG. 3 . FIG. 3 shows in the x-z plane the specific point P toward which the capsule should move. A corresponding environment Ω is given for this point P, where the edge of the environment is a rectangle, which is reproduced in FIG. 3 in broken lines. The corresponding points P 1 to P 4 are located at a spacing {right arrow over (T)} x shifted to the left or right of or at a spacing shifted above or below point P. The forces F 1 =F(P 1 ) at point P 1 , F 2 =F(P 2 ) at point P 2 , F 3 =F(P 3 ) at point P 3 and F 4 =F(P 4 ) at point P 4 generated by the magnetic field of the coils system are considered in the subsequent optimization, with the points always having to be directed into the environment Ω.
[0049] Overall the following boundary conditions relating to the generation of a magnetic field maximum must be given in the environment of the specific spatial point P:
[0050] 1. The magnetic field {right arrow over (B)} at the specific position P must be strong enough and correctly aligned so the desired orientation of the capsule is achieved. The magnetic field {right arrow over (B)} must therefore have roughly the same direction in a sufficiently large environment around point P. This environment should contain at least the above positions P 1 , P 2 , P 3 , P 4 . This condition is fulfilled if a sufficiently strong magnetic field is demanded at the specific spatial position P.
[0051] 2. For the points P 1 , P 2 , P 3 , P 4 on a predetermined convex environment, which according to FIG. 3 is represented by a rectangle, the magnetic force lies on the capsule in each of these points within this convex environment, i.e. the magnetic force is directed into the convex environment. In the case where there are no external disruptions, it is therefore ensured that, following entry into the convex environment, the capsule will never leave this environment as the forces are always directed such that the capsule is pushed into the environment. It is also ensured that the point at which the magnetic force disappears lies within this convex environment in the vicinity of point P. Consequently, in the absence of external disruptions, the capsule will always move toward the specific point P and also remain there.
[0052] 3. The absolute value of the currents in the individual coils must be less than respective maximal values. Without limiting the generality it is assumed in the exemplary embodiment described here that the maximum current is equal for each coil. This current is designated I max hereinafter.
[0053] The above conditions 1, 2 and 3 can be described as a convex optimization problem. In one variant the optimization is described as a maximization of the respective currents in the individual coils. For a predetermined maximal current I max , a minimal magnetic field B min , in the x direction and a predetermined constant c (which should be small and is typically less than 0.01), according to the optimization problem values I, ε, δ are sought, so the following applies:
[0000] max I,δ,ε ε
[0000] ε>0,δ>0 δ<ε
[0000] B x ( P )> B min
[0000] B y ( P )< cB min
[0000] B z ( P )< cB min
[0000] F z ( P 1 )>ε
[0000] −δ< F x ( P 1 )<δ
[0000] F z ( P 3 )<−ε
[0000] −δ< F x ( P 3 )<δ
[0000] −< F z ( P 2 )<δ
[0000] F x ( P 2 )<−ε
[0000] −δ< F z ( P 4 )<δ
[0000] F x ( P 4 )>ε
[0000] I max <I<I max ,komponentenweise component-wise
[0054] Here the variables ε and δ represent force values which according to the above optimization should be selected in such a way that the force which pushes the capsule into the center of the rectangle with the corners P 1 to P 4 , is maximized, wherein corresponding restrictions in relation to the magnetic field, the force direction and the currents should be heeded as boundary conditions. The boundary condition 0<δ<ε together with the boundary conditions in relation to the components of the corresponding forces F 1 to F 4 at the points P 1 to P 4 ensure that the magnetic forces always point into the rectangle formed by the points P 1 to P 4 .
[0055] The above optimization problem is a linear program as the forces and fields are linear combinations of the currents. The solution to such optimization problems is sufficiently known from the related art and any standard method may be used to solve this problem.
[0056] In a second variant the optimization problem is formulated in such a way that a minimal value of the above force value ε is specified and the Euclidean norm of the currents is minimized. In this case variables I, δ are sought for predetermined variables ε, B min , and c, so the following applies:
[0000] min δ,I ∥I∥ 2
[0000] δ>0, δ<ε
[0000] B x ( P )> B min
[0000] B y ( P )< cB min
[0000] B z ( P )< cB min
[0000] F z ( P 1 )>ε
[0000] −δ< F x ( P 1 )<δ
[0000] F z ( P 3 )<−ε
[0000] −δ< F x ( P 3 )<δ
[0000] −δ< F z ( P 2 )<δ F x ( P 2 )<−ε
[0000] −δ< F z ( P 4 )<δ
[0000] F x ( P 4 )>ε
[0057] The boundary condition −I max <I<I max can optionally also be taken into account in this optimization problem.
[0058] In contrast to the preceding optimization problem this optimization problem is a quadratic program with linear side conditions. The solution to such optimization problems is also sufficiently known from the related art and a standard method may be used for the solution. The above optimization problems can also be simply expanded by taking into account different weights for the currents, so, for example, the resistance losses in the coil system are minimized.
[0059] The embodiments described above have been described using the example of a movement of the capsule with two translational and three rotational degrees of freedom. The proposed systems may optionally also be used for the movement of a capsule with more or less translational or rotational degrees of freedom. By way of example a scenario is shown in FIG. 4 in which the translational degree of freedom of a movement also exists in the y direction. Instead of a rectangle according to FIG. 3 , the environment Ω is described by a polyhedron which has six corners P 1 to P 6 . Analogous to the embodiment in FIG. 3 the boundary condition that the magnetic forces in the individual points P 1 to P 6 are directed into the polyhedron should also be taken into account in the solution to the optimization problem. By way of example corresponding magnetic forces are again indicated by arrows, wherein for reasons of clarity only one of the arrows is designated by reference character F.
[0060] The variants of the method just described have a series of advantages. In particular the mechanical movement of a patient or the coil system during the medical examination of the patient is no longer required. Furthermore, it is no longer necessary for the position of the capsule in the work space of the coil system to be measured because by appropriate adjustment of the currents independently of its current position the capsule always moves toward the position of the magnetic field maximum.
[0061] The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention covered by the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV , 69 USPQ2d 1865 (Fed. Cir. 2004). | A coil system for the contactless magnetic navigation of a magnetic body in a work space, has a plurality of coils and a current controller for controlling the respective currents in the plurality of coils. In order to navigate the magnetic body to a variably predeterminable position in the work space, the current controller is designed such that the currents in the plurality of coils are such that the magnetic forces generated by the currents and acting upon the magnetic body at multiple positions at the edge of a convex environment around the predetermined position are directed into the environment. The coil system has the advantage that a movement of the magnetic body toward a spatial position is achieved without any mechanical movement of the coil system and without a positioning system for determining the position of the magnetic body. The coil system is utilized particularly in a medical device, wherein a magnetic body in the form of a probe is moved in the body of a patient. In this way, fast navigation of the probe in the patient's body can be achieved without mechanical movements of the patient table or of the coil system. | 0 |
FIELD OF THE INVENTION
The present invention relates to switch input circuits. In particular, the present invention relates to a switch input circuit having a power-saving device, for example during an application of a wetting current to the switch or switches.
BACKGROUND INFORMATION
Automotive switching systems that are connected to electronic control units may require a certain current flow when the switch contacts are closed, in order to ‘clean’ the contacts of any oxidation or other contaminants. This current may be referred to as the wetting current, and may be defined with reference to a,particular voltage, for example >10 mA at 12 volts.
An approach may be to simply provide a pull-up or pull-down resistor associated with the input processing circuitry in the control unit. This pull-up resistor may be driven by a transistor so that the wetting current may be switched on or off by a control signal connected to the base of the transistor, thereby reducing quiescent current flow.
When the switch contacts are closed, power may be dissipated by the pull-up resistor in the form of heat. Therefore, a suitable resistor may be required to be chosen which may dissipate this heat under the worst case conditions, for example at maximum battery voltage and maximum operating temperature. Depending on the application, for example if the circuit is located in a confined space and there are many switch inputs, the heat generated may cause problems with other electrical components. The problems with power dissipation may become even worse in truck systems having 24 volt batteries, because power may be proportional to voltage.
However, it may also be desirable to keep the wetting current at a relatively high level over the contact cleaning period, in order to effectively clean the switch or switches.
For example: for a 24 volt supply for a truck switch input circuit, a resistor of 1800 Ohms may be required to provide 10 mA at 18V, and may dissipate 320 mW at 24 volts. At the maximum 32 volts, this resistor may dissipate 570 mW.
SUMMARY OF THE INVENTION
The present invention may provide an exemplary method of providing a wetting current to at least one switch through a respective resistor, characterized by modulating the wetting current to reduce average power consumption of the respective resistive element.
The pulse width modulation signal may be supplied to the base of a transistor to periodically allow the wetting current to flow through the emitter and collector of the transistor into the switch input circuit, in accordance with the duty cycle of the pulse width modulation signal.
The method may further include the step of sensing the number of closed switches connected to the switch input circuit. The method may further include the step of providing adjustment of the pulse width modulation signal in response to the sensed number of closed switches. The step of providing adjustment may include increasing the duty cycle of the pulse width modulation signal, if the sensed number of closed switches increases.
The method may further include the step of determining the voltage level of a voltage supply of the circuit. The step of determining may include sensing the voltage level using an analog-to-digital converter to thereby determine a digital value representative of the voltage level. The method may further include the steps of: determining, from the digital value, which of a plurality of predetermined voltage ranges the voltage level of the voltage supply falls within; and adjusting the duty cycle of the pulse width modulation signal depending on the relevant voltage range of the voltage supply.
The present invention may further provide a switch input circuit having a current source for providing the wetting current to at least one switch through a respective resistive element, characterized by a modulation arrangement for modulating the wetting current to provide a reduced average power consumption of the respective resistive element.
The present invention may further provide a switch input circuit having improved power consumption characteristics, the circuit including a current source for supplying a wetting current to at least one switch, and a pulse width modulation signal for modulating the supply of the wetting current to the at least one switch to thereby reduce the average wetting current thus supplied.
The present invention may further provide a method of improving power consumption characteristics of a switch input circuit, including the steps of: providing a wetting current to at least one switch; modulating the wetting current with a pulse width modulation signal to reduce the average wetting current provided to the at least one switch.
Exemplary embodiments of the present invention may be implemented without additional hardware, provided that the filter capacitors used on the inputs are sufficient to ensure electromagnetic compatibility (EMC), and that the microcontroller delivers the appropriate pulse width modulation (PWM) signal.
DETAILED DESCRIPTION
FIG. 1 shows a switch input circuit.
FIG. 2 shows a switch input circuit having an added R-C circuit.
FIG. 3 shows a normal voltage divider circuit used in the switch input circuit.
FIG. 4 shows the voltage divider circuit of FIG. 3 with the pull-down resistor removed.
DETAILED DESCRIPTION
FIGS. 1 and 2 show a switching system 2 , which includes a switching circuit 4 having a number of parallel switches 8 and a switch input circuit 6 . Switch input circuit 6 includes a number lines 16 corresponding to the number of switches, each line being connected through a series resistor R S to a voltage supply V BAT through a transistor 12 . Optionally, a grounded capacitor C S may also be connected to each line 16 , if required for EMC.
A control line 14 is connected to the base of transistor 12 to control the current flowing through it. By increasing the voltage of control line 14 , transistor 12 may be shut off, and by decreasing the voltage of control line 14 , transistor 12 may be turned on. Therefore, if an alternating signal such as a PWM signal is applied to control line 14 , the current supply to switching circuit 4 may be periodically turned on and off.
By using PWM control of the wetting current, the size and cost of switch input circuit 6 may be reduced, as well as the power dissipation of pull-up resistor R S . Essentially, the PWM signal produces an input signal to switching circuit 4 having an average voltage, which is less than the battery voltage and therefore may consume less power (as power is directly proportional to voltage). Thus, while the transistor is turned on, the peak current is greater than the normal wetting current, but the average value of the wetting current over time is the correct wetting current.
Switch input circuit 6 may include a simple R-C filtering circuit, as shown in FIG. 2, to reduce potential electromagnetic interference (EMI) which may otherwise be generated by switch input circuit 6 .
Switch input circuit 6 includes a microcontroller 100 for applying the PWM signal to control line 14 and for receiving input from each of lines 16 via a voltage divider circuit 110 as shown in either of FIGS. 3 or 4 . The microcontroller may have suitable outputs and inputs to connect to lines 14 and 16 , respectively. The microcontroller may be of an available programmable type which may produce a PWM signal of different duty cycles. The inputs from lines 16 may be used by the microcontroller as feedback control in determining the appropriate PWM duty cycle to provide the necessary wetting current to switching circuit 4 .
In R-C filtering circuit 10 , resistor R F dissipates some power and reduces the wetting current. The value may be chosen according to each application of the invention so as not to dissipate too much power with all switches on. To compensate for the reduction in wetting current, which may decrease with an increased number of switches, the microcontroller senses the number of active (closed) switches and adjusts the PWM duty cycle accordingly. If the number of active switches increases, the PWM duty cycle may be increased by the microcontroller. Conversely, it the number of active switches decreases, the PWM duty cycle may be decreased by the microcontroller.
The duty cycle of the PWM signal may also be adjusted in response to changes in battery voltage to further limit power dissipation. The microprocessor may react to the sensed battery voltage in several limited ranges, effectively providing open loop control over the PWM signal. The microcontroller used here may be an analog-to-digital convertor to enable simple sensing of the analog voltage level in terms of an 8-bit value (for example). For the 24 volt example described previously, by using PWM control at 32 volts, the power dissipated through the resistor may be limited to approximately 220 mW. If the microprocessor also senses battery voltage ranges (e.g. range 1: 18-25V, range 2: 25-32V), then, in the higher range, a lower PWM duty cycle is used to decrease the amount of power dissipated (to approximately 110 mW if the voltage range is 25-32 V). Further calculations and details are provided below.
Alternatively, closed loop feedback control may be used to continually modify the PWM duty cycle in response to the measured battery voltage, but this may involve greater computational load on the microprocessor.
By providing PWM modulation of the wetting current, a resistor may be saved from the normal voltage divider circuit (shown in FIG. 3) and used to convert the voltage at the switch to voltages that the microcontroller may sample. Because the average applied voltage is less, the pull-down resistor in the divider may be saved, and only the series resistor may be required to be retained for current limiting purposes.
A microcontroller with 0-5 volt inputs may be arranged to have inputs from a 24 volt system reduced by using a voltage divider (e.g. 100K and 33K resistors). If the average voltage is sufficiently reduced by PWM, then the 33 k pull-down resistor may be removed, leaving only the 100 k series resistor.
The switch input circuit may be implemented with no additional hardware. However a further option may include using a simple R-C low pass filter if required for EMC reasons. A microcontroller with built-in PWM outputs may be provided, but this may be achieved using a normal microcontroller output port. For additional power reduction, the microcontroller also may require some arrangement of sensing the battery voltage, if not continuously (for example, by using an analog-to-digital converter), then at least to sense two different voltage supply ranges.
A suitable microcontroller may be the Motorola MC68HC08AZ32. This unit may be an 8-bit controller which includes an 8-bit analog-to-digital converter (e.g., A/D 120) and a software programmable PWM output having a variable duty cycle and variable frequency.
The control software of the microcontroller may use a fixed PWM output to reduce the average voltage or, if using R-C filter 10 , may be required to determine the PWM duty cycle to use as a function of the number of switches pressed. In addition, the PWM duty cycle may be adjusted as a function of the battery voltage.
The following description applies only to the latter two cases (R-C filter and battery voltage sensing).
The microcontroller may be arranged to monitor the switches in a traditional manner, but may be required to note the sampling point of the signal. The switch input may only be sampled while the wetting current is applied. Extending this further for optimum performance may involve sampling just before the wetting current is switched off (to ensure maximum wetting action), but the sampling may be done some other time during the pulse, in which case time constants in the switch circuit from R-C filtering effects may be required to be considered. A procedure of the microcontroller (operating as a cyclic task) determines the number of switches currently pressed and dynamically adjusts the PWM duty cycle in accordance with look-up tables. If the battery-voltage sensing feature is used, then the function may change to a different look-up table, or alternatively apply a transfer function to modify the existing look-up table.
When a switch is initially pressed, there may be a higher current for a short time before the PWM adjusts. This time may include the debounce and filtering times for the switches and battery voltage, to prevent noise and transients from causing undesirable adjustments to the PWM duty cycle. Even if this reaction time were as much as 100 ms, the power peak experienced may not cause any problems, as the resistors used may be able to withstand short peaks.
The frequencies of PWM operation may be chosen after considering several factors such as generated EMI, such as, for example, in the audio range (e.g. if applicable, may be chosen in conjunction with EMI filter circuit). The switching losses in the drive transistor at high frequencies may also be required to be considered.
For determining the frequency of the PWM signal [Freq=1/ (T ON +T OFF )], the following factors may be required to be considered:
The frequency is large enough so that instantaneous current I INST (which is larger that the average current), does not adversely affect system components (pull-up resistor, driver transistor, switch contacts). At a very low frequency (i.e. a longer ON cycle), the power dissipated in these components during the ON cycle may exceed their maximum ratings before the OFF time allows them to recover or cool down. The frequency may be typically greater than 100 Hz to satisfy this requirement.
The frequency should not be in the audio range (20 Hz-20 kHz), otherwise radiated or conducted EMI may interfere with other components such as car radios (with perceivable noise in the speakers).
The frequency should be less than the transition frequency of the driver transistor, as above this frequency, the transistor rapidly loses gain and may not work at all. This may be in the order of lMHz for general purpose transistors.
If an R-C filter is specifically chosen to reduce generated EMI, then the frequency may be required to be chosen in conjunction with the time constant of the R-C filter. A typical example may be to set the PWM frequency to 250 KHz, and set the time constant of the R-C filter to 10 μsec (F=100 KHz), so that the R-C filter may smooth the rise and fall times of the output to reduce EMI.
The following formulas may be derived from Ohm's laws (V=IR, P=IV). The symbols used are as follows:
V BAT
Reference battery voltage for desired wetting
current
I WET
Desired wetting current for each switch
I TOT
Total current through R F with no PWM
I SW
Individual switch current with no PWM
R F
Filter resistor
R S
Switch pull-up resistor
NUM
Number of active switches (contacts closed)
T ON
Time period of the ON pulse of the PWM signal
T OFF
Time period of the PWM signal for which there
is no pulse
Duty
Duty cycle in percentage; Duty = T ON /( T ON + T OFF )
Furthermore, the average current I AVG through a switch may be equivalent to wetting current I WET and may be related to instantaneous current I INST by I WET =I AVG =I INST × Duty.
The current and individual current with no PWM control:
Total current: I TOT =V BAT /R P +R S /NUM) (1)
Switch current: I SW =I TOT /NUM=V BAT /(R F ×NUM+R S ) (2)
Now the PWM duty cycle may be required to be chosen to reduce the average current through each switch to the desired level (I WET ).
Duty cycle: Duty (100%)=100×I WET ×NUM/I TOT (3)
By substitution from (1) and (2) may become:
Duty cycle: Duty (100%)=100×1 (R F ×NUM+R S )/V BAT (4)
If additional battery voltage sensing is now used, then the duty cycle may be re-calculated for that range by using a new V BAT value. See the example below for more details.
Example (1)
No PWM Control (Traditional Approach)
In this example, the operating battery voltage range is 18 to 32 volts; the desired wetting current I WET =10 mA (minimum) at 18 volts; the number of switches active is NUM, the maximum number of switches active is 6.
To achieve 10 mA at 18 volts, we may require R S =1800 Ohms.
At 18 volts, each resistor dissipates 180 mW. At 32 volts, each resistor dissipates 569 mW, and the wetting current is I WET =17.8 mA.
TABLE (1)
Calculated values with no PWM at V BAT = 32 volts
Wetting
Pwr in
Tot
NUM
current
each R S
Current
Tot Pwr
switches
(ea − mA)
(W)
(A)
(W)
1
17.8
0.569
0.02
0.57
2
17.8
0.569
0.04
1.14
3
17.8
0.569
0.05
1.71
4
17.8
0.569
0.07
2.28
5
17.8
0.569
0.09
2.85
6
17.8
0.569
0.11
3.41
Example (2)
Using PWM Control, but no Battery Voltage Sensing
In this example, the operating battery voltage range is 18 to 32 volts; the desired wetting current I WET =min. 10 mA at 18 volts; the filter includes a R F =47 Ohm series resistor, with a 100 nF parallel capacitor; the pull-up resistors on each switch are R S =680 Ohm; the number of switches active is NUM, and the maximum number of switches active is 6.
Therefore, using the above values, equation (4) becomes:
Duty cycle: Duty (100%)=(47×NUM+680)/V BAT
TABLE (2)
Calculated values with PWM (no voltage sensing)
at V BAT = 32 volts
Wetting
Pwr in
Pwr in
Tot
NUM
DUTY
current
R F
each R S
current
Tot Pwr
switches
(100%)
(ea − MA)
(W)
(W)
(A)
(W)
1
40.4%
17.78
0.01
0.21
0.02
0.23
2
43.0%
17.78
0.06
0.21
0.04
0.49
3
45.6%
17.78
0.13
0.21
0.05
0.78
4
48.2%
17.78
0.24
0.21
0.07
1.10
5
50.8%
17.78
0.37
0.21
0.09
1.45
6
53.4%
17.78
0.53
0.21
0.11
1.82
Example (3)
Using PWM Control, Including Battery Voltage Sensing in Two Ranges
In this example, the operating battery voltage range is 18 to 32 volts:
Range 1 =18 to 25V
Range 2 =25 to 32V
The desired wetting current I WET =10 mA at 18 volts; the R-C filter includes a R F =47 Ohm series resistor, with a 100 nF parallel capacitor; the pull-up resistors on each switch are R S =680 Ohm; the number of switches active is NUM, and the maximum number of switches active is 6.
For range 1 , the wetting current is 10 mA at 18 volts.
TABLE (3)
Calculated values with PWM for Range 1,
with V BAT = 25 volts
Wetting
Pwr in
Pwr in
Tot
NUM
DUTY
current
R F
each R S
current
Tot Pwr
switches
(%)
(ea − MA)
(W)
(W)
(A)
(A)
1
40.4%
13.89
0.01
0.13
0.01
0.14
2
43.0%
13.89
0.04
0.13
0.03
0.30
3
45.6%
13.89
0.08
0.13
0.04
0.48
4
48.2%
13.89
0.15
0.13
0.06
0.67
5
50.8%
13.89
0.23
0.13
0.07
0.88
6
53.4%
13.89
0.33
0.13
0.08
1.11
For range 2 the wetting current is 10 mA at 25 volts.
TABLE (4)
Calculated values with PWM for Range 2,
with V BAT = 32 volts
Wetting
Pwr in
Pwr in
Tot
NUM
DUTY
current
R F
each R S
current
Tot Pwr
switches
(%)
(ea − MA)
(w)
(W)
(A)
(A)
1
29.1%
12.80
0.01
0.11
0.01
0.12
2
31.0%
12.80
0.03
0.11
0.03
0.25
3
32.8%
12.80
0.07
0.11
0.04
0.40
4
34.7%
12.80
0.12
0.11
0.05
0.57
5
36.6%
12.80
0.19
0.11
0.06
0.75
6
38.5%
12.80
0.28
0.11
0.08
0.95
Summary of the Calculations:
TABLE (5)
Summary
Maximum power in circuit
Example
(6 input switches)
1. No PWM
3.41 W
2. PWM with EMI filter, and no
1.82 W
battery sensing
3. PWM with EMI filter, and battery
1.11 W
sensing in 2 ranges
As may be seen in Table 5, the power dissipated in the input circuit under worst case conditions may easily be reduced by half. There may also be substantial cost savings by using smaller resistors, and PCB (printed circuit board) savings as a result.
In summary, there may be three main desired effects of exemplary embodiments of the present invention:
1. Power: The power dissipated by series resistors R S , may be reduced. Thus, less heat may generated, and the circuit board temperature may be reduced, which may lead to greater reliability of the electronics.
2. Size: Because less power may be dissipated, smaller sized resistors may be used. In addition, resistors in the voltage divider circuits may be dispensed with.
3. Cost: There may be cost savings because smaller resistors are used, some resistors may become unnecessary and may be eliminated, and also because less circuit board space may be required for placement and heat dissipation.
It may be understood by persons skilled in the art that alterations and modifications may be made to some features of the described exemplary embodiments of the present invention without departing from the spirit and scope of the present invention. | A method and corresponding apparatus for improving the power consumption of a switch input circuit is described having resistive elements, the method including the steps of providing a wetting current to at least one switch through a respective resistive element, and modulating the wetting current with a pulse width modulation signal to provide a reduced average voltage applied to the respective resistive element, and thereby reduce the power consumption of the circuit. | 8 |
This is a division of application Ser. No. 8/408,913 filed Mar. 22, 1995.
BACKGROUND OF THE INVENTION
The odorous compounds of plants are volatile and are usually separated from the plant material by steam distillation. They are known as the volatile or essential oils, and consist of hydrocarbons, alcohols, ethers aldehydes and ketones: In the evaluations of conifers and in the oils from citrus fruits and from eucalyptus trees, alicyclic hydrocarbons of the composition C 10 H 16 were found to be especially abundant, and it is to these compounds that the term "terpene" was applied in the restricted sense. It soon became evident, however, that compounds containing 15, 20, 30 and 40 carbon atoms also are closely related to terpenes, and the term "terpene" in its broadest sense now includes all such compounds, which comprise repeating iso-C 5 units.
Many of the essential oils are employed in various flavors and fragrances, and their medicinal or biocidal potential has been the subject of continued investigation. For example, the cyclic terpenones, α-ionone and β-ionone, were reported to exhibit moderate antibacterial activity against S. mutans by I. Kubo et al., J. Agric. Food Chem., 41, 2447 (1993). This bacterium is responsible for causing dental caries. Carvone, the chief component of spearmint oil, was reported to exhibit antifungal activity by V. Moleyar et al., Food Microbiol., 3, 331 (1986). Kubo et al., J. Natural Products, 57, 9 (1994) subsequently reported that a number of cyclic and acyclic terpene alcohols, including geranylacetol, farnesol and farnesyl acetol, exhibited activity against Pr. acnes, the bacterium responsible for acne. However, the linear ketone derived from farnesylacetol, farnesylacetone, was found to be inactive.
While some of these natural products may be potent enough for practical use, the synthesis or extraction of highly branched cyclic or alicyclic terpenes can be complex. Furthermore, terpenes such as ionone, a component of cedar oil, can cause allergic skin reactions. Nonetheless, essential oils and other phytochemicals are by definition biodegradable and renewable. Therefore, a continuing need exists for compounds of natural origin which exhibit useful levels of biocidal activity.
SUMMARY OF THE INVENTION
The present invention provides a method to inhibit the growth of microorganisms, particularly microorganisms that are responsible for mammalian skin pathologies, comprising contacting the microorganisms with an effective growth-inhibiting amount of a 3-alken-2-one of the general formula (I): ##STR1## wherein n is 6-16 and X═Y═H or X and Y together are a covalent bond. Preferably n is 5-11 and X═Y═H, or n is 6-10 and X and Y together are a covalent bond. Preferably the 3,4-double bond is in the E- or trans-configuration.
Thus, the present invention also provides a composition adapted for topical application to the skin comprising an effective antimicrobial amount of at least one compound of formula (I), in combination with a dermatologically acceptable carrier. Preferred compositions in accord with the present application are therapeutic compositions adapted for topical application, as to the skin of a mammal afflicted with, or at risk of affliction with, a pathology associated with a microorganism such as a bacterium, a yeast or a fungus. Novel compounds of formula (I) are also within the scope of the invention, including 3-hexadecen-2one.
The term "skin" as used herein is to be construed broadly, to include the epidermis, the lips, the scalp, the epithelium of the eye, the surfaces of body cavities, including the mouth, ear, nose, vagina, anus and the like, and the surfaces of wounds or lesions in the skin. The term "antimicrobial" or "inhibit," as used with respect to the growth of microorganisms, is defined to encompass both complete inhibition (killing) of the microbes, as well as significant inhibition in growth or sporulation, as determined by the assays described herein, or by other standard assays, such as those disclosed by A. M. Janssen et al., Planta medica, 53, 395 (1987). Thus, the term "antimicrobial" encompasses the use of the present compounds in deodorant compositions, to control body odor, as well as in therapeutic compositions. All percentages are by weight unless otherwise noted.
DETAILED DESCRIPTION OF THE INVENTION
A. Preparation
The 3-alken-2-ones of the present invention which are not commercially available, or which are novel compounds can be prepared by a number of methods available to the art. For example, 3-alken-2-ones of general formula RCH═CH--C(O)CH 3 can generally be prepared by the crossed aldol condensation of acetone and the alkanal (RCHO), followed by the acid-catalyzed elimination of water from the resultant hydroxy ketone. See, for example, B. V. Burger et al., J. Chem. Ecol., 16, 397 (1990) (3-dodec-2-one) and G. Tishenko et al., J. Gen. Chem. USSR, 33, 134 (1963) (3-nonen-2-one). Alternatively, they can be prepared by the Wittig or Wittig-Horner reaction.
Y.-Z. Huang et al., Synth. Commun., 19, 501 (1989) have also reported a general synthesis of 2-alken-2-ones (trans-RCH═CHC(O)CH 3 ) by the reaction of the aldehyde (RCHO) with α-bromoacetone in the presence of tri-n-butylstibine for 1-16 hr at 25°-50° C., and prepared compounds wherein R is n--C 4 H 9 , n--C 8 H 17 or n--C 11 H 23 . The 3-alken-2-one wherein R is n--C 13 H 26 has been reported by R. Kazlauskas et al., Aust. J. Chem., 33, 2097 (1980).
The 3-alkene-2-one wherein R is C 7 H 15 has been reported by H. A. Palma-Fleming et al., Phytochem., 22, 1503 (1983). The 3-aken-2-one wherein R is C 9 H 19 , was prepared by A. A. Croteau et al., Tet. Letters, 24, 2481 (1983), who report a general synthesis of E/Z mixtures of 3-alken-2-ones by the condensation of lithiated α-silylketimine (Me 3 Si--CHLi--C(═Nt--Bu)Me) with RCHO, followed by hydrolysis. Also, the preparation of (Z)-3-alken-2-ones by the condensation of alkenyl lithiocuprates with acetyl halides has been reported by N. Jabri et al., Tetrahedron, 42, 1369 (1986). The preparation of 3-tetradecen-2-one (R═C 10 H 21 ) has been reported by J. Kang et al., Bull. Korean Chem. Soc., 15, 306 (1994).
B. Bioactivity
The present compounds and compositions comprising them can be employed in a wide range of antimicrobial applications, including surface disinfecting, and for treating foods such as fruits and seeds. The present compounds are particularly useful to inhibit the growth of pathological microorganisms, such as bacteria, fungi and yeasts on the skin of humans and of animals such as household pets, farm animals and zoo animals. Such gram-positive microorganisms include Propionibacterium acnes which is the primary pathogen which causes human acne vulgaris, and the streptocci and staphylococci which cause impetigo. Mycotic infections of animals and humans can also be treated, including tinea capitis, tinea cruris (jock itch), tinea corporis (ringworm), tinea pedis (athlete's foot) and tinea unguium. Fungi associated with such dermatophytosis include T. mentagrophytes, M. audevinii, T. rubrum, E. fioccosum, M. pelineum and Candida albicans.
The present compounds are also effective against fungi associated with infections of the membranes of body cavities. Such infections include thrush, vaginitis and paronychia. See R. T. Yousef et al., Mykosen, 21, 190 (1978) and H. Gershon, J. Pharm. Sci., 68, 82 (1979). The present compounds can also be used in cosmetic and skin-cleansing compositions such as soaps, shampoos, deodorants, and skin softening lotions, where they can function as deodorants, i.e., to control odor-causing bacteria on the skin. The present compounds can also be employed in dentifrices, chewing gums, and mouthwashes to inhibit the growth of Streptococcus mutans, which is a causative agent for dental caries, and in shampoos, rinses, and other haircare products, to inhibit Pityrosporum ovale (dandruff, skin lesions in immune-suppressed subjects). Infections due to Staphylococcus aureus are also susceptible to these compounds.
C. Compositions
Although in some instances, the present compounds may be administered in pure form, i.e., when they are liquids, it will generally be desirable to administer them to the skin as compositions or formulations, in combination with a dermatologically acceptable carrier, which may be a solid or a liquid.
Useful solid carriers include finely divided solids such as talc, clay, microcrystalline cellulose, silica, alumina and the like. Useful liquid carriers include water, alcohols or glycols or water-alcohol/glycol blends, in which the present compounds can be dissolved or dispersed at effective levels, optionally with the aid of non-toxic surfactants. Adjuvants such as flavorings, fragrances and additional antimicrobial agents can be added to optimize the properties for a given use. The resultant liquid compositions can be applied from absorbent pads, used to impregnate bandages and other dressings, or sprayed onto the affected area using pump-type or aerosol sprayers. The liquid compositions can also be employed as eyedrops, mouth washes, douches, etc. Antibacterial presaturated wipes are disclosed by Anderson (U.S. Pat. No. 4,896,768).
Thickeners such as synthetic polymers, fatty acids, fatty acid salts and esters, fatty alcohols, modified celluloses or modified mineral materials can also be employed with liquid carriers to form spreadable pastes, gels, ointments, soaps, and the like, for application directly to the skin of the user.
The total concentration of one or more compounds of formula (I) in the present compositions can be varied widely, and will depend on factors such as the compatibility of the active ingredient(s) with the vehicle, the potency of the active ingredient(s) and the condition to be treated. Generally, the concentration of the compound(s) of formula (i) in a liquid composition, such as a lotion, will be from about 0.1-25 wt-%, preferably from about 0.5-10 wt-%. The concentration in a semi-solid or solid composition such as a gel or a powder will be about 0.1-5 wt-%, preferably about 0.5-2.5 wt-%.
The present compounds of formula (I) are particularly useful to treat human or animal acne by topical application, as gels, ointments, lotions, soaps, and the like. For a further discussion of the pathology and etiology of acne, and of the formulation of aqueous cream and gel vehicles as carriers for other agents used to treat acne, see Klein et al. (U.S. Pat. No. 4,692,329). The total dosage delivered will depend on the extent of the infected area to be treated, the severity of the infection and the number of applications, as determined by the subject's dermatologist, physician or veterinarian.
The present invention will be further described by reference to the following detailed examples.
EXAMPLE 1
Synthesis of (E)-3-Alken-2-ones and (E)-3,13-Tetradecadien-2-one
To 5.0 g of piperidine, 5.0 g of glacial acetic acid and 250 mL of acetone at reflux in a 500 mL round-bottomed flask was added 0.10 mole of one of the following aldehydes (octanal, nonanal, decanal, undecanal, 10-undecenal, dodecanal, tridecanal, or tetradecanal) in 50 mL of acetone dropwise over 0.5 hours. After addition, the solution was refluxed for an additional 5 hours. The acetone was removed in vacuo and the residue was placed in 50 mL of diethyl ether. The ether solution was washed with 2×50 mL water, 2×50 mL 1 M HCl and 2×50 mL saturated NaHCO 3 . The ether solution was dried with anhydrous CaCl 2 and the ether was removed in vacuo. A pure sample of each compound was obtained by preparative gas chromatography.
EXAMPLE 2
Spectral Data for (E)-3-Alken-2-ones and (E)-3,13Tetradecadien-2-one
Mass spectra of the following compounds were recorded on a Hewlett-Packard gas chromatograph (Model 5890) fitted with a mass selective detector (Model 5970) using a 12 m cross-linked methyl silicone capillary column. The gas chromatograph was programmed so the oven temperature was kept at 40° C. for 4 minutes, then increased to a final temperature of 250° C. at a rate of 30° C./min and kept at this temperature for four minutes. Mass spectral fragments below m/z=35 were not recorded. The mass selective detector was tuned using perfluorotributylamine and the internal computer tuning program.
The 1 H and 13 C NMR spectra of the compounds were recorded at 300 MHz and 75 MHz respectively on Bruker QE plus. Samples were dissolved in CDCl 3 , and chemical shifts are given in ppm relative to tetramethylsilane (TMS) at zero ppm using the solvent peak a 77.0 ppm as the internal standard. The synthetic 3-alken-2-ones and 3,13-tetradecadien-2-one were shown to be the (E)-isomer by the 1 H-NMR coupling constant of 15.9 Hz for the olefinic protons.
A. (E)-3-Undecen-2-one (1)
300 MHz 1 H-NMR (CDCl 3 ) δ=6.78(dt, 1H, J=15.9 Hz, 6.9 Hz), 6.03(dt, 1H, J=15.9 Hz, J=1.48 Hz), 2.21(s, 3H), 2.19(quart, 2H), 1.44(m, 2H), 1.26(m, 8H) and 0.85(t, 3H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.74, 148.68, 131.29, 32.50, 31.75, 29.17, 29.08, 28.12, 26.82 22.65, 14.09; and El-MS m/z=97(7), 83(5), 81(6), 71(15), 69(18),68(6), 55(50), 43(100), 41(40) and 39(19).
B. (E)-3-Dodecen-2-one (2)
300 MHz 1 H-NMR (CDCl 3 ) δ=6.73(dt, 1H, J=15.9 Hz, 6.9 Hz), 5.99(dt, 1H, J=15.9 Hz, J=1.48 Hz), 2.18(s, 3H,) 2.15(quart, 2H), 1.38(m, 2H), 1.21(m, 10H) and 0.81(t, 3H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.80, 148.72, 131.31, 32.53, 31.87, 29.39, 29.23, 28.13, 26.84, 22.69 and 14.13; and El-MS m/z=97(15), 83(11), 82(9), 81(8), 71(25), 69(18), 55(50), 43(100), 41(37) and 36(18).
C. (E)-3-Tridecen-2-one (3)
300 MHz 1 1 H-NMR (CDCl 3 ) δ=6.81(dt, 1 H, J=15.9 Hz, 6.9 Hz), 6.06(dt, 1H, J=15.9 Hz, J=1.48 Hz), 2.24(s, 3H) 2.22(quart. 2H), 1.46(m, 2H), 1.26(m, 12H) and 0.88(t, 3H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.80, 148.69, 131.24, 32.47, 31.85, 29.46, 29.37, 29.27, 29.17 28.07, 26.79, 22.65 and 14.09; El-MS m/z=96(M + , 2), 181(8), 97(31), 96(14), 83(22), 81(20), 71(34), 69(31), 55(65), 43(100), 41(44); and FT-IR (neat) 2925 2854, 1700, 1677, 1628, 1467, 1360, 1253, 1189 and 980 cm -1 .
D. (E)-3-Tetradecen-2-one (4)
300 MHz H-NMR (CDCl 3 ) δ=6.79(dt, 1H, J=15.9 Hz, 6.9 Hz), 6.05(dt, 1H, J=15.9 Hz, J=1.48 Hz), 2.23(s, 3H), 2.21(quart, 2H), 1.45(m, 2H), 1.26(m, 14H) and 0.87(t, 3H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.79, 148.71, 131.31, 32.53, 31.94, 29.62, 29.57, 29.43, 29.36 29.23, 28.13, 26.84, 22.72 and 14.15; El-MS m/z=97(21), 84(9), 83(8), 81(12), 71(30), 69(18), 55(50), 43(100), 41(50) and 39(18).
E. (E)-3, 13-Tetradecadien-2-one (5)
300 MHz 1 H-NMR (CDCl 3 ) δ=6.80(dt, 1H, J=15.9 Hz, 6.9 Hz), 6.06(dt, 1H, J=15.9 Hz, J=1.48 Hz), 5.80(m, 1H), 4.95(m, 2H), 2.24(s, 3H), 2.22(quart, 2H), 2.03(quart, 2H), 1.46(m, 2H) and 1.28(m, 10H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.83, 148.71, 139.18, 131.32 114.20, 33.83, 32.52, 29.38, 29.21, 29.12, 28.94, 28.13, 26.87; El-MS m/z=97(20), 95(14), 81(21), 71(19), 69(17), 67(23), 55(59), 43(100), 41(71) and 39(35).
F (E)-3-Pentadecen-2-one (6).
300 MHz 1 H-NMR (CDCl 3 ) δ=6.80(dt, 1H, J=15.9 Hz, 6.9 Hz), 6.05(dt, 1H, J=15.9 Hz, J=1.48 Hz), 2.23(s, 3H), 2.21(quart, 2H), 1.46(m, 2H), 1.26(m, 16H) and 0.88(t, 3H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.79, 148.71, 131.31, 32.53, 31.96, 29.66, 29.57, 29.44, 29.38 29.33, 29.24, 28.14, 26.85, 22.73 and 14.16; El-MS m/z=97(18), 84(10), 81(11), 71(28), 69(16), 68(10), 67(10), 55(46), 43(100), and 41(40)
G. (E)-3-Hexadecen-2-one (7)
300 MHz 1 H-NMR (CDCl 3 ) δ=6.80(dt, 1H, J=15.9 Hz, 6.9 Hz), 6.06(dt, 1H, J=15.9 Hz, J=1.48 Hz), 2.24(s, 3H), 2.22(quart, 2H), 1.47(m, 2H). 1.26(m, 18H) and 0.88(t, 3H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.83, 148.74, 131.31, 32.54, 31.97, 29.71, 29.68, 29.58, 29.54 29.44, 29.41, 29.25, 28.15, 26.85, 22.74 and 14.17; El-MS m/z=97(18), 84(8), 83(8), 82(8), 81(9), 71(30), 69(15), 55(42), 43(100), and 41(50).
H. (E)-3-Heptadecen-2-one (8)
300 MHz 1 H-NMR (CDCl 3 ) δ=6.80(dt, 1H, J=15.9 Hz, 6.9 Hz), 6.07(dt, 1H, J=15.9 Hz, J=1.48 Hz), 2.24(s, 3H), 2.22(quart, 2H), 1.47(m, 2H), 1.26(m, 20H) and 0.88(t, 3H); 75 MHz 13 C-NMR (CDCl 3 ) δ=198.83, 148.74, 131.32, 32.54, 31.97, 29.70, 29.58, 29.44, 29.41 29.34, 29.25, 28.15, 26.87, 22.74 and 14.18; and El-MS m/z=252(M+, 3), 97(19), 84(8), 83(10), 81(11), 71(28), 69(14), 55(39), 43(100) and 41(50).
EXAMPLE 3
Bioassays
The microorganisms tested were from the American Type Culture Collection (Rockville, Md.). They are Bacillus subtilis ATCC 9372 Brevibacterium ammoniagenes ATCC 6872, Staphylococcus aureus ATCC 12598, Streptococus mutans ATCC 25175, Propionibacterium acnes ATCC 11827, Pseudimonas aeruginosa ATCC 10145, Enterobacter aerogenes ATCC 13048, Eschericia coli ATCC 9637, Proteus vulgaris ATCC 133315, Saccharomyces cerevisiae ATCC 7754, Candida utilis ATCC 9226, Pityrosporum ovale ATCC 14521, Penicillium chrysogenum ATCC 10106 and Trichophyton mentagrophytes ATCC 18748.
The bacterial culture media except for S. mutans was 0.8% nutrient broth (BBL), 0.5% yeast Extract (Difco) and 0.1% glucose (NYG broth). S. mutans was cultured in 3.7% brain heart infusion broth (Difco). All fungi, except P. ovale and T. mentagrophytes were cultured in a 2.5% malt extract broth (BBL). P. ovale was cultured in 1% bactopeptone (Difco), 0.5% yeast extract, 1% glucose and 0.1% corn oil. For T. mentagrophytes the culture media was 1% bactopeptone and 4% glucose.
Freeze dried samples were prepared for testing as follows. B. subtilis, S. cerevisiae, C utilis, and P. ovale, were shake-cultured for two days at 30° C. P. chysogenum and T. mentagrophytes were shake-cultured for 5 days at 30° C. B. ammoniagenes and E. aerogenes were stationarily cultured at 30° C. S. aureus S. mutans, P. acnes, P. aeruginosa, E. coli and P. vulgaris were stationarily cultured at 37° C.
The minimum inhibitory concentration (MIC) of the 3-alken-2-ones (compounds 1-4, 6-8) and 3,13-tetradecadien-2-one (compound 5) was performed using a two-fold serial broth dilution. Each test compound was dissolved in DMF and 30 μL of this sample was dissolved in 3 mL of the applicable medium. A 30 μL sample of the previously described culture of each microorganism was added to the various medium solutions. After two days, the cultures of B. subtilis, S. cerevisiae, C utilis, B. ammoniagenes, E. aerogenes, S. aureus, S. mutans, P. acnes, P. aeruginosa, E. coli and P. vulgaris were examined for turbidity (OD at 660 nm). The fungi, P. ovale, P. chysogenum and T. mentagrophytes, were examined visually for growth at 3 days (P. ovale) and 5 days (P. chrysogeum and T. meuagrophytes). The MIC was determined as the lowest concentration for each compound that no growth was observed. The highest concentration used in these tests was 800 μg/mL.
TABLE 1__________________________________________________________________________MIC of (E)-3-Alken-2-ones and (E)-3,13-tetradecadien-2-one(μg/mL)Organism 1 2 3 4 5 6 7 8__________________________________________________________________________Bacillus subtilis ATCC 9372 100 100 100 >800 >800 >800 >800 >800Brevibacterium ammoniagenes ATCC 6872 200 100 100 >800 >800 >800 >800 >800Staphylococcus aureus ATCC 12598 200 100 50 >800 >800 >800 >800 >800Streptococus mutans ATCC 25175 100 50 25 25 25 200 400 800Propionibacterium acnes ATCC 11827 50 25 12.5 12.5 12.5 6.25 3.13 3.13Pseudimonas aeruginosa ATCC 10145 >800 >800 >800 >800 >800 >800 >800 >800Enterobacter aerogenes ATCC 13048 >800 >800 >800 >800 >800 >800 >800 >800Eschericia coli ATCC 9637 >800 >800 >800 >800 >800 >800 >800 >800Proteus vulgaris ATCC 133315 50 50 800 >800 >800 >800 >800 >800Saccharomyces cerevisiae ATCC 7754 800 800 >800 >800 >800 >800 >800 >800Candia utilis ATCC 9226 50 400 >800 >800 >800 >800 >800 >800Pityrosporum ovale ATCC 14521 100 100 100 100 200 400 >800 >800Penicillium chrysogenum ATCC 10106 100 100 800 800 800 >800 >800 >800Trichophyton mentagrophytes ATCC18748 100 100 25 12.5 12.5 800 >800 >800__________________________________________________________________________
As demonstrated by the data summarized in Table 1 the greatest activity observed with compounds 1-8 occurred against P. aches, the primary pathogen responsible for causing human acne. Compounds 1-5 also exhibited substantial activity against T. mentagrophytes, the causative agent of athlete's foot and compounds 1-7 inhibited Streptococcus mutans (dental caries). Compounds 1-6 also exhibited somewhat lesser activity against P. ovale (dandruff) and compounds (1)-(3) were active against S. aureus and Proteus vulgaris. Specifically, (E)-3-tridecen-2-one (3), showed activity against all of the gram-positive bacteria (B. subtilis, B. ammoniagenes, S. aureus, S. mutans, and P. acnes) in the test. It was most active against P. acnes, having a minimum inhibitory concentration (MIC) of 12.5 μg/mL. This compound was not active against the gram-negative bacteria, P. aeruginosa, E. aerogenes and E. coli. Activity against yeast was mixed, no activity was seen against S. cerevisiae and C utilis, although P. ovale showed moderate inhibition. Weak activity was seen with fungi P. chysogenum, while the fungi T. mentagrophytes had a MIC of 25 μg/mL.
(E)-3-tetradecen-2-one (4), showed activity against some gram-positive bacteria (S. mutans, and P. acnes) in the test. It was most active with P. acnes having a minimum inhibitory concentration (MIC) of 12.5 μg/mL. This compound was not active against the gram-negative bacteria, P. aeruginosa, E. aerogenes and E. coli. Activity against yeast was mixed, no activity was seen against S. cerevisiae and C. utilis, although P. ovale showed moderate inhibition. Weak activity was seen with fungi P. chrysogenum, while the fungi T. mentagrophytes had a MIC of 12.5 μg/mL.
The synthetic products, (E)-3-hexadecen-2-one (7) and (E)-3-heptadecen-2-one (8), were inactive to all of the bacteria and fungi in the test, except S. mutans and P. acnes. With S. mutans (7) was weakly active, but (7) and (8) exhibited strong activity (3.13 μg/mL) against P. acnes.
EXAMPLE 4
A powder composition may be prepared having the following formulation:
______________________________________ Per Canister______________________________________Compound 4 1.0 gTalc 99 g______________________________________
EXAMPLE 5
A lotion composition may be prepared having the following formulation:
______________________________________ Per Canister______________________________________Compound 7 1.0 gCetyl Alcohol 25 gGlyceryl Stearate 25 gGlycerol 20 gWater 10 gStearyl Alcohol 10 g______________________________________
EXAMPLE 6
A lotion composition may be prepared having the following formulation:
______________________________________ Per Canister______________________________________Compound 7 0.5 gCompound 4 0.5 gCetyl Alcohol 25 gGlyceryl Stearate 25 gGlycerol 20 gWater 10 gStearyl Alcohol 10 g______________________________________
Other examples of useful dermatological compositions which can be used to deliver the compounds of claim 1 to the skin are disclosed in Jacquet et al. (U.S. Pat. No. 4,608,392), Geria (U.S. Pat. No. 4,992,478), Smith et al. (U.S. Pat. No. 4,559,157) and Wortzman (U.S. Pat. No. 4,820,508).
All publications and patents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | A method to inhibit microbial growth is provided comprising topically administering to a mammal afflicted with a pathology associated with microbial growth, such as a dermatological condition, an effective amount of a linear (C 12 -C 22 ) 3-alken-2-one or 3,ω-alkadien-2-one. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to European application 13169211.3 filed May 24, 2013 the contents of which are hereby incorporated in its entirety.
TECHNICAL FIELD
The present invention relates to a gas turbine, more particular, to a damper for reducing the pulsations in a combustion chamber of a gas turbine.
BACKGROUND
In conventional gas turbines, acoustic oscillation usually occurs in the combustion chamber of the gas turbines during combustion process due to combustion instability and varieties. This acoustic oscillation may evolve into highly pronounced resonance. Such oscillation, which is also known as combustion chamber pulsations, can assume amplitudes and associated pressure fluctuations that subject the combustion chamber itself to severe mechanical loads that my decisively reduce the life of the combustion chamber and, in the worst case, may even lead to destruction of the combustion chamber.
Generally, a type of damper known as Helmholtz damper is utilized to damp the pulsations generated in the combustion chamber of the gas turbine. Currently, one of the main difficulties in utilization of such damper is the fact that the space available for these dampers is limited. One possible approach in addressing such situation is to place the damper on the outer side of the combustion chamber. In practice, the thermal expansion of the different layers composing the combustion chamber prevents directly applying such dampers.
A damping arrangement for reducing resonant vibrations in a combustion chamber of a gas turbine is disclosed in US2004/0248053A1, wherein the combustion chamber comprises an outer wall-surface part and an inner wall-surface part facing the combustion chamber, gastightly encloses an intermediate space, into which cooling air can be fed for purposes of convective cooling of the combustion chamber wall. At least one third wall-surface part is provided, which, with the outer wall-surface part, encloses a gastight volume. The gastight volume is connected gastightly to the combustion chamber by at least one connecting line. A gasket is welded at an end of the connecting line that is located in the gastight volume, and covers the outer wall surface part to provide gas tightness. With this gasket and connecting lines, the damping arrangement may compensate thermal expansion difference between the outer and inner wall-surface part in one direction.
A combustion chamber suitable for a gas turbine engine is provided in US2006/0123791A1, which comprise at least one Helmholtz resonator having a resonator cavity and a resonator neck in flow communication with the chamber interior. The Helmholtz resonator is fixed to an inner casing of the combustion chamber, with the resonator neck penetrating into the interior of the combustion chamber through an opening on the inner wall of the combustion chamber. An annular sealing member is provided around the outer periphery of the neck to provide gas tight seal between the neck and the opening. The neck provides limited relative axial movement of the neck with respect to the combustion chamber so that substantially no load is transferred from the resonator neck to the combustion chamber during engine operation.
A combustor for a gas turbine including at least one resonator is disclosed in WO2012/057994A2, which comprises an outer liner and an inner liner. The resonator is coupled to the outer liner. The combustor liner includes a throat extending from the base of the resonator penetrating into the combustion chamber through the inner liner and the outer liner. The combustor liner further includes a grommet assembly that allows for relative thermal expansion between the inner liner and the outer liner proximate the throat in a first direction along the axis of the throat and a second direction perpendicular to the first direction.
Even with above mentioned development in the pulsation damping field, there exist a large space to improve the compensation effect in eliminating thermal expansion difference.
SUMMARY
It is an object of the present invention is to provide a damper for a gas turbine that may compensate relative rotation generated between the combustor chamber and the damper, in particular, the resonator cavity of the damper, due to thermal expansion difference.
This object is obtained by a damper for reducing the pulsations in a combustion chamber of a gas turbine, wherein the damper comprises: a resonator cavity with an inlet and a neck tube in flow communication with the interior of the combustion chamber and resonator cavity, and a compensation assembly pivotably connected with the neck tube and is inserted between the resonator cavity and the combustion chamber to permit relative rotation between the combustion chamber and the resonator cavity.
According to one possible embodiment, the neck tube is air-tightly attached at a first end thereof to a wall of the combustion chamber, the compensation assembly is pivotably connected with a second end of the tube neck, wherein the compensation assembly comprises a bulb portion formed on the second end of the neck tube and a socket portion air-tightly fitted with the bulb portion to provide the relative rotation between the combustion chamber and the resonator cavity. According to another one possible embodiment, the compensation assembly further comprises a first sliding part formed on the socket portion and a second sliding part air-tightly fitted with the first sliding part to provide relative slide along a direction parallel to a longitudinal axis of the neck tube between the first sliding part and the second sliding part.
According to another one possible embodiment, the compensation assembly further comprises a third sliding part formed on the second sliding part and a fourth sliding part formed on the inlet of the resonator cavity that is air-tightly fitted with the third sliding part to provide relative slide in a direction traversing the longitudinal axis of the neck tube between the third sliding part and the fourth sliding part.
According to another one possible embodiment, the wall of the combustion chamber comprises an outer wall and an inner wall located radially inwards than the outer wall, and the neck tube is air-tightly attached at the first end thereof to the inner wall of the combustion chamber, and passing through an opening on the outer wall with a grommet air-tightly attached to a peripheral of the neck tube in order to cover the opening on the outer wall.
According to another one possible embodiment, the third sliding part comprises a protrusion formed thereon where the protrusion is allowed to air-tightly slide against the fourth sliding part.
According to another one possible embodiment, the neck tube is air-tightly attached at a first end thereof to the inlet of the resonator cavity, the compensation assembly is pivotably connected with a second end of the tube neck, wherein the compensation assembly comprises a bulb portion formed on the second end of the tube neck and a socket portion air-tightly fitted with the bulb portion to provide the relative rotation between the combustion chamber and the resonator cavity.
According to another one possible embodiment, the compensation assembly further comprises a first sliding part formed on the socket portion and a second sliding part air-tightly fitted with the first sliding part to provide relative slide along a direction parallel to a longitudinal axis of the neck tube between the first sliding part and the second sliding part.
According to another one possible embodiment, the compensation assembly further comprises a third sliding part formed on the second sliding part and a fourth sliding part formed on the wall of the combustion chamber that is air-tightly fitted with the third sliding part to provide relative slide in a direction traversing the longitudinal axis of the neck tube between the third sliding part and the fourth sliding part.
According to another one possible embodiment, the third sliding part comprises a protrusion formed thereon where the protrusion is allowed to air-tightly slide against the fourth sliding part.
With the damper according to the present invention, by way of providing the compensation assembly, it is assured the relative rotation between the combustion chamber and the resonator cavity is compensated, hence operation life is elongated.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advantages and other features of the present invention will become more apparent upon reading of the following non-restrictive description of preferred embodiments thereof, given for the purpose of exemplification only, with reference to the accompany drawing, through which similar reference numerals may be used to refer to similar elements, and in which:
FIG. 1 shows a schematic cross section view of the damper with part of the combustion chamber of a gas turbine according to one embodiment of the present invention, in which some part is cut way for the purpose of clarity;
FIG. 2 shows a schematic cross section view of the damper with part of the combustion chamber of a gas turbine according to another embodiment of the present invention, in which some part is cut way for the purpose of clarity.
DETAILED DESCRIPTION
FIG. 1 shows a schematic cross section view of a damper 100 with part of the combustion chamber 200 of a gas turbine according to an embodiment of the present invention, in which some part is cut way for the purpose of clarity. The damper 100 comprises a resonator cavity 110 with a box or cylinder shape as delimitated by a peripheral wall 102 and an inlet 104 . As shown in FIG. 1 , the major part of the resonator cavity 110 is cut away as this would not prevent full and complete understanding of the technical solutions of the present invention. Also, only parts of the combustion chamber 200 closely related to the present invention is shown in FIG. 1 for clarity and simplicity. The resonator cavity 110 is air tightly attached to a structure 106 of a combustion chamber 200 by fasteners, not shown in FIG. 1 . In an example implementation of the present invention, the structure 106 of the combustion chamber 200 may be a casing of the combustion chamber 200 . Those skilled in the art should appreciate that the structure 106 provides carrier for the resonator cavity 110 , and should not be limited to the casing of the combustion chamber as described herein. In addition, the damper 100 comprises a neck tube 120 that is in flow communication with the resonator cavity 110 through a compensation assembly 130 according to the present invention in order to compensate relative movement between the resonator cavity 110 and the combustion chamber 200 .
According to one example embodiment, the neck tube 120 is air tightly attached at a first end 122 thereof to the wall of the combustion chamber 200 . For example, the first end 122 of the neck tube 120 may be welded to the wall of the combustion chamber 200 . As one possible implementation that may be applied in a double wall combustion chamber where the combustion chamber 200 comprises an inner wall 202 and an outer wall 204 radially located outward than the inner wall 202 , the first end 122 of the neck tube 120 may be air tightly attached to the inner wall 202 of the combustion chamber 200 , with the neck tube 120 extending through an opening 206 on the outer wall 204 . In this case, a grommet 208 may be air tightly attached, such as welded, to a peripheral of the neck tube 120 in order to cover the gap generated between the neck tube 120 and the opening 206 , providing air tightness.
As an alternative embodiment, the grommet 208 may be dispensed when the present invention is applied in a single wall combustion chamber.
According to one example embodiment of the present invention, the compensation assembly 130 may pivotably connected with the neck tube 120 and is inserted between the resonator cavity 110 and the combustion chamber 200 to permit relative rotation between the combustion chamber 200 and the resonator cavity 110 . In this embodiment, the compensation assembly 130 may be pivotably connected with a second end 124 opposite to the first end 122 of the tube neck 120 . In particular, the compensation assembly 130 may comprise a bulb portion 126 formed on the second end 124 and a socket portion 132 air-tightly fitted with the bulb portion 126 to provide the relative rotation between the combustion chamber 200 and the resonator cavity 110 . During operation of the gas turbine, the relative rotation between the combustion chamber 200 and the resonator cavity 110 due to different thermal expansion may be compensated or absorbed by the compensation assembly 130 , so as to prevent potentially structural damage.
In addition, the compensation assembly 130 may comprise a first sliding part 134 formed on the socket portion 132 on a opposite side therefrom, and a second sliding part 136 air-tightly fitted with the first sliding part 134 to provide relative slide along a direction parallel to a longitudinal axis of the neck tube 120 between the first sliding part 134 and the second sliding part 136 . During operation of the gas turbine, the relative slide between the first sliding part and the second sliding part may compensate the relative movement along the longitudinal axis of the neck tube 120 between the combustion chamber 200 and the resonator cavity 110 due to different thermal expansion.
Furthermore, the compensation assembly 130 my comprise a third sliding part 138 formed on the second sliding part 136 opposite to the first sliding part 134 and a fourth sliding part 108 formed on the inlet 104 of the resonator cavity 110 that is air-tightly fitted with the third sliding part 138 to provide relative slide in a direction traversing the longitudinal axis of the neck tube 122 between the third sliding part 138 and the fourth sliding part 108 . During operation of the gas turbine, the relative slide between the third sliding part 138 and the fourth sliding part 108 may compensate the relative movement in a direction traversing the longitudinal axis of the neck tube 120 between the combustion chamber 200 and the resonator cavity 110 due to different thermal expansion.
As shown in FIG. 1 , the fourth sliding part 108 may be provided by an end face of the inlet 104 , which may represent one possible solution that may be adopted by those skilled in the art. However, equivalent structures may be utilized as the fourth sliding part 108 . For example, when the resonator cavity 110 is attached by means of an intermediate component, such as a plate with opening to adjust the size and dimension of the inlet 104 , not shown, to the structure 106 of the combustion chamber 200 , the fourth sliding part 108 may be provided by the plate. As another example, even a portion of the structure 106 of the combustion chamber 200 may be used to provide the fourth sliding part 108 , provided the structure 106 is specifically shaped to provide a recess below the inlet 104 against which the third sliding part 138 may slide.
As one possible implementation, the resonator cavity 110 may be a cylinder shape with a circular inlet 104 . In this case, the circular inlet 104 comprises a flange disposed therearound, by which the resonator cavity 110 is attached to a casing of the combustion chamber 200 . In this implementation, the bulb portion 126 may be formed around the second end 124 of the neck tube 120 with a pipe shape sized to adapt certain applications. The socket portion 132 and the first sliding part 134 of the compensation assembly 130 may be provided by a ring with certain width and thickness, where the socket portion 132 will be formed as a circular groove on the inner peripheral surface in the ring, and the first sliding part 134 will be the outer peripheral surface of the ring. In this case, FIG. 1 may represent a cross section view of the compensation assembly 130 . The second sliding part 136 of the compensation assembly 130 may be provided by a sleeve with an inner diameter to air tightly fitted with the outer diameter of the ring in order to provide the relative slide between the ring and the sleeve. Further, the third sliding part 138 may be provided by a circular plate with a protrusion at a peripheral thereof. The circular plate may be integrated with the sleeve. The protrusion of the circular plate may be allowed to air tightly slide against an end face of the flange as the fourth sliding part in order to provide relative slide between the circular plate and the resonator cavity. Those skilled in the art should appreciate that, the above implementation intends to be one example only, and should not be interpreted as any limitation to the scope and application of the present invention. In accordance with teaching in the present disclosure, those skilled in the art may adapt the present invention to different applications where the shapes, dimensions and structures of the resonator cavity, compensation assembly and neck tube may be different, all of which should be considered to fall into the protection scope of the present invention.
According to another example embodiment, as shown in FIG. 2 , a cut-away schematic cross section view of a damper 100 according to the present invention is provided. The damper 100 comprises a resonator cavity 110 with a box or cylinder shape as delimitated by a peripheral wall 102 and an inlet 104 . The resonator cavity 110 is air tightly attached to a structure 106 of a combustion chamber 200 by fasteners, not shown in FIG. 2 . In an example implementation of the present invention, the structure 106 of the combustion chamber 200 may be a casing of the combustion chamber 200 . Those skilled in the art should appreciate that the structure 106 provides carrier for the resonator cavity 110 , and should not be limited to the casing of the combustion chamber as described herein. In addition, the damper 100 comprises a neck tube 120 that is in flow communication with the resonator cavity 110 through a compensation assembly 130 according to the present invention in order to compensate relative movement between the resonator cavity 110 and the combustion chamber 200 . As an embodiment shown in FIG. 2 , the neck tube 120 is air tightly attached at a first end 122 to the inlet 104 of the resonator cavity 110 . For example, the first end 122 of the neck tube 120 is integrated with the inlet 104 of the resonator cavity 110 . As another example, the first end 122 of the neck tube 120 may be welded with the inlet 104 of the resonator cavity 110 . In this embodiment, the compensation assembly 130 is pivotably connected with a second end 124 of the neck tube 120 .
According to one example embodiment of the present invention, the compensation assembly 130 may comprises rotation compensation structures. In particular, the compensation assembly 130 may comprise a bulb portion 126 formed on a second end 124 opposite to the first end 122 of the neck tube 120 and a socket portion 132 air-tightly fitted with the bulb portion 126 to provide the relative rotation between the combustion chamber 200 and the resonator cavity 110 . During operation of the gas turbine, the relative rotation between the combustion chamber 200 and the resonator cavity 110 due to different thermal expansion may be compensated or absorbed by the compensation assembly 130 , so as to prevent potentially structural damage.
In addition, the compensation assembly 130 may comprise a first sliding part 134 formed on the socket portion 132 on a opposite side therefrom, and a second sliding part 136 air-tightly fitted with the first sliding part 134 to provide relative slide along a direction parallel to a longitudinal axis of the neck tube 120 between the first sliding part 134 and the second sliding part 136 . During operation of the gas turbine, the relative slide between the first sliding part and the second sliding part may compensate the relative movement along the longitudinal axis of the neck tube 120 between the combustion chamber 200 and the resonator cavity 110 due to different thermal expansion.
Furthermore, the compensation assembly 130 my comprise a third sliding part 138 formed on the second sliding part 136 opposite to the first sliding part 134 and a fourth sliding part 108 formed on the wall 210 of the combustion chamber 200 that is air-tightly fitted with the third sliding part 138 to provide relative slide in a direction traversing the longitudinal axis of the neck tube 122 between the third sliding part 138 and the fourth sliding part 108 . As shown in FIG. 2 , the fourth sliding part 108 is provided by a surface of the wall 210 of the combustion chamber 200 .
It should be noticed that, in particular application where relative rotation between the combustion chamber and the resonator cavity is significant and relative movement between them along the longitudinal axis of the neck tube and along a perpendicular direction traversing the longitudinal axis of the neck tube is negligible, the first and second sliding parts of the compensation assembly may be integrally formed, and the third and fourth sliding parts of the compensation assembly may be integrally formed or fixed by fasteners. In this case, the compensation assembly may only compensate relative rotation between the combustion chamber and the resonator cavity by means of the bulb portion of the neck tube and the socket portion of the compensation assembly.
It should also be noticed that, in another applications where relative rotation and relative movement need to be compensated simultaneously, the sliding part pairs, i.e. the first and second sliding part, the third and fourth sliding part may be utilized both or either pair of them, in combination with the bulb portion of the neck tube and the socket portion of the compensation assembly. Those skilled in the art will appreciate proper combinations of the compensation structures to achieve desired rotation and/or movement compensation.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | The invention relates to a damper for reducing the pulsations in a combustion chamber of a gas turbine. The damper includes a resonator cavity with an inlet and a neck tube in flow communication with the interior of the combustion chamber and resonator cavity, and a compensation assembly pivotably connected with the neck tube. The compensation assembly is inserted between the resonator cavity and the combustion chamber to permit relative rotation between the combustion chamber and the resonator cavity. With the damper according to the present invention, by way of providing the compensation assembly, it is assured the relative rotation between the combustion chamber and the resonator cavity is compensated, hence operation life is elongated. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in International Patent Application No. PCT/DK2005/000625 filed on Sep. 30, 2005 and Danish Patent Application No. PA 2004 01494 filed Sep. 30, 2004.
FIELD OF THE INVENTION
The invention relates to a refrigeration system e.g. of the kind installed in supermarkets and comprising a plurality of refrigerated display cases or storage rooms, in the following in general referred to as refrigerated spaces. The system comprises a closed-loop system for circulation of a refrigerant between a compressing unit, a condenser, and one or more refrigerated spaces with evaporators for evaporation of the refrigerant. In particular, the invention relates to a system wherein the compressing unit comprises a variable capacity element, e.g. a plurality of standard reciprocating compressors or scroll compressors to provide a variable volumetric compressing capacity for compressing the refrigerant. The system provides a cooling capacity to meet a cooling demand to refrigerate the atmosphere of the refrigerated spaces, in the following referred to as the secondary fluid. The vapour of evaporated refrigerant is communicated at a suction pressure to an inlet of the compressing unit. The invention further relates to a method of controlling a refrigeration system.
BACKGROUND OF THE INVENTION
Large refrigerating systems, e.g. for supermarkets, typically have one single compressing unit with a plurality of compressors working in parallel to provide compressed refrigerant via a condenser to a plurality of refrigerated spaces. In the refrigerated space, the refrigerant is evaporated in an evaporator whereby the temperature of the ambience, i.e. the temperature of the secondary fluid, is decreased. To adjust the temperature in separate refrigerated spaces individually, each of the spaces has separate evaporators with adjustable inlet valves. Usually, the inlet valve is temperature controlled, i.e. the valve of a refrigerated space opens and closes based on the temperature of the secondary fluid. If liquid refrigerant by accident leaves the evaporator, the compressors can be severely damaged. For that reason, the above-mentioned valve is usually inserted serially with a thermostatic valve which changes the flow rate based on the superheat of the refrigerant at the outlet of the evaporator. The thermostatic valve thus ensures that the refrigerant which is released into the evaporator is completely evaporated when it leaves the evaporator.
After the evaporation, vapour of refrigerant from each of the refrigerated spaces is led to an intake of the compressing unit. At the intake, suction pressure generated by the evaporated refrigerant is measured by a pressure gauge. If the suction pressure is high, the evaporation temperature is also high, and the required cooling may not be available. On the contrary, if the suction pressure is low, the efficiency of the compressors is reduced. In a traditional system, the compressing capacity of the compressing unit, i.e. the specific amount of refrigerant which is compressed, is controlled based on the suction pressure. When the pressure reaches an upper level, the compressing capacity is increased by switching on additional compressors, and when the pressure reaches a lower level, the compressing capacity is decreased by switching out additional compressors.
In one specific implementation, the compressor capacity is controlled by a PID based structure using the actual suction pressure as feedback. The compressor capacity can be controlled by use of the following mathematical expression
CC ( t ) = K p ( e ( t ) + 1 T i ∫ e ( t ) ⅆ t , ) Equation 1
with the control error
e ( t )=suction pressure setpoint( t )−actual suction pressure( t ) Equation 2
The compressor capacity control is divided into two terms, a proportional term and an integral term. The proportional part, shown as the first part of Equation 1, reacts directly on the actual control error. The integral term, shown as the last term of Equation 1, reacts on the integral of the control error. Hence, the integral term is responsible for eliminating steady state errors, and the proportional part reacts on set-point changes and control errors caused by changes in cooling demands. The tuning values Kp and Ti can be used to tune the controller to the system dynamics.
In a refrigeration system with more evaporators operating in hysteresis mode, the cooling demand varies much when the flow of refrigerant to the evaporators is switched in and out by an evaporator valve. This can have the undesirable effect on the compressor capacity control, that it will start or stop a compressor each time the evaporators switch in or out, which causes an increased wear on the compressors.
One problem is that the known PI or PID based compressor capacity control systems are only able to react in a causal way which in practice means that a short positive peak in the cooling demand can cause a start of a compressor, shortly after followed by a stop of the same or of another compressor of the system. In such a situation, a preferred operation would have been to continue without the starting and stopping of the compressor, i.e. to ignore the brief changes of the cooling demand.
In a system with discrete capacity values, one further problem related to a PID based controller is that the lower compressor capacity value will produce a small negative control error. The negative error causes the integral part to start a compressor whereby the control error becomes slightly positive with a compressor stop as a result. The effect can be seen as a limit-cycle on the compressor capacity, even with constant cooling demand. A remedy to avoid the limit-cycle can be to introduce a dead-band where the integral part is only updated when the numerical control error is larger than a given value. However, the general problem, i.e. that the PID based structure can only react in a causal way, remains.
In addition to the above mentioned problem of frequent compressor start/stop cycles, control of refrigeration systems is complicated by relatively long time constants. As an example, it takes long time from an evaporator valve is actuated until the temperature in a corresponding refrigerated space is changing, or it takes long time from a cover is removed from a refrigeration display case until the demand for additional cooling capacity is observed. On the other hand, the time it takes from the compressor capacity is changed to the change has an effect on the pressure on the suction side of the compressing unit, is relatively short.
In a refrigeration system of the kind mentioned in the introduction, fluctuations, e.g. due to switching of the evaporator valves are expected. An increased cooling demand could be caused by these fluctuations or it could be caused by a more permanent change of the cooling demand. If an increase is caused by fluctuation, it would not be suitable to change the compressor capacity, whereas if the change is of a more permanent nature, the compressor capacity should be changed. A traditional system, e.g. a PI(D) based system is not capable of determining if a cooling demand is caused by fluctuation, and in some cases, a traditional system would therefore react on fluctuation by regulating the compressor capacity by switching a compressor on or off unnecessarily, whereby compressor wear increases.
SUMMARY OF THE INVENTION
It is an object of the invention to enable better control of a refrigeration system. Accordingly, the invention provides a system of the kind mentioned in the introduction, characterised in that the system further comprises a control system adapted:
to establish an estimate of a future cooling demand, and
to control the cooling capacity to adapt to the estimate.
Since the cooling capacity is controlled to compensate for future changes in the cooling demand in contrast to the traditional systems wherein the compressing capacity is controlled based on an actually needed cooling capacity, a better control with less changes to the compressing capacity can be achieved. Since each change in the capacity implies wear on the compressing unit, the invention further facilitates a more economical operation of the system. Depending upon the implementation, one advantage of the invention could be that it facilitates a non-causal reaction to set-point changes and disturbances. Where a traditional, e.g. PID based, control approach in refrigeration systems reacts on disturbances when they occur, a system according to the present invention employ estimates of future disturbances to optimize the control action. Hence the controller can react to disturbances before they occur and thereby reduce the effects of the disturbances. Another advantage over PID based control could be the ability to compensate for saturations, such as a maximum compressor capacity. If future saturation is predicted, the controller can adjust the pre-saturated control action to compensate for the future saturation. This enables an optimal sequence of control actions, also referred to as a trajectory of actions, taking the saturations into account. In practice, the refrigerated space may be cooled to a temperature which is lower than an actually desired set-point temperature in order to compensate for a predicted future cooling demand which exceeds the available cooling capacity of the system.
The cooling capacity may be controlled by controlling at least one of the compressing capacity and the mass flow through the evaporators. The compressing capacity could be controlled e.g. in discrete steps by switching a compressor on or off, or the compressing capacity could be controlled by varying the displacement performed by the compressing unit(s), e.g. by varying the rotational speed of a piston or scroll compressor. The mass flow could be varied via an inlet valve controlling the flow through the evaporator.
During filling of the evaporator, the flow of the refrigerant is preferably controlled to achieve a minimum superheat region. For this purpose, a thermostatic expansion valve or an electronically controlled valve is inserted e.g. in an inlet of the evaporator. The evaporator will produce the maximum cooling capacity for the given operation condition. The temperature of the secondary fluid of the refrigerated space is controlled e.g. by a hysteresis control which switches said filling control on and off to keep the air temperature within the desired temperature band. For a fixed value of the compressing capacity and flow of refrigerant, the cooling capacity depends on the temperature difference between the evaporating temperature and the temperature of the secondary fluid. The compressor control affects the operation conditions by controlling the suction pressure to achieve a desired evaporation temperature. Hence, the objective of the compressor control is to achieve a suction pressure that produces an evaporating temperature that enables the system to meet the cooling demands. If the evaporating temperature is too close to the temperature of the secondary fluid, the system cannot meet the cooling demand. A too low evaporating temperature is undesirable because the compressor uses more energy than necessary because the pressure difference between the inlet and outlet is increased.
The estimated future cooling demand could be comprised in a mathematical model which gives the cooling estimate based on a time of the day, or the cooling estimate could be logged in a table, e.g. with corresponding values of time and estimated demand, e.g. for an hour, a day, or a year. A prediction of future cooling demands can be established in different ways. Examples are:
by observing past changes in cooling demands. This can be done by estimating the mass-flow of refrigerant through the compressor by using the suction pressure and compressor capacity as input to a model of the refrigeration system. Calculating the inlet and outlet specific enthalpy can be done by using temperature and pressure as input to a refrigerant specific enthalpy function. Future cooling demands can then be predicted based on the past values. This will enable capturing of demand variations during a 24 hour, a weekly, or a yearly cycle.
by logging past measurement of physical entities such as the temperature of the spaces in which the refrigeration system is installed, e.g. the temperature of a supermarket. From said logged values, a model of how the physical entities influence the cooling demands can be established. Using the model and predictions of the physical entities, the future cooling demands can be predicted.
by establishing a theoretical model of how said physical entities influence the cooling demands. Using the theoretical model and prediction of said physical entities such as a local weather forecast to predict future cooling demands.
It is preferred to achieve the predicted cooling effect while maintaining the suction pressure with a low variance. At the same time, it is preferred to keep the number of compressor start/stops at a minimum. The reason for keeping a steady suction pressure is that the evaporating temperature is directly functionally dependent on the suction pressure and that a steady evaporating temperature makes the refrigeration system operate more efficiently. The reason for minimizing the number of compressor start/stops is that compressor starts increase the wear on the compressors.
From the prediction of the cooling demand, it is possible to reduce the number of start/stops and at the same time it is possible to reduce the variance of the evaporating temperature compared to a conventional PID based controller.
In case of a short peak in the cooling demand, a conventional PID controller detects the rise of the cooling demand and will thus increase the cooling capacity. After the peak, the conventional PID detects the reduction of the cooling demand and therefore reduces the cooling capacity. In the system according to the present invention, the controller will take a future demand into account, and base the cooling capacity on an optimum for the predicted time horizon. Hence, a short peak will typically not cause a change of cooling capacity, but a more permanent change of cooling demand will cause a swift change of capacity to match the demand.
The control system may have a computer processing unit, CPU, and data storage means to establish a first data set comprising predicted future values of cooling demands and thus demands of compressing capacities, e.g. at different points in time. The control system may further contain other sets of data, e.g. in the form of mathematical models or tables from which a specific cooling demand can be derived e.g. based on external operating conditions. Such external conditions may embrace: an outside temperature, a general atmospheric humidity in the environment of the refrigeration system, a number of customers entering the space, e.g. a supermarket, to which the refrigeration system belongs, the arrival of new items to the refrigerated spaces of the supermarket or more simply, the time of the day.
The first and other data set(s) could be established based on data recorded during previous operation of the system, e.g. data which are logged at specific points in time of the day, e.g. in combination with knowledge about an opening hour of the supermarket, knowledge about a time of arrival of new products for the refrigerated spaces etc. All of these external operating conditions could be logged in a second data set.
The compressing unit could have any number of compressors of any kind, e.g. reciprocating compressors, rotary compressors, or scroll compressors. One or more of the compressors could have variable speed, and they could be individually turned on and off by the control system. The evaporators could be regular evaporators of the kind known from existing display cases in supermarkets. The evaporators have valves which are operated e.g. based on the temperature of the refrigerant when it leaves the evaporator, e.g. a thermostatic expansion valve. The evaporators may also have valves which are operated by a signal from the control system, typically a Pulse Width Modulated (PWM) solenoid valve. In the last-mentioned case, the control system may further be in communication with temperature sensing means for sensing the temperature of the secondary fluid in the refrigerated spaces, and with means for determining the superheat of the refrigerant leaving the evaporator.
The cooling capacity depends on the suction pressure, the mass flow of the refrigerant, the evaporation pressure and the condensation pressure. However, future values of the suction pressure in combination with a value of the mass flow can, in one embodiment, express the future values of the cooling demand or it may express required future compressor capacities. In this embodiment, the suction pressure and the mass flow are therefore the controlled variables. In practice, both of these variables may be varied to obtain a future cooling capacity, or one of the variables may be fixed to a specific value while the other variable is varied to obtain the desired cooling capacity. Throughout this document, the suction pressure is mentioned as a controlled variable. This is implicitly understood to be with a fixed mass flow, and in any of the examples, the suction pressure may be substituted with the mass flow as the controlled variable. In one example, a first data set of the controller comprises expected values of suction pressures for different points in time, and the values are determined e.g. based on the previously recorded suction pressures for corresponding external operating conditions. As an example, the controller may comprise a table with values of outside temperatures, expected arrival of articles for the refrigerated spaces, humidity etc, and corresponding values of suction pressures. From an actually measured external condition and the table, the controller could be capable of predicting a future suction pressure and to control the compressing capacity in accordance therewith.
In a simple implementation, the second data set comprises values of cooling capacities or values of suction pressures and mass flow which have previously been recorded at different points in time. By use of a clock and the previously recorded cooling capacities, the CPU can predict future values of cooling demands. As mentioned previously, the suction pressure and mass flow may influence the cooling capacity and may therefore in certain embodiments be used to express the cooling capacity. In a traditional system, the level of the suction pressure may have caused an increase or a decrease in the compressing capacity. In a system according to the invention, however, an approaching change in the suction pressure may be predicted, and in some cases this change renders the change in capacity unnecessary.
In a preferred embodiment, the controller comprises a cost function that assigns costs to deviation of the controlled variable (suction pressure and/or mass flow) from the set-point. It can also include other entities that need to be considered in an optimal control such as the number of compressor start/stops. A prediction horizon is considered, and the horizon is divided into a number of time steps. A control action is assigned to each time step and a cost value associated with operation of the system according to the control action and within the time step is determined. The costs for operating the system in all time steps according to the sequence of control actions are summed up. A similar calculation is made with respect to sequences of alternative control actions, and the sequence which gives the lowest costs is selected, and the system is controlled in accordance with the first control action of this sequence of actions. Subsequently, the calculation is repeated for a horizon which is shifted one time step forward.
By means of the costs, it is considered how close the cooling capacity is to the cooling demand, i.e. a difference between the demanded and the achieved cooling capacity is given a cost value, and this cost value is compared with a cost value associated with an attempt to reduce the difference. As an example, the cooling capacity may be insufficient, but it may be considered too expensive to reach a higher capacity taking a predicted future demand into consideration. This we will be explained in further details later.
In this embodiment, the controller works by identifying a set of compressor capacities that minimizes said cost function using a model of the system, said cooling demand predictions, and actual system measurements. The first compressor capacity of the set is used as the control action. At the next time instance the procedure is repeated using new system measurement and updated demand predictions.
Identifying the optimal set of compressor capacities can be achieved using different methods.
A basic method implements a least square method which solves the unconstraint optimizing problem. It is desirable to include compressor capacity constraints, whereby solutions containing capacities outside the obtainable region (0-100%) can be avoided. Details on the least square methods can be found in “Predictive Control with Constraints” by J. M. Maciejowski, Prentice Hall.
Defining the convex optimizing problem as quadratic programming problem, this can be described as a “going downhill” algorithm. The problem with the quadratic programming problem is that it assumes that the compressor capacity can be assigned continuous values. This is in contradiction to most compressor control systems, where the capacity only can take quantified values by stopping and starting compressors. The optimality guarantee is lost when quantifying the optimal capacities. Hence, a graph-search method can be utilized to explore the prediction trajectory. Due to the limited number of capacity values, the number of possible states grows with the number of possible new capacity values from a given state. This limits the number of prediction steps which must be investigated. One approach is to apply a grid with comparable states assigned to a cell in the grid. For each cell in the grid, the state with the lowest cost value can be selected, and the other states with higher costs can be disregarded for that grid. This limits the number of states to a maximum of the number of the cells multiplied with the number of new capacity values and therefore facilitates faster data processing in the controller. Accordingly, one embodiment of the invention relates to a system which is adapted to determine:
a first switching sequence compressing a first element of a first time step, the element being indicative of an increased compressing capacity compared with a compressing capacity of a previous time step,
a second switching sequence compressing a first element of the first time step, the element being indicative of an unchanged compressing capacity compared with a compressing capacity of a previous time step, and
a third switching sequence compressing a first element of the first time step, the element being indicative of an decreased compressing capacity compared with a compressing capacity of a previous time step
and for each of the first, second and third switching sequences, the system is adapted to add elements being indicative of an increased, an unchanged, and a decreased compressing capacity, respectively. The system thereby determines 3M (3 raised to the power of M) switching sequences each comprising M elements each being indicative of an increased, an unchanged, and a decreased compressing capacity in an Mth time step compared with a compressing capacity of a previous, (M−1)th, time step.
The system being further adapted to determine for each of the switching sequences a cooling capacity which is derivable by the switching sequence and a cost value representing the cost of operating the system in accordance with the switching sequence. The system may further be adapted to select a cheapest mode of operating the system being the one out of the switching sequences with the lowest cost value.
The system being further adapted to control the compressing unit in accordance with the cheapest mode of operation, at least for a period of time corresponding to the first time step by controlling the compressing unit to provide the compressing capacity of the first element in the switching with the lowest cost value.
The procedure can be continued for any number of subsequent time steps, and preferably, the procedure is repeated each time the system has been controlled at least for a period of time corresponding to the first time step.
With respect to the computing capacity of the CPU, the reduction in the amount of data is an advantage. To further facilitate computation, the number of M cooling capacities could be grouped into groups of specific ranges of cooling capacities, and for each group, one cheapest mode of operation could be selected e.g. for each time step or for each specific number of time steps. After a number of time steps, the outcome of the described process could be a large number of switching sequences and corresponding cooling capacities. By grouping this number into a relatively low number of groups, e.g. into 2, 3, 4 or more groups wherein each group comprises cooling capacities within a specific range, and by selecting one single, cheapest, mode of operation for each group, the amount of data for calculating the next time step is reduced to that selected number of groups, and the calculation can thereby be simplified.
As mentioned previously, an increased wear occurs each time a compressor is turned on. The cost involved with operation of a compressing unit therefore not only depends on the energy which is consumed by the compressor(s) during operation, but it also depends on the number of changes to the compressing capacity. Accordingly, the cost value could comprise not only the costs of operating the compressing unit in accordance with the switching sequences, but also the costs of the switching between the compressing capacities included in the switching sequences.
In one embodiment, the controller calculates a difference between the cooling capacities derived by each of the switching sequences and a predicted cooling demand i.e. what is predicted to be a required cooling capacity at the specific point in time—i.e. after the M time steps. Based on the difference, the controller calculates cost values representing the costs of operating the system with these differences between the required cooling capacity and the capacities derived by the switching sequences. The system includes in theses cost values, values representing the costs of the required switching compressors on or off according to the switching sequences. At the end, the controller controls, at least in the first time step, the compressors in accordance with the sequence giving the lowest costs, i.e. taken the difference and the switching into account.
The length of the time-steps may be of equal size, e.g. equal to five times a dynamic time constant of a response to the control of the compressing capacity. A shorter sampling-step requires more prediction steps to reach the same prediction horizon, and if the sampling-step is selected much longer, the controller will not be able to react to changes as fast.
In a second aspect, the invention provides a method of operating a refrigeration system of the kind mentioned in the introduction, the method comprising the steps of:
estimating of a future cooling demand, and
controlling the cooling capacity to adapt to the estimate.
The method could further comprise any step corresponding to the features mentioned in connection with the first aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention will be described in further details with reference to the drawing in which:
FIG. 1 illustrates the effect on the evaporator enthalpy difference when the condenser pressure is increased, and
FIG. 2 shows a diagrammatic view of a system according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In a typical refrigeration system, the cooling demand varies significantly during operation. In a supermarket system, night covers may shield the refrigerated spaces during closing hours. In this event, the cooling demand is typically reduced. On the contrary, the cooling demand is increased when the supermarket opens, and the staff and customers start to move goods into, or out of the refrigerated spaces.
If the refrigerated spaces have been loaded with warm goods or when over stacking the goods, the cooling demand is significantly increased. Also, since the sensible load is increased by high surrounding temperatures, such high temperatures cause a higher cooling demand. Similarly, a high absolute humidity gives a higher cooling demand because of the increased latent load when some of the cooling is used to condensate the humidity or to build up ice in the evaporator.
A higher outdoor temperature does not change the cooling demand, but it may increase the condensing temperature. Such an increase may reduce the enthalpy difference in the evaporator, and may reduce the efficiency of the refrigeration system. The cooling capacity can be expressed as the product of the enthalpy difference of the refrigerant while passing the evaporator and the mass-flow of the refrigerant through the evaporator. Hence, to maintain a constant cooling capacity, the refrigerant mass flow must be increased to compensate for the decrease of said enthalpy difference. FIG. 1 illustrates the effect on the evaporator enthalpy difference when increasing the condenser pressure. It shows that the inlet enthalpy is increased, but the outlet enthalpy is not affected.
FIG. 2 shows a refrigeration system, e.g. for a supermarket. The system comprises a compressing unit A with a plurality of compressors 1 coupled in parallel between an intake 2 and an outlet 3 . The compressing capacity of the compressing unit is adjustable. The capacity is adjusted discretely by switching single compressors on or off. In more advanced systems, however, the capacity of single compressors can be adjusted by regulating the compressors speed, e.g. via a frequency converter. The outlet manifold is connected to an inlet of a condenser 4 in which the compressed refrigerant is condensed. The condenser comprises a condenser control, D, which controls a fan 5 to adjust the heat exchange between the condenser and the surrounding atmosphere. The evaporators 6 of a plurality of refrigeration display cases 7 (of which only one is shown) are coupled in parallel to an outlet 8 of the condenser to receive the condensed refrigerant. Each refrigeration display case comprises an evaporator and an inlet valve 9 capable of adjusting a flow rate of the condensed refrigerant entering the evaporator. The energy which is necessary to evaporate the refrigerant is drawn from the interior, E, of the refrigeration display cases in which the temperatures thereby are reduced. Vapour of refrigerant from each of the refrigeration display cases are collected at the intake 3 of the compressing unit A. The control unit F on/off controls the valve to either open or close passage of refrigerant to the evaporator based on the temperature in the display case. The control unit G controls the valve based on the superheat of the refrigerant. As an input, the control unit G receives a temperature difference TSH between the evaporation temperature of the refrigerant when it enters the evaporator and the temperature of the refrigerant when it leaves the evaporator.
At the intake 3 , suction pressure of the evaporated refrigerant is measured by the pressure gauge, and a pressure signal is communicated to the control unit, C.
In a regular control system, the compressing capacity is controlled to maintain a suction pressure within a certain range, c.f. the previous description of the background of the invention. When the pressure reaches an upper level, the compressing capacity is increased by switching on additional compressors, and when the pressure reaches a lower level, the compressing capacity is decreased by switching off additional compressors. Correspondingly, the inlet valves 9 of each of the refrigeration display cases 7 are controlled based on the temperature of the associated refrigeration display cases.
In accordance with the invention, the control unit C is also connected to the inlet valves 9 of the refrigeration display cases 7 . The control unit comprises a calculating unit and data storage means, and during operation, it is adapted to establish a first data set comprising predicted future values of suction pressures at different points in time. The prediction is calculated based on a second data set representing predicted future operating conditions for the refrigeration system. As an example, the second data set comprises meteorological data, e.g. various temperatures at specific points in time, or the second data set comprises information about an amount of items which in the future will be received in the refrigeration display cases at specific points in time or information about opening hours of the supermarket, at which time isolating hatches of the refrigeration display cases are removed.
Example 1
In the following, an example of a set of control algorithms for a refrigeration system according to the invention is presented for a system wherein the controller is adapted to optimize a cost function representing the costs of operating the system. In the cost function, the energy which is consumed by the compressors during operation and the wear on a compressor caused by a startup of the compressor is taken into consideration.
By formulating an objective function (=cost function), an optimal control sequence can be computed for a specified prediction horizon (N). This is done by finding a future control sequence that minimizes the objective function. In the objective function, the different objectives for the control can be weighted and thereby taken into account in controlling of the system.
In a supermarket refrigeration system an objective function may take the compressor capacity as an input and may read as follows:
J ( k ) = W · ∑ i = 1 N P suc ( T ( k + i ) | Tk ) - P suc , ref ( T ( k + i ) | Tk 2 ︸ Weighed deviation from the wanted suction pressure ( P suc , ref ) … + R · ∑ i = 1 N Cc ( T ( k + i ) | Tk ) - Cc ( T ( k + i - 1 ) | Tk 2 ︸ Weighed shift in the compressor capacity ( Comp . cap ) … + P · ∑ i = 1 N Cc ( T ( k + i ) | Tk ) 2 ︸ Weghting large compressor capacities Equation I
Where
P suc Suction pressure P suc, ref Suction pressure reference W Weight for punishing deviation s from the suction pressure reference Cc Compressor capacity (defined as the actual percentage of the max. capacity R Weight for punishing large variation s on the compressor capacity P Weight for punishing large compressor capacities N Prediction horizon k Sample number i Counting variable T Sample time
Notations:
∥ν∥ 2 specifies the 2-norm which is the squared absolute length of the vector ν. P suc (T(k+1)/Tk) specifies the predicted value of P suc (T(k+1)) where the prediction is done at time Tk.
In equation 1, the objective is to keep the suction pressure (P suc ) close to the reference (P suc, ref ) without any large variation in the compressor capacity (Cc) and using only small compressor capacities. Other objectives could, however, be taken into account, e.g. by adding more terms in the objective function.
If estimates of the future required cooling demand ({dot over (Q)} req ) is available, these can be taken into account while computing the future compressor capacities (Cc).
The mass flow in the refrigeration system can be computed as
{dot over (m)}=Cc max ·( Cc/ 100)·η vol ·V sl ·ρ suc ( P suc ,SH ) Equation 2
However, the mass flow may as previously mentioned be controlled by a valve, and the control of this valve may thus also determine the mass flow when the pressure drop over the valve and the valve characteristics are known. If the system comprises a plurality of refrigerated spaces which are individually fitted with a valve, the mass flows through the valves has to be summed up to achieve the total mass flow in the system.
In this function, Cc is defined in percentage of maximum capacity Ccmax of the compressor(s).
where
Cc max
Maximum capacity of the compressor(s)
η vol
Volumetric efficiency
P sl
Stroke volume of the compressor
SH
The superheat at the inlet of the compressor
ρ suc
Density of the refrigerant at the inlet of the compressor
(typically as a function of the suction pressure and the
superheat (SH)
The actual cooling capacity is given by:
{dot over (Q)} act ={dot over (m)}·Δh ( P c ,P suc ,SH,SC ) Equation 3
Where
Δh
Increase of enthalpy in the refrigerant across the evaporator
(typically as a function of the condensing pressure, the suction
pressure, the superheat, and the sub-cooling)
P c
Condensing pressure
SC
The sub-cooling at the outlet of the condenser
If it is assumed that the superheat (SH) and the condensing pressure (P c ) is controlled to specific values by other controllers, they can be assumed constant. The sub-cooling (SC) is typically defined at least substantially by the mechanical construction of the refrigeration system and SC is therefore assumed to be constant. In a more advanced implementation, SH, P c and SC are measured at each time step.
Combining Equation 2 and Equation 3 and assuming SH, P c , and SC are constant, the following can be obtained:
Q . act = Cc max · Cc 100 · η vol · V sl · ρ suc ( P suc ) · Δ h ( P suc ) Equation 4
Wherein Cc is defined in percentage of maximum capacity for the system.
Assuming that the required cooling demand ({dot over (Q)} req ) is known for a number of N steps into the future that is:
Q
.
req
(
T
(
k
+
1
)
)
Q
.
req
(
T
(
k
+
2
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⋮
Q
.
req
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T
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k
+
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}
known
!
Then in order to meet the request for the required cooling demand the actual cooling capacity should be the same for each time step (1 to N) that is:
Q
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req
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k
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)
=
Q
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act
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Inserting Equation 4 gives:
Q
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req
(
T
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k
+
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=
Cc
max
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Cc
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T
(
k
+
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/
100
·
η
vol
·
V
sl
·
ρ
suc
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T
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k
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Δ
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100
·
η
vol
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sl
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100
·
η
vol
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sl
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suc
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Δ
h
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P
suc
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T
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k
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Equation
5
That is: the objective function (Equation 1) should be minimized under the constraint that Equation 5 is fulfilled:
Minimize
:
J
(
k
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=
W
·
∑
i
=
1
N
P
suc
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T
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k
+
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|
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-
P
suc
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ref
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k
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2
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+
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∑
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k
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s
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t
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100
·
η
vol
·
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sl
·
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suc
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T
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Δ
h
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req
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T
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k
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T
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/
100
·
η
vol
·
V
sl
·
ρ
suc
(
P
suc
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T
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k
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h
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suc
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⋮
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.
req
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T
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=
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100
·
η
vol
·
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sl
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suc
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T
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k
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1
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·
Δ
h
(
P
suc
(
T
(
k
+
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Equation
6
Solving this optimization problem gives a vector containing the sequence of future control actions (Cc) for the N-step prediction horizon:
Cc
(
T
(
k
+
1
)
)
Cc
(
T
(
k
+
2
)
)
⋮
Cc
(
T
(
k
+
N
)
)
In a typical implementation only the first control signal in this sequence (Cc(T(k+1)) ) is applied, at the next time step new measurements are taken and the optimization program is solved once again based on the updated measurements. In some applications more than only the first control signal could be applied to save computation time.
A more detailed theoretical description is presented in a technical paper with the title “Hybrid MPC In Supermarket Refrigeration Systems” by Lars F. S. Larsen, Tobias Geyer and Manfred Morari. The article was published at the 16 th IFAC World Congress cf. www.ifac-control.org. The article can be downloaded from http://control.ee.ethz.ch/index.cgi?page=publications&action=list&publty=all&ifagroup=7
The article is hereby incorporated by reference.
While the present invention has been illustrated and described with respect to a particular embodiment thereof, it should be appreciated by those of ordinary skill in the art that various modifications to this invention may be made without departing from the spirit and scope of the present invention. | The invention provides a refrigeration system with a compressing unit, and a method of controlling a refrigeration system. To facilitate a better control, the capacity of the compressing unit is controlled based on a predicted future cooling demand rather than an actually determined cooling demand. The invention further provides a system wherein a cost value for changing the cooling capacity of the system is taken into consideration. | 5 |
TECHNICAL FIELD
[0001] This invention relates generally to interconnected lock assemblies used to secure doors. More particularly, the present invention relates to an interconnected lock assembly which provides a feature to remotely lock the interconnected lock assembly. This application claims the benefit of U.S. Provisional Application No. 60 / 176 , 996 filed January 19 , 2000 , herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] An interconnected lock assembly is characterized by an inside handle, either knob or lever, which simultaneously retracts both a deadlatch and a deadbolt. Such a lock assembly is commonly found in public accommodations such as hotels and motels in which, for security purposes, the occupant wishes to set both a deadlatch and a deadbolt. The same type of lock assembly may also be found in a residential or other environments. It is particularly important that both locks be retracted by the turning of a single inside operating member as it has been found that in the event of a fire or other panic situation it is desirable that the occupant only need turn a single knob or lever to operate all of the lock mechanisms in a particular door.
[0003] Such interconnected lock assemblies have been on the market for a number of years. Some interconnected lock assemblies are adjustable to compensate for varying distances between the latch assemblies. The adjustable feature is particularly helpful if there is a slight misalignment of the latch assembly bores, or when retrofitting an existing door if the distance between bore centerlines is not the same as the distance between the latch assemblies of the interconnected lock. U.S. Pat. No. 6,128,933 discloses an adjustable interconnected lock which enables interconnection of an exterior assembly that has an adjustable spacing between the exterior dead bolt assembly and a lower lock assembly.
[0004] One problem with interconnected lock assemblies is that when leaving, the user can open the door by using just the interior handle, even if the door is locked, but must use a key to lock the door behind them. This can provide an inconvenience especially when the keys are not readily available, the user is carrying objects, the user does not have a key, or the user is in a hurry. Thus the convenience and ease of operation provided by the interconnect lock is lost.
[0005] The foregoing illustrates limitations known to exist in present interconnected lock assembly designs. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to provide an interconnected lock assembly with a locking mechanism which can throw the deadbolt and lock the door in response to a remote control signal. This and other objects of the present invention are provided by an interconnected lock assembly for mounting in a door. The interconnected lock comprising a first lock assembly including an inside handle and an outside handle, and a second lock assembly interconnected to said first lock assembly. The second lock assembly comprises a deadbolt assembly operably connected to a deadbolt latch. The deadbolt latch comprises a deadbolt movable between an extended position and a retracted position. The interconnected lock further comprises a locking mechanism selectively engageable by a remote control signal to move the deadbolt to an extended position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is an exploded perspective view of the interconnected lock assembly with remote locking of the present invention;
[0008] [0008]FIG. 2 is a perspective view of the assembled interconnected lock assembly with remote locking in accordance with the present invention of FIG. 1;
[0009] [0009]FIG. 3 is a side elevational view of the assembled interconnected lock assembly with remote locking, shown without the escutcheon assembly, in accordance with the present invention of FIG. 1;
[0010] [0010]FIG. 4A is an rearward perspective view of the escutcheon assembly, in accordance with the present invention of FIG. 1;
[0011] [0011]FIG. 4B is an frontal perspective view of the escutcheon assembly, in accordance with the present invention of FIG. 1;
[0012] [0012]FIG. 5 is an exploded perspective view of the backplate assembly in accordance with the present invention of FIG. 1;
[0013] [0013]FIG. 6A is a partial side elevational view of the backplate assembly with the carrier component removed and the remote locking solenoid removed, showing the catch mechanism components;
[0014] [0014]FIG. 6B is a partial side elevational view of the backplate assembly with the carrier component removed and the remote locking solenoid removed, revealing the catch mechanism in a disengaged catch position;
[0015] [0015]FIG. 7A is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in an extended position;
[0016] [0016]FIG. 7B is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in a partially extended position;
[0017] [0017]FIG. 7C is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in a retracted position;
[0018] [0018]FIG. 8A is a partial side elevational view of the backplate assembly with the carrier component removed, revealing the remote locking mechanism components;
[0019] [0019]FIG. 8B is a partial side elevational view of the backplate assembly with the carrier component removed, revealing the remote locking mechanism in a disengaged catch position; and
[0020] [0020]FIG. 9 is a top plan view of the remote locking transmitter used with the remote locking feature of the present invention.
DETAILED DESCRIPTION
[0021] Referring now to the drawings, wherein similar reference characters designate corresponding parts throughout the several views, there is generally indicated at 10 an adjustable interconnected lock assembly with a remote locking feature of the present invention. Referring specifically to FIGS. 1 and 2, lock assembly 10 comprises a first or lower interconnected lock assembly 18 comprising outside housing assembly 12 , rose 14 , and outside knob/lever 16 , attached from the outside of a door (not shown) through a first or lower bore in the door, and through a back plate assembly 20 positioned on the inside of the door, to inside housing assembly 22 . Interconnect cam 24 , escutcheon assembly 28 , and inside knob/lever 26 are attached to inside housing assembly 22 on the inside of the door. Although not shown, a latch assembly could be operably connected between outside housing assembly 12 and inside housing assembly 22 . Interconnected lock assembly 10 also comprises a second or upper interconnected lock assembly 40 comprising a deadbolt housing assembly 42 and a deadbolt latch assembly 44 . Deadbolt housing assembly 42 is attached from the outside of the door through a second or upper bore and operably connected to deadbolt latch assembly 44 , and through back plate assembly 20 and secured thereto by deadbolt plate 46 and mounting screws 48 . Deadbolt housing assembly 42 is operably connected to a deadbolt pinion 50 which engages a deadbolt rack 52 connected to back plate assembly 20 as discussed in detail below. The lower interconnected lock 18 and upper interconnected lock 40 are standard configurations that are well-known in the art, and as such, the workings of these locks will not be described in detail, except as they relate to the present invention.
[0022] Referring now to FIG. 3, interconnected lock 10 shown with escutcheon assembly 28 removed. Back plate assembly 20 comprises a carrier component 54 vertically movable on, and slidably attached to a back plate 56 by a plurality of tangs 58 . Deadbolt rack 52 is oriented vertically and fixedly attached to carrier component 54 such that it engages pinion 50 . Interconnected lock 10 is adjustable in that upper lock assembly 40 can move up or down to properly fit the upper bore of the door. Deadbolt plate 46 is movable within a slot 62 in back plate 56 to allow the proper positioning of upper lock assembly 40 . Upper lock assembly 40 is then secured to deadbolt plate 46 by mounting screws 48 which secure upper lock assembly 40 in a fixed position. Deadbolt assembly 42 is operably connected to deadbolt pinion 50 by a driver bar 60 which is co-rotatingly attached to deadbolt pinion 50 . Carrier component 54 is shown in a 15 raised, or unlock position. When carrier component 54 is in a lowered, or locked position, a mating cam surface 64 of carrier component 54 engages cam 24 . Cam 24 is attached to knob/lever 26 in a co-rotating manner such that rotation of knob/lever 26 rotates cam 24 which engages mating cam surface 64 , causing carrier component 54 to move vertically, upwardly to a raised, or unlock position. 20 The rack 52 attached to carrier component 54 causes deadbolt pinion 50 to rotate as carrier component 54 moves either upward or downward. Driver bar 60 co-rotates with deadbolt pinion 50 . Rotation of driver bar 60 causes retraction and extension of deadbolt 90 of deadbolt latch assembly 44 in a standard fashion. Accordingly, as carrier component 54 moves upward, deadbolt 90 of deadbolt latch assembly 44 is retracted, allowing the door to be opened. Deadbolt 90 is shown in an extended position and a retracted position in FIGS. 7A and 7C, respectively. Deadbolt 90 is distinguished from standard deadbolts in that deadbolt 90 includes a cam surface 96 at a distal end. While cam surface 96 is similar to cam surfaces used in standard spring latch assemblies, cam surface 96 only partially extends along the extended deadbolt 90 as best shown in FIG. 7C. Accordingly, the door cannot be closed when the deadbolt 90 is in an extended position. However, when the deadbolt 90 is partially extended in a manner that cam surface 96 is configured as shown in FIG. 7B, the door can be closed as cam surface 96 will engage strike plate 94 , forcing deadbolt 90 to retract. It should be noted that depression of deadbolt 90 results in deadbolt latch assembly 44 rotating deadbolt pinion 50 in a standard manner, moving carrier component 54 to a raised position.
[0023] Referring now to FIGS. 4A and 4B, escutcheon assembly 28 comprises escutcheon 30 , thumbturn 32 , and thumbturn link component 34 . Thumbturn 32 is coupled to thumbturn link component 34 in a co-rotating manner through an aperture in escutcheon 30 . Thumbturn link component 34 comprises at least one pin 36 which engages an aperture 38 in rack 52 , linking thumbturn 32 to carrier component 54 . It is noted that rack 52 can be positioned on either side of carrier component 54 such that a pin 36 will engage an aperture 38 in rack 52 , allowing thumbturn 32 to be appropriately attached for right and left-hand opening doors. Movement of the carrier component 54 results in rotation of thumbturn 32 , and conversely, rotation of thumbturn 32 causes movement of carrier component 54 and extension and retraction of said deadbolt 90 .
[0024] Referring now to FIG. 5, the back plate assembly 20 is shown in greater detail. To enable the remote locking function of the present invention, interconnected lock 10 utilizes carrier component 54 which is biased in a downward, or locked position. Accordingly, a spring carriage 72 is attached to carrier component 54 . Spring carriage 72 houses a spring 74 such that one end of spring 74 is attached to the assembled spring carriage 72 /carrier component 54 and the other end of spring 74 is fixedly attached to back plate 56 . Spring 74 is of sufficient strength to cause carrier component 54 to move downward to locked position and cause extension of deadbolt 90 of deadbolt latch assembly 44 . Backplate assembly 20 further comprises an electronic module 66 housing a power component 68 shown as a plurality of batteries to operate an automatic locking solenoid 70 and a signal receiver 75 . Electronic module 66 may also be used to power a speaker 78 or status lights 91 .
[0025] In order to prevent spring 74 from returning carrier component 54 to a locked position, back plate assembly includes a catch mechanism 80 comprising a catch component 82 , a catch release 84 , and a spring trigger rod 86 as shown in FIGS. 6A and 6B. Catch component 82 and catch release 84 are each pivotally attached to back plate 56 by a pin 88 . Catch release 84 is biased toward catch component 82 by catch release spring 83 . Spring trigger rod 86 is affixed to carrier component 54 and moves along a guide portion 92 in catch component 82 . Spring trigger rod 86 is also biased toward spring 74 .
[0026] The operation of interconnected lock 10 is best described in a dynamic manner starting with carrier component 54 position in a lowered, or locked position. Interconnected lock 10 includes a keyless exit feature in which enables automatic locking actuation. Movement of carrier component 54 from a locked position to an unlocked position can be accomplished by either rotating inside knob/lever 26 , rotating thumbturn 32 , or by turning a key to rotate the rotating driver bar 60 of deadbolt assembly 42 , typically with a key. As carrier component 54 moves upward, spring trigger rod 86 moves upward along guide portion 92 of catch component 82 from its initial position A, shown in FIG. 6A. Movement of carrier component 54 and attached rack 52 causes rotation of pinion 50 and driver bar 60 , retracting deadbolt 90 of deadbolt latch assembly 44 . At the end of the carrier component 54 travel, the deadbolt 90 of deadbolt latch assembly 44 is fully retracted. Spring trigger rod 86 , now at position C, and catch release 84 , biased by catch release spring 83 , force a tab feature 93 of catch 82 to move underneath spring carriage 72 in a manner locking carrier component 54 in an unlocked position. Spring 74 is now in an extended position, storing energy needed to extend the deadbolt 90 . At this point, further opening enclosing of the door will not affect catch mechanism 80 as the guide path of the spring trigger rod 86 does not release the spring carriage 72 . Spring trigger rod 86 will move upward from position A to position C along guide path 92 of catch component 82 . When carrier component 54 moves downward, trigger spring rod 86 will move downward from position C, through position B, back to position A. Spring trigger rod 86 deviates from guide path 92 in the downward direction. Guide path 92 of catch component 82 is configured with a ramp portion between lowered portions generally corresponding to positions A and C. Between positions A and C, trigger spring rod 86 moves up a ramp portion to a drop-off 76 shown generally adjacent to position B. In the downward direction, spring trigger rod 86 is forced by the wall of drop-off 76 to move off of catch component 82 to a position below a portion of catch release 84 . In normal operation of the lock 10 , spring trigger rod 86 will continue downward from position B and return to position A. Accordingly, standard operation of the lock does not affect the catch mechanism.
[0027] In order to actuate the keyless exit feature, when deadbolt 90 of deadbolt latch assembly 44 is retracted, to him thumbturn 32 is rotated to an intermediate position. Rotation of thumbturn 32 causes thumbturn link component 34 to rotate. At least one pin 36 of thumbturn link component 34 engages rack 52 , such that rotation of thumbturn 32 causes carrier component 54 to move partially downward, partially extending deadbolt 90 of deadbolt latch assembly 44 . In addition, spring trigger rod 86 moves from position C to a position adjacent catch release 84 , shown as position B.
[0028] Referring now to FIG. 6B, operation of the keyless exit feature is shown. The deadbolt 90 is in a partially extended position such as that shown in FIG. 7B. When cam surface 96 of deadbolt 90 is driven back by a strike plate 94 of the door jamb (not shown) such as when the door is closed, linear movement of deadbolt 90 within deadbolt latch assembly 44 is converted to rotation of deadbolt pinion 50 in a standard manner. Rotation of deadbolt pinion 50 causes carrier component 54 to move upward, moving spring trigger rod 86 to position D, forcing catch release 84 to rotate and free catch 82 . This action allows spring carriage 74 /carrier component 54 to move downward under the force of spring 72 . As carrier component 54 moves downward, the deadbolt 90 of deadbolt latch assembly 44 is fully extended via the interaction of the deadbolt pinion 50 and rack 52 .
[0029] When the keyless exit function is not in use, interconnected lock 10 will operate as a normal, or standard, interconnected lock.
[0030] The remote locking feature of the present invention utilizes solenoid 70 operably connected to catch release 84 as shown in FIG. 8A. A remote signal device 98 is utilized with the remote locking mechanism, shown in FIG. 9 as a standard keychain transmitter of the type used to unlock cars, garages, etc., When the remote locking signal is received by signal receiver 75 , solenoid 70 retracts catch release 84 , allowing catch component 82 to rotate away from spring carriage component 72 , as shown in FIG. 8B. Carrier component 54 is then permitted to move downward under the biasing force of spring 74 . As previously described, downward movement of carrier component 54 causes extension of deadbolt 90 of deadbolt latch assembly 44 , thus locking the door.
[0031] Although the present invention has been described above in detail, the same is by way of illustration and example only and is not to be taken as a limitation on the present invention. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims. | An interconnected lock assembly with a locking mechanism which can throw the deadbolt and lock the door in response to a remote control signal. The interconnected lock comprising a first lock assembly including an inside handle and an outside handle, and a second lock assembly interconnected to said first lock assembly. The second lock assembly comprises a deadbolt assembly operably connected to a deadbolt latch. The deadbolt latch comprises a deadbolt movable between an extended position and a retracted position. The interconnected lock further comprises a locking mechanism selectively engageable by a remote control signal to move the deadbolt to an extended position. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a process, and an apparatus, for the indexing and retrieval of data.
There are many known systems for indexing and retrieving information. At one extreme, there are simple sets of sequentially arranged record cards, which are up-dated and searched directly by a user. At the opposite extreme, there are the highly sophisticated systems in which the data is stored in computerised form on, for example, magnetic disc files. The up-dating and searching of data with such a system will probably be carried out by means of a large computer system. The user will communicate with the system by means of a visual display unit, or other form of data terminal.
There have also been proposals for systems in which data is recorded in microfilm, or microfiche, form and each unit of data on the film is accompanied by an encoded recording. This recording would be a bar code representative of a unit serial number, in a typical case. The code representation can be sensed optically to allow automatic selection of a desired unit of data. A system of this last-mentioned kind in which an encoded recording accompanies the film is less expensive than a large computerised system. However, it does require a substantial investment in equipment and also requires skilled staff to operate the system.
SUMMARY OF THE INVENTION
The invention provides a process for retrieving, from a file of information items, each item which matches the desired values of retrieval criteria. A magnetically recorded index tape is formed which is separate from the file of information items and carries details of the values of the retrieval criteria which obtain for each item. In preparing the tape a criteria recorder is used which has a number of recording positions each of which can be either set or unset. Each recording position corresponds to a value of a retrieval citerion, and there is more than one recording position for each criterion, the different positions corresponding to different alternative values of that criterion. For each item, the positions which correspond to the particular values which obtain for that item are set, the remainder being unset. The criteria recorder is read and a string of binary electrical signals generated, each of which represents the setting of one of the recording positions. This string is recorded serially on the magnetic index tape, together with the index number of the item. When it is desired to retrieve those items which have particular desired values of the retrieval criteria, these desired values are entered in an electronic register the binary stages of which correspond to the different retrieval-criterion values, the stages which correspond to the desired values being set and the remainder unset. The index tape is then read and the string of signals representing the retrieval-criterion values of each item compared one by one with the signals representing the stages of the electronic register. Each item for which a predetermined number of set stages of the register match the corresponding signals in the string -- and for which, therefore, a desired value obtains for each of a predetermined number of retrieval criteria -- has its index number displayed as a guide to retrieving the information item itself from the file of information items.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows part of a form which is used as a criteria recorder;
FIG. 2 is a schematic illustration of a recording on part of a magnetic tape;
FIG. 3 is a schematic drawing of a search system which uses the tape of FIG. 2;
FIG. 4 is a schematic diagram of a second embodiment;
FIG. 5 is a partial illustration of an overlay for use with the embodiment of FIG. 4;
FIG. 6 is a schematic diagram of an arrangement for data input and output; and
FIGS. 7 & 8 are more detailed schematic diagrams of parts of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As a first example, a form which is manually marked and is then read automatically by an optical mark reading equipment is utilised as a criteria recorder. The function of the criteria recorder is to provide a simple means for containing binary signals which represent the retrieval criteria of the information items.
It will be assumed for the sake of illustration that the employee records of a company are to be made available for information retrieval. The file containing the full details of each employee is recorded on microfilm, for example, and may thereafter be referred to by index number which consists of the reel and frame references.
It may be necessary to search the records on the basis of one or more of a large number of criteria such as age, duration of employment, qualifications, salary, etc. These criteria are sub-divided into ranges, or other alternatives, which will be called the values of the criteria.
All the values of the retrieval criteria which obtain for one employee are recorded on a pre-printed form, which is preferably designed for mark sensing, and which, as has been mentioned, is used as a criteria recorder. Part of such a form 1 is shown in FIG. 1. The form is divided by printed lines to provide groups of boxes 2 and 3. The boxes 2 are numbered serially, numbers 21 to 40 being shown in the drawing, specifying one of the possible values of the criterion to which it relates. Each box also contains criterion information. For example, box serial number 27 relates to employment for a period of 1 to 5 years; box serial number 37 relates to employment in grade SS4 of a salary scale. The criterion headings are printed on the left-hand side of the form against the appropriate line. The user of the form indicates that a particular value of a criterion obtains for the employee by making marks 4, in box 3 which is below the relevant box 2 the recording position formed by the box being thereby set. Preferably, the form is arranged so that it can be read by a conventional optical mark reading equipment 5 (FIG. 3), or alternatively by conventional equipment for conductive mark sensing of record cards. Suitable optical mark readers are available commercially, such as, for example, the Bell and Howell 9000.
The mark reader scans the recording positions of the form 1 and loads the result into a buffer 6, a binary 0 and a binary 1 indicating that a position is unmarked and marked, respectively. The buffer unloads the data serially on to a magnetic tape recorder. The recorder preferably employs a cassette mechanism such as is used for recording data signals from telemetry systems. Suitable recorders are available commercially, such as, for example, the Kennedy 330. The recorder may have a four track recording facility so that tape 9 has blocks 8 (FIG. 2a) of data recorded along the tracks. Each of the blocks 8 consists of three main parts, a starter 10, a data part 11 and a label 12. The starter part includes synchronising signals for use during reading, a block number and any other control information which may be required. The data part 11 consists of a string of binary digits which represent the marking positions on the document. The digit string which would represent the positions 21 to 40 of the form shown in FIG. 1 would be 010000010010000001. The label 12 contains the identifying or index number of the item. In the present example, it would be the reel and frame number on which the data for that particular employee is recorded in full. The label information may be marked on, and automatically read from, the form 1, or it may be entered into the buffer 6 by means of an auxilliary key board 13. Suitable keyboards are available commercially, such as, for example, the Keytronics Inc. PN542. Alternatively, as will be described, the index number can be entered from a matrix of light emmitting diodes.
The forms are read in sequence until the data from all of them has been recorded on the tape 9, which thus forms an index tape for the file of microfilm records. Currently available tape cassettes can provide a recording capacity in excess of 2 million characters. This will be sufficient to accommodate the data from quite a large file. However, it will be appreciated that more than one cassette may be used if this is necessary.
When it is desired to access items from the microfilm file, the cassette is placed in a reader 14. The desired values of retrieval criteria by which the items are to be selected are entered by the operator by means of a key board 15. The key board similar to the keyboard 13 may load data into either register 16, register 17, or logic match circuit 18. The register 16 is loaded with a binary string which represents the values of those criteria which are necessary for an exact match. For example, position 22 will contain a binary one if a requirement is that the employee should be in the 30 - 40 age group.
The register 17 is loaded with a binary string which represents alternative features. For example, a binary one in positions 31 and 33 may be used to indicate that the employee should be either single or widowed.
The contents of the registers can be circulated under control of timing signals on line 19, and applied to comparator circuits 20 and 21. The data read from the tape by unit 14 is also fed to the comparators 20 and 21 via a buffer 22. Thus, the outputs from the two comparators provide an indication of the degree of correspondence between the data string which has been read from the tape 9 and the data in the registers 16 and 17. These outputs are fed to the logic match circuit 18 which determines whether or not the desired degree of correspondence has been achieved. For example, there might be five necessary conditions specified by the register 16 and six alternative conditions specified by the register 17, with a match of three out of the six conditions being acceptable. The number of alternative conditions which is acceptable is fed into the circuit 18 from the key board 15. The comparison circuit may, for example, be as described in U.S. Pat. No. 3,265,974 for improvements in Signal Detecting Methods and Devices issued to Roy Thomas and assigned to English Electric-Leo Computers Limited. The comparators 20 and 21 are thus each an AND-gate which outputs a pulse each time both the bit emerging from the shift register 16 and 17 connected to it and the bit from the tape are a binary one (representing the fact that a particular retrieval-criterion value is both desired and present in the record being read from the tape). The logic match circuit 18 then comprises a counter for each of the gates 20 and 21 which totals the pulses issued by the gate and a decoder which detects whether the output reaches the predetermined value which determines whether the desired degree of correspondence has been achieved. The registers 16 and 17 and the buffer 22 may each be provided in integrated circuit form as one of the two 256-bit shift register of a National Semiconductor MM 5012.
The data output from the buffer 22 is also fed to a display unit 23, which may be a low cost printer, such as for example is available commercially as the Practical Automation Inc. DMTP3, or visual display device, or, alternatively, as will be described, a matrix of light emitting diodes which can also be used as the criteria recorder. The display unit also receives control signals from the logic match circuit 18, so that the unit 23 is caused to display the index number, that is part 22, of each data block which meets the match requirements. The overall operation of the units of the system is synchronised by timing signals which are generated by a control unit 24. Conveniently, the unit 24 may be a suitably programmed mini-computer such as a Digital Equipment Corporation PDP8, or an Intel 8080. The functions performed by the comparators 20 and 21 and by the logic match circuit 18 may also be provided by the mini-computer. Alternatively, these functions may be provided by individual logic circuits which are well known in the art. Other known logic functions such as `n out of m` and `not match` may be provided. One or more counters may be provided for tallying the numbers of match conditions of various kinds for the purpose of file analysis.
It will be appreciated that the system described above provides a relatively powerful data retrieval system in a simple manner. This simplicity results particularly from the use of an input record 1 which is simple to code and which provides the data in a manner which is suitable for recording directly on the tape 9 without a complicated encoding process. Because of this lack of encoding, the data may be entered through a manually operated device, if so desired, rather than by use of a mark reader.
A modified arrangement will now be described in which the criteria recorder is in the form of a matrix of light-emitting diodes. The individual diodes are set to be lit or unlit to represent the presence or absence of a particular retrieval criterion value. Thus, each diode corresponds to a box 3 on the form of FIG. 1, and the state of the diode corresponds to the presence or absence of a mark 4 in the box.
Referring to FIG. 4, the apparatus includes a display 41 formed by a regular array of light-emitting diodes 42 (not all shown). The LEDs are energised by control circuitry 43, to which is also connected a "light-pen" (a wand carrying a photo-sensitive transistor) 44. Data to or from the display passes between the control circuitry 43 and other equipment 45 the nature of which depends on how the display is being used, and in this case comprises the remainder of the tape-search system described with reference to FIG. 3.
Each LED receives an energising waveform containing either short or long pulses. The short pulses are of such a duration that an LED receiving them does not appear lit; the long pulses are of such a duration that the LED appears continuously lit. The pulses are supplied to the LEDs in sequence and are derived from a recirculating shift register with as many stages as there are LEDs.
When the wand 44 is pointed at an LED 42 it senses the flashes resulting from the energising pulses and outputs a signal to the control circuitry 43, which prevents the bit corresponding to the detected LED being recirculated to the first stage of the register. It then, depending on whether it has been switched to a LIGHT or ERASE state, either sets or unsets the first stage of the register, which causes the corresponding LED to be either lit or unlit. The action of the wand 44 is therefore to turn the LED at which it is pointed either on or off.
Once in every scanning cycle the contents of the shift register are transmitted to the other equipment 45, which is thus informed of the state of each LED. The display consequently acts as an input device. It can also act as an output device, because bits from the other equipment 45 can be introduced into the shift register (and thus displayed) in preference to recirculated or newly entered bits.
The individual LEDs are labelled by a replaceable partially transparent overlay. FIG. 5 shows an example of an overlay to illustrate the way the display is used. It is mounted in a fame (not shown) which fits precisely in position over the array of LEDs and may, to locate, it be provided with recesses or apertures to engage corresponding projections on the display 41.
Both the entry and display of data can be performed by the display device, the other equipment 45 including in this case a mini-computer having an input register that receives the data output from the display and an output register that supplied data to it.
With the overlay shown in FIG. 5 the system is being used to hold retrieval criterion values of property for sale, the full details of which are held separately on microfilm. The overlay is divided into three sections, a Requirements section 55, a Controls section 56 and a Results section 57. The overlay is generally opaque with transparent panels through which some of the LEDs 42, which are arranged as a regular array, are visible; the panel 58 headed Price is one example. The whole Results section 57 is also transparent. Visible LEDs are labelled by wording or numbers beside them.
Assume first that the device is to be used to from the index tape. The Ready diode in the Controls section 56 will glow to show that the operator can proceed. He will then point the wand 44 at the LED labelled Record in the Mode panel of the Control section 56, and this LED will light up. At the same time the control circuitry 43 will transmit the state of this LED to the mini-computer, which is programmed to recognise the significance of this particular bit being set, when it will be prepared to record the information to follow. (The actual programming of the mini-computer is by wellknown techniques and does not form part of this invention). The operator will then input the characteristics of each house to be recorded by pointing at the appropriate LED in each panel of the Requirements section 55 -- that, say, the price is less than 14,000 pounds, there are 3 bedrooms and it is a semi-detached house (other features such as the location, type of garage, etc. may be present but are not shown). The details of the house are followed by the reel and frame numbers of the corresponding microfilm record. The various LEDs pointed at will be illuminated. The operator can verify them, change any incorrect ones by using the ERASE switch on his wand, and then, by pointing at the Go LED in the Control section 56 cause them to be recorded.
Other properties can then be recorded similarly.
To find out if there is a property held on microfilm meeting any particular set of criteria the operator first sets the apparatus in the appropriate mode by pointing at the LED labelled Search. He then inputs the requirements, following each by pointing at one of the Feature LEDs to indicate the weight to be attached to that requirement. When he points at Go, bits will be set corresponding to the lit LEDs and the tape will be searched for records having a predetermined logical relationship of match or near-match with these bits. When one is found the mini-computer will halt the tape and output bits causing the appropriate LEDs to display the location in the Results section. When the result has been noted or inspected the operator can continue the search by pointing at Next.
When the tape reaches the end of a track End lights and the operator can cause the tape to be rewound by pointing at Rewind. In this instance the output produced by the mini-computer is a signal controlling the tape apparatus.
In the search mode the Results section is used only for output. It is under the continuous control of the mini-computer and pointing the wand at it has no effect. Similarly (for this application) Ready and End are output LEDs only. Diodes outputting information can be made to flash to attract the operator's attention or act as a warning.
The operation of the matrix of LEDS will now be described in more detail.
Referring to FIG. 6 the data to be displayed is held in a shift register 101. It receives its input from a logical net 202 (described in more detail with reference to FIG. 8) to which there are various inputs. One is the output from the register 101 itself, which is recirculated along a path 30. The others the data from an input register 40, entered under the control of a LOAD signal 50, and the signal from a wand 60 holding a photo-sensitive transistor 70. This signal passes through a Schmitt trigger 80 and a pulse checker 90 and is entered under the control of a bistable 100 having a LIGHT state 110 and an ERASE state 120.
Besides being recirculated, the output from the register 101 goes to an output data register 130 and an OR gate 140.
An oscillator 150 clocks the shift register 101. It supplies clock pulses which advance the contents of the register 101 stage by stage. The clock pulses are also supplied to a pulse generator 160, the output of which forms the second input to the OR gate 140; and a pair of binary counters in sequence, a less-significant counter 170 and a more-significant counter 180. The output from the counter 170 is in parallel along the lines 190 and goes to a column decoder 200 having outputs 210 (not all shown); the output from the other counter 180 is in parallel along the lines 220 and goes to a row decoder 230 having outputs 240 (not all shown).
The oscillator 150 produces square-wave clock pulses. At every clock pulse the contents of the shift register 101 are advanced by one stage and the emerging bit is recirculated via the path 30 with the appropriate delay introduced. Thus the position in which any particular bit is stored will vary during the cycle, each bit returning to its original position in the register after a complete cycle of as many clock pulses as there are stages in the register.
The output from the register consists of a waveform containing a signal for each emerging ONE-bit and none for each ZERO-bit. The waveform is repeated once each complete cycle.
The pulse generator 160 produces a short pulse at the start of every clock pulse. The outputs from the pulse generator 160 and the shift register 101 are both applied to the OR gate 140 and if the emerging stored bit is a ONE the signal that represents it will absorb the short pulse from the pulse generator; if the stored bit is a ZERO the OR gate will superimpose the short pulse on the output from the register. Therefore in the output 250 from the gate 140 a long signal represents a ONE-bit and a short signal a ZERO-bit.
The clock pulses are also supplied to the less-significant digital counter 170. It produces a parallel binary output on the lines 190, the output advancing by one at each clock pulse. Every time the counter reaches its maximum it returns to zero and also supplies a signal that advances the second counter 180 which also produces a parallel binary output. This counter returns to zero after the complete clock cycle corresponding to the number of stored bits. With 64 stored bits, the two counters may as an example both count to eight, so that each has the three output lines 190 or 220 as shown. The more-significant counter 180 will then advance once every eight clock pulses and return to zero after 64 pulses.
The binary decoder 200 has a separate output 210 for each value of the counter 170, and (provided it is enabled -- see below) produces a signal on the line 210 corresponding to the current value of the counter. The output of the decoder 200 thus scans the various lines 210 in turn. The decoder 230 functions similarly and produces an output on each line 240 in turn, the signal advancing once every cycle of the decoder 200. There are thus, at any one time, outputs to a pair of lines 240 and 270. The drivers 260 and 280 then allow current to flow through the corresponding pair of lines 270 and 290, energising the light-emitting diode 300 that connects them.
The two decoders 200 and 230 and enabled by the output 250 from the OR gate 140. Each output 210 from the column decoder 200 passes through a driver 260 to a line 270 and each output 240 from the row decoder 230 passes through a driver 280 to a line 290; the two drivers 260 and 280 are described in more detail with reference to FIG. 7.
Light-emitting diodes 300 (not all shown) are connected as an orthognal array or matrix between each of the pairs of lines 270 and 290. These diodes 300 display the data stored in the register 101. there are as many diodes 300 as there are stages in the register 101, which in turn equals the number of bits to be displayed.
The operation of the device will now be described. It will first be assumed that the register 101 has just been loaded with input data and that no signal is being received from the photo-sensitive transistor 70 in the wand 60. That means that the device is displaying static data which is not being modified by the operator. Under these circumstances the output from the register 101 is recirculated along the path 30 through the network 202 back to the input to the register 101.
Each stage of the register 101 will hold a separate one of the bits to be displayed, the stage being (say) set if it holds the value ONE and unset if it holds the value ZERO. As an example, it has proved suitable in this form of apparatus to use a register of 64 stages.
The output from the decoders 200 and 230 is inhibited unless there is a signal on the output 250 from the OR-gate 140 which enables the decoders. There is such a signal once every clock interval, either long or short, depending on the value of the corresponding bit at the output of the register 101.
The action of the counters 170 and 180 and the decoders 230 and 250 is thus to scan the diodes 300 one by one and row by row directing energising pulses to each of them in turn.
As a result of being energised each diode 300 emits a flash of light. The length of a flash depends on the length of the energising pulse but its exact shape and timing depends on the characteristics of the diode.
Each individual diode 300 receives the pulses representing the particular bit whose timing corresponds to the stage in the cycle at which it is scanned. Each diode is thus associated with a different bit and will emit either short or long flashes depending on the value of that bit.
The durations of the energising pulses and the frequency of the complete scanning cycle are chosen to be such that a diode energised by long pulses appears lit and substantially flicker-free to an observer in normal lighting conditions, and a diode energised by short pulses appears not to be lit. As examples of values that have proved suitable, with 64 stages the long pulses may be 200 microseconds and take substantially a whole clock interval (giving approximately 78 flashes per second) and the short pulses 20 microseconds.
The appearance of the diodes will depend on the conditions in which they are observed. A diode energised by short pulses which appears completely unilluminated in normal conditions may glow noticeably in a darkened room. Nevertheless there will still be enough contrast between the two stages of illumination for the operation to be able to determine whether a diode is "on" or "off".
The diodes 300 can be overdriven (that is, run at more than their specified power rating) for the short periods they are energised without the average consumption over the whole cycle exceeding that rating. For example, with 64 stages it has been found satisfactory to overdrive the diodes by a factor of four. The apparent brightness will then be greater than if the diodes were run, during the periods for which they are illuminated, at their specified rating. The brightness of the diode can be made variable by providing an adjustment for the degree of overdrive.
Referring to FIG. 7, the driver circuits 260 and 280 will now be described. Each line 210 is connected to the base of a transistor 320 through a base-current limiting resistor 310. The transistor 320 receiving a signal will supply current from a supply 330 through a power limiting resistor 340 to the corresponding column-conductor 27.
The row-conductors 240 are connected to transistors 350, the appropriate one of which is made conductive by a signal to its base, which is connected through a base current limiting resistor 360 and capacitor 370 to one of the lines 240 and through a bias resistor 380 to the negative supply 390.
The capacitor 370 provides AC coupling to ensure that if the scanning cycle stops the diodes will be protected against overload.
Referring to FIG. 8, the logic net 202 will now be described in more detail. The data from the input register 40 and the LOAD signal 50 are passed through an AND-gate 400 to an OR-gate 410 and thence to the input of the shift register 101. The LOAD signal 50 is also inverted and applied to AND gate 420 whose output is the other input to the OR gate 410.
The outputs from the pulse-checker 90 and bistable 100 pass through an AND-gate 430 to an OR-gate 440. The signal from the pulse-checker is also inverted and applied with the recirculated signal on the path 30 to an AND-gate 450. Its output goes to the OR-gate 440, which feeds the AND-gate 420.
It has so far been assumed that the device is displaying static information. There is then no signal from the pulse checker and no LOAD signal 50. The signal on the path 30 is therefore recircuulated to the register 101. However, the displayed data can also be altered in two ways. First, data can be entered from an external source, for example a computer. This happens when there is a LOAD signal 50, which inhibits recirculation through the gate 420 and allows data from the input register 40 to be admitted. The LOAD signal may be present for a full repeat cycle, allowing a complete fresh set of contents to be entered, or may allow an individual bit to be replaced. By alternately clearing and setting a particular bit at intervals of several cycles the associated diode can be caused to flash, for example to attract an operator's attention.
The state of individual stored bits can also be altered by an operator. Consider the case where he wishes to set the bit associated with an unlit diode. First, the bistable 100, which may be operated by a switch on the wand 60, is set in the LIGHT state in which it produces an output on line 11. Then the operator points the wand 60 at the diode and the photo-sensitive transistor 70 picks up the short flashes from it. For each flash it will produce an output which will be rounded by the cumulative characteristics of the light-emitting diode 300 and the photo-sensitive transistor 70.
This output is checked first for level by the Schmitt trigger 80 which prevents the wand responding to stray light or other diodes and produces a square wave when operated by a valid signal, and then for timing by the pulse-checker 90, which tests for an output just before and after output from the Schmitt trigger 80 is due to start. If these conditons are both met it produces an output.
This inhibits recirculation through the gate 450. The bit which would be due to be recirculated is the bit causing the flash detected (in this instance an unset bit since the diode is unlit). In its place the output from the pulse-checker allows the output from the bistable 100 to be introduced into the shift register, and the appropriate bit is thus set. In the next cycle it will cause a long flash from the associated diode corresponding to the lit state. While the wand is pointed at the diode (and clearly it cannot be removed instantaneously) the pulse-checker will detect these flashes, and reintroduce the bit afresh each cycle.
Alternatively, the pulse-checker can additionally test for a signal after the short pulse is due to be ended. This permits the type of pulse to be determined. A gate can then be included to allow the long pulse to inhibit the transmission of the signal from the pulse; checker to the net 202. Thus only the detection of the initial short pulse inhibits recirculation and sets the appropriate bit.
The erase a bit, the bistable 100 is cleared to the ERASE state and the wand pointed at the associated diode. The pulse-checker will pass the sensed pulse, which inhibits recirculation of the bit that caused the (long) flash. There is now no other signal at the gate 430, so there is no input to the register 101 from the wand. The appropriate bit is thus cleared and the diode extinguished. Again, if the pulse-checker distinguishes between long and short pulses, recirculation can be restored when the short flashes resulting from the cleared bit are detected. The response of the wand and the following circuitry can be made specific enough for there to be a response from one diode at a time only, and not simultaneously from any of its neighbours. This is helped if the photo-transistor 70 is made directional by capping it with a fibre-optic light conducting tube. The diodes may also have a moderately restricted emission angle. There is then no need to provide the operator with any separate control to determine when the wand is to enter data; it is enough for him to bring the wand up to a diode whose state he wants to change. But, if desired, such a control can be provided as a press switch on the wand 60 controlling the signal passing along the line from the wand.
It will be understood that the register 130 of FIG. 6 is equivalent to the buffer 6 of FIG. 3 and the data which is held in it can be used to control recording of a string of binary bits on the tape 9 in a conventional manner.
The examples which have been described above will have made clear the simple manner in which information can be entered and processed. It takes a user of the system only a few minutes of practice to become proficient in entering new information, or in making enquires, whether the uses a form or a matrix of LEDS as the criterias recorder. Furthermore, the use of binary signal strings for representing the criterion makes the necessary apparatus relatively simple and inexpensive. | A process is disclosed for indexing and retrieving information items recorded on a media and each given an index number. The process uses a criteria recorder having, for each value of a retrieval criterion, a recording position capable of holding a single bit. For each item the recorder is set according to the characteristics of the item and the resulting binary pattern recorded as a train of bits, together with the corresponding index number, on a magnetic index tape. To retrieve items meeting specified retrieval criteria, an electronic register is set with the bit pattern corresponding to those criteria, the tape searched for matching patterns, and the corresponding index numbers displayed as a guide to retrieving the actual items. | 6 |
REFERENCE TO RELATED APPLICATIONS
This application is a national stage application under 35 USC 371 of International Application No. PCT/RU2012/000484, filed Jun. 21, 2012, which claims the priority of Russian Patent Application No. 2011125946, filed Jun. 22, 2011, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to the field of producing olefin oligomers. They are a widely used as copolymers, a raw material for the preparation of oils and lubricants, a raw material for the preparation of other chemical products. More specifically, the invention relates to a production of olefin oligomers by an olefin trimerization process.
BACKGROUND OF THE INVENTION
An oligomerization reaction is usually carried out as a homogenous catalytic process in the presence of metallorganic catalysts. The output stream of an oligomerization reactor usually is a mixture of olefin oligomers, namely, reaction products, an initial olefin, a catalyst and/or residues thereof and often a solvent. In order to separate reaction products, various methods are used in this field of the art. For example, Russian patent No. 2131405 describes a method of isolating products of a trimerization reaction of olefins, said products being obtained by means of a catalyst comprising chromium compounds and organoaluminum compounds; the method comprising contacting a reaction product stream from the outlet of a reactor with an alcohol, in the course of which a catalyst system is deactivated. After that, the olefin product is separated, and a residue is contacted with an aqueous base, thereby forming a chromium-containing solid sediment. Then, the solid sediment, an aqueous layer and an organic layer are separated with subsequent addition of a mineral acid to an aqueous phase. A drawback of the method is the presence of an alcohol in the reaction mixture, which can result in the residues of this alcohol ending up in an olefin product and in a recurrent solvent if it is used, which, in turn, leads to impairing of the quality thereof. In addition, heavy olefin products can be contaminated with this alcohol during the treatment hereof with an acid. Furthermore, the use of the indicated method results in the complication of the scheme and the control system of the process because it is necessary to thoroughly control a proportion of alcohol and/or amine, to add firstly the alkaline solution before adding the acidic solution, and to separate the precipitated sediment.
Russian patent No. 2249585 mentions another drawback of the aforesaid method, namely, the isolation of hydrogen halide in the presence of alkyl-aluminum halides in the catalyst system. Therefore, the solution is further improved by adding an amine, instead of an alcohol or in addition to an alcohol, to bind a released hydrogen halide. However, this entails an additional complication of the scheme and the necessity to utilize/isolate residues of the amine or a salt thereof.
U.S. Pat. No. 5,750,816 describes the solution that is closest to the proposed one, said solution optionally includes addition of alcohol, amine, phenol, carboxylic acid and other compounds for the maintenance of the catalyst components in a dissolved state. At the same time, the use of these components is not obligatory. In order to simplify the scheme, a by-product polymer that is usually formed in a trimerization reaction is not separated from the reaction product stream before a distillation column, wherein the separation of the reaction products and a solvent when used from residues of the catalyst and the by-product polymer isolated in the solid state is carried out. At the same time, the content of the column botton is heated to a temperature of 200° C. or more to separate high-boiling reaction products. It is noted that the preliminary separation of the polymer before the distillation step in this method results in the sedimentation of the catalyst residues in the form of a resin on the surface of a heater and in impairing the operation thereof. A drawback of this method is the formation of a solid residue after the distillation, said residue comprising by-product polymer and catalyst residues, and it is difficult to utilize said residue because a fine-dispersed polymer contaminated with the catalyst residues is capable of holding a significant amount of substances comprised in the catalyst residues, due to adsorption and/or absorption. This hampers their isolation by conventional methods such as the treatment with acidic or alkaline, aqueous or organic solution. Furthermore, the presence of a dispersed by-product polymer in the stream of products from the reactor to the distillation column requires the maintenance of an increased temperature or other methods making it possible to avoid the sedimentation of a polymer in the line and in apparatuses which are present in the production line, including measuring devices.
The problem to be solved within the scope of the present invention is an isolation of products of an oligomerization reaction of olefins comprising a terminal double bond, from the output stream of an oligomerization reactor, and a separation of a polymeric by-product and catalyst residues, including aluminum and chromium compounds.
In order to solve the problem, a method is provided that does not comprise adding any agents to deactivate a catalyst system, wherein the method consists in isolation of products of an oligomerization reaction of olefins comprising a terminal double bond, said reaction being conducted by the action of a catalyst comprising chromium compounds, a nitrogen-containing ligand and organoaluminum compounds, said method comprising the following three sequential steps:
a) isolating at least one liquid product of the oligomerization reaction of olefins from an output stream of an oligomerization reactor;
b) treating a residue with an aqueous solution of an acid; and
c) separating an organic layer and an aqueous layer.
The problem is solved by a method that does not comprise adding any agents for deactivating a catalyst system. The method comprises the step of separating a by-product polymer from the output stream of an oligomerization reactor before feeding the stream into a distillation column. The distillation is carried out stepwise, at first isolating at least one olefin reaction product. In order to avoid the formation of a resin during the distillation of high-boiling reaction products after the step of separating at least one olefin, a mixture that is formed after the separation and comprises the high-boiling reaction products, is treated with an aqueous solution of an acid to separate catalyst residues, first of all aluminum and chromium compounds, in the form of water-soluble salts, with subsequent separation of aqueous and organic phases. Then, the organic phase may be fed to the next distillation step to isolate high-boiling products.
Firstly, the use of the proposed methods allows the isolation of target reaction products, avoiding the ingress of impurities of foreign substances, such as alcohols into products and/or recurrent solvent, and elimination of the necessity of the separation of these foreign substances. Secondly, the use of the proposed method makes it possible to avoid the contamination of lines and devices between the reactor and the distillation column with a side product. Thirdly, the solution makes it possible to separate catalyst residues from a polymer by-product, thus facilitating the regeneration of the catalyst or separation of metal compounds from catalyst residues, while avoiding the precipitation of a resin during the distillation of the high-boiling reaction products. Thus, the proposed solution makes it possible to achieve results exceeding or at least comparable with earlier known methods, and avoiding drawbacks inherent herein.
DETAILED DESCRIPTION OF THE INVENTION
It is most preferable to use the proposed invention for oligomerization of olefins comprising a terminal double bond, such as ethylene, propylene, butene-1, hexene-1.
Now the great quantity of methods using different catalysts and catalyst systems mainly comprising chromium compounds is proposed for carrying out the oligomerization reaction. According to the claimed method, it is preferable to use catalysts with a high activity and selectivity to target oligomerization products to improve the efficiency of the process.
All the steps of the manufacture of an oligomerization catalyst system are preferably conducted under conditions excluding the contact of the components of the catalyst system with water and atmospheric oxygen. Especially, it is recommended to avoid the contact of an organoaluminum compound and oligomerization catalyst system with moisture and oxygen after mixing all components of the oligomerization catalyst system, including an organoaluminum compound. The contamination of the catalyst with traces of moisture and/or oxygen may result in an increased formation of a by-product polymer, thus impeding the process of isolating oligomerization products of olefins.
It is preferable that the high active catalyst system for conducting the oligomerization reaction is prepared with the use of a chromium source, a nitrogen-containing ligand, an organoaluminum compound, a halogen-containing compound, and using SHF-radiation exposure. However, other known high-active oligomerization catalyst systems are contemplated in carrying out the invention.
Any organic or inorganic chromium compound or a mixture of these compounds may be used as a chromium source. An oxidation state of chromium in the indicated compounds may vary within a range of from 0 to 6. Generally, the chromium source has the formula CrXn, wherein substituents X may be the same or different and may represent an organic or inorganic residue, and n is an integer from 1 to 6. The organic residues may comprise from 1 to 20 carbon atoms in one residue and are selected from the group consisting of an alkoxy group, alkylcarboxylic and ketonic residues, pyrrolide and an amide moiety. The inorganic residues comprise, but are not limited to, for example, halides, sulfates and/or oxides. Examples of the chromium compounds include, but are not limited to, for example, chromium (III) chloride, chromium (III) acetate, chromium (III) tris-ethylhexanoate, chromium (III) acetylacetonate, chromium (III) pyrrolide, and chromium (II) acetate.
In order to increase the selectivity of the catalyst system to hexene-1, halogen-containing compounds are preferably used as an additional component of the oligomerization catalyst system, the halogen-containing compounds having general formula RmXn, wherein R is an organic or inorganic radical, X is fluoro, chloro, bromo, or iodo, m+n>0. AlEt 2 Cl, AlEtCl 2 , and CHCl 3 may serve as examples of such compounds.
The nitrogen-containing ligand may be an organic compound including a pyrrole ring fragment, i.e. a five-membered aromatic ring having one nitrogen atom. Examples of the nitrogen-containing ligands include, but are not limited to, pyrrole, 2,5-dimethylpyrrol, lithium pyrrolide C 4 H 4 NLi, 2-ethylpyrrol, indole, 2-methylindole, and 4,5,6,7-tetrahydroindole. The use of pyrrole or 2,5-dimethylpyrrole is most preferable.
The organoaluminum compound may be an alkylaluminum compound, a halogenated alkylaluminum compound, an alkoxyalkylaluminum compound and mixtures thereof. The organoaluminum compound should include both at least one non-hydrolyzed compound represented by the general formulae AlR 3 , AlR 2 X, AlRX 2 , AlR 2 OR, AlRXOR and/or Al 2 R 3 X 3 , wherein R is an alkyl group, X is a halogen atom. Examples of these compounds include, but are not limited to, triethylaluminum, diethylaluminum chloride, tripropylaluminum, triisobutylaluminum, diethylaluminum ethoxide and/or ethylaluminum sesquichloride. Triethylaluminum or a mixture of triethylaluminum and diethylaluminum chloride is the most preferable organoaluminum compound.
In order to increase the activity of the catalyst system, it is preferable to use exposure of the organoaluminum compound and the halogen-containing compound by SHF-radiation. Preferably, the organoaluminum compound, and also optionally halogenide, optionally in the form of a solution in a hydrocarbon solvent, are exposed by SHF-radiation, and then are mixed with the chromium source and nitrogen-containing ligand. The addition of halogenide is optional, but provides the best results. In the course of the exposure, the exposed material or a mixture of substances should be in a vessel transparent for the SHF-radiation, for example, in a glass, fluoroplastic, or polypropylene vessel. The radiation power and time of the exposure may be arbitrary. However, for the best results, the time of the exposure of from 30 sec to 20 minutes, and the SHF-radiation nominal power of from 100 to 50000 W per 1 gram of the used organoaluminum compounds in terms of the elementary aluminum are preferable. Such exposure does not generally result in heating an organoaluminum compound or a solution thereof more than for 10° C. The time of the exposure of more than 20 minutes usually does not provide additional advantages for the properties of the obtained trimerization catalyst system. The time of the exposure of less than 30 sec may be insufficient to provide significant alterations in the properties of the organoaluminum compound and, optionally, halide, which, in turn, provides an insufficient increase in activity and/or selectivity of the catalyst system thereby obtained.
It is preferable to minimize the time between the termination of the exposure and the beginning of the mixing of an organoaluminum compound and, optionally, halide with a chromium source and a nitrogen-containing ligand. It is desirable that the indicated time is less than 1 minute. If this time is more than 3 minutes, the properties of the obtained catalyst system may worsen as compared with the system prepared of the SHF-radiated organoaluminum compound which was added less than one minute after the termination of the exposure. In particular, the activity of the obtained catalyst system may decrease. If a period of time between the termination of the exposure and the beginning of the mixing is more than 20 minutes, there is no a significant difference between the catalyst systems obtained with using an SHF-radiated organoaluminum compound and the catalyst systems obtained with using an aluminum-containing compound that was not exposed by the SHF-radiation.
In general, to obtain the oligomerization catalyst system, 1 mole of chromium based on elemental chromium may be admixed with 1-50 moles of a nitrogen-containing ligand and 1-250 moles of an organoaluminum compound based on elemental aluminum in the excess of an unsaturated hydrocarbon. If a halide source is used, its amount is usually from 1 to 60 moles based on the element (halogen). It is preferable to use 1 mole of chromium based on elemental chromium admixed with 2-8 moles of a nitrogen-containing ligand and 10-80 moles of aluminum based on elemental aluminum in the excess of the unsaturated hydrocarbon. If a halogen source is present, its amount of from 1 to 20 moles of halide based on elemental halogen is preferable.
The oligomerization reaction may be carried out by any method known in the art, using an oligomerization catalyst system. The above described catalyst system is preferable due to high activity and selectivity thereof.
It is preferable to use an aliphatic hydrocarbon solvent that does not comprise a significant amount of unsaturated compounds since it may worsen conducting the oligomerization reaction and complicate the isolation of the reaction products because of an increased formation of a by-product polymer. It is the most preferable to use a hydrocarbon solvent that is saturated compound and is not an oligomerization product or initial olefin. Heptane, cyclohexane, pentane, cyclopentane, butane, decane, methylcyclohexane may serve as examples of such a solvent. It is also possible to use other hydrocarbon solvents.
It is preferable that hydrogen be present in the reaction mixture when carrying out the oligomerization reaction. This reduces both the total amount of a by-product polymer formed and an amount of polymer precipitated on the reactor walls. This, in turn, facilitates the separation of stream coming out of the oligomerization reactor from the by-product polymer.
It is preferable to separate the output stream of the oligomerization reactor from a solid phase before the isolation of a liquid oligomerization product.
The output stream of the oligomerization reactor may be separated from a by-product polymer before the step of separating gaseous olefins (degassing step), if present, or after the degassing step. The by-product polymer may be separated by any known separation method, for example, by centrifugation or filtration.
After filtration and degassing, when used, the stream from the oligomerization reaction is directed to the step of separating products, in the course of which at least one olefin product is isolated. For example, if ethylene is used as an initial olefin, then usually a main oligomerization product, namely hexene, is separated at the step of distilling. To improve the process efficiency, it is also advisable to recycle the used solvent. The separation may be carried out by any method, but distillation is believed to be most simple and convenient. Different apparatuses for distillation may be used making it possible to isolate the reaction products and a solvent on one or more columns. At the same time, semi-volatile products having a molecular weight more than 4 times the molecular weight of an initial olefin should not be separated at this step from the catalyst residues.
Then, the bottom residue after the distillation of the olefin product, and optionally a solvent, is treated with an aqueous solution of an acid. It is recommended to use, as the acid, acids having the acid value pKa of not more than 7, for example, acetic acid, formic acid, phosphoric acid or other acids. It is recommended to use acids, aluminum and chrome salts of which have a solubility of not less than 10 g/l in water. Due to this, the aluminum and chromium compounds pass to an aqueous solution and may be used for the regeneration or safe utilization. The organic phase free of aluminum and chromium compounds is separated from the aqueous phase by conventional methods and then said phase is optionally separated by distillation to isolate a residual amount of volatile reaction products, a solvent and heavy reaction products.
In order to reduce the amount of wastes formed, it is preferable to remove chromium and aluminum ions from an aqueous solution and to increase the concentration of acid in the solution, thus allowing the re-use of the aqueous solution for treating the bottom residue. In order to purify the aqueous solution from chromium and aluminum ions, it is possible to use, for example, a cation-exchange resin making it possible to precipitate chromium and aluminum ions and regenerate the acid. Many acids are known to form complex ions with chromium ions, and these complex ions are deposited on the cation-exchange column in an insufficient degree. Therefore, in case of the use of a cation-exchange column to isolate chromium and aluminum ions, sulfuric, hydrochloric, nitric, chloric and other acids are preferable since anions of these acids do not form complex ions with the chromium cations.
When an aqueous solution used for the treatment of the distillation residue passes through a cation-exchange column (for example, KU-2-8 according to State Standard 20298-74), aluminum and chromium salts are precipitated on the cation-exchange column, and the concentration of acid in the aqueous solution increases up to a value close to the acid concentration in the initial aqueous solution before the treatment of the bottom residue. This makes it possible to re-use the aqueous solution after passing the ion-exchange column for treating the bottom residue. Chromium and aluminum ions may be isolated by known procedures of regeneration of cation-exchange columns, for example, by washing with a 10-20% aqueous solvent of sulfuric acid.
To provide a better understanding of the proposed technical solution, examples of embodiments of the invention are presented below. They are provided only to illustrate the invention, and are not intended to limit the scope of the invention.
Example 1
55.5 mg (0.115 mM) of chromium (III) ethylhexanoate (Cr(EH) 3 ) and 54.9 mg (0.575 mM) of 2,5-dimethylpyrrole (DMP) are admixed in 10 ml of ethylbenzene in a dry flask filled with nitrogen. A solution of tri-ethyl aluminum (TEA) in toluene (1.9 mole/l) in an amount of 2.25 ml (4.28 mM) is admixed with a solution of diethylaluminum chloride (DEAC) in hexane (1.0 mole/l) in an amount of 1.5 ml (1.5 mM). The obtained mixture of organoaluminum compounds is exposed by SHF-radiation for 6 minutes at a nominal power of 400 W. Then, the solution of TEA and DEAC is added to a mixture of ethylbenzene, DMP and Cr(EH) 3 for 30 seconds to obtain a brown solution which after 15 minutes gains the orange-yellow colour. The solvents are removed under vacuum. The residue is diluted with 10 ml of cyclohexane and then is additionally diluted with cyclohexane up to the volume of 2.00 l. The obtained solution of the catalyst system having chromium concentration of 3.0 mg/l is used in the trimerization reaction of ethylene.
140 ml of a solvent of the catalyst system is added to a 0.5 l reactor, hydrogen is added to achieve a partial pressure of 0.5 bar, and then ethylene is fed, wherein the total pressure of 15 bars (gauge) is maintained in the system for 35 minutes. Ethylene absorption is 29.1 g. Then, the catalyst system solution and hydrogen are fed at rates of 140 g/h and 0.2 nl/h, respectively, and the reactor is discharged at a rate equal to the sum of the rates of feeding ethylene and the catalyst system solution. The output stream of the reactor is passed through a filter and a flow regulator and is directed to a degasser. The liquid phase from the degasser is fed to rectification, and a main reaction product (hexene-1), a solvent (cyclohexane) and heavy reaction products together with the catalyst residues are isolated. After the beginning of the discharge of the reactor, the reaction is carried out for 5 hours.
Heavy reaction products comprising catalyst residues are separated from the bottom residue and are mixed with a 10%-aqueous solution of acetic acid in an amount of 25 ml per 100 ml of the bottom residue, providing an effective contact between phases. The aqueous solution and the precipitate are separated from the organic solution. 50 ml of a 10% solution of Na CO 3 are added to the aqueous solution and the precipitate. The brown precipitate is filtrated and dried on air. The results of the reaction are presented in Table 1.
Example 2
74.0 mg (0.154 mM) of Cr(EH) 3 and 73.2 mg (0.769 mM) of DMP are admixed in 10 ml of ethylbenzene in a dry flask filled with nitrogen. A solution of TEA in toluene (1.9 mole/l) in an amount of 2.9 ml (5.51 mM) is admixed with a DEAC solution in hexanes (1.0 mole/l) in an amount of 2.15 ml (2.15 mM). The obtained mixture of organoaluminum compounds is exposed by SHF-radiation for 6 minutes at a nominal power of 400 W. Then, the solution of TEA and DEAC is added to a mixture of ethylbenzene, DMP and Cr(EH) 3 for 30 seconds, to obtain a brown solution which after 15 minutes gains orange-yellow colour. The solvents are removed under vacuum. The residue is diluted with 10 ml of cyclohexane and then is additionally diluted with cyclohexane up to the volume of 2.00 l. The obtained solution of the catalyst system having the chromium concentration of 4.0 mg/l is used in the trimerization reaction of ethylene.
170 ml of a solvent of the catalyst system is added to a 0.5 l reactor, hydrogen is added to achieve a partial pressure of 0.5 bar, and then ethylene is fed, wherein the total pressure equal to 9 bars is maintained in the system for 30 minutes. The absorption of ethylene is 21.1 g. Then, the catalyst system solution and hydrogen are fed at a rate of 165 g/h and 0.2 nl/h, respectively, and the reactor is discharge at a rate equal to the sum rate of the rates of feeding ethylene and the catalyst system solution. The output stream of the reactor is passed through a filter and a flow regulator and is directed to a degasser. The liquid phase from the degasser is fed to rectification and a main reaction product (hexene-1), a solvent (cyclohexane) and heavy reaction products together with the catalyst residues are isolated. After the beginning of the discharge of the reactor, the reaction is carried out for 4 hours.
The heavy reaction products are reprocessed in the same way as in example 1. The results of the reaction are presented in table 1.
Example 3
74.0 mg (0.154 mM) of Cr(EH) 3 and 73.2 mg (0.769 mM) of DMP are admixed in 10 ml of ethylbenzene in a dry flask filled with nitrogen. A solution of TEA in toluene (1.9 mole/l) in an amount of 2.9 ml (5.51 mM) is admixed with a DEAC solution in hexanes (1.0 mole/l) in an amount of 2.15 ml (2.15 mM). Then, the solution of TEA and DEAC is added to a mixture of ethylbenzene, DMP and Cr(EH) 3 to obtain a brown solution, which after 15 minutes gains orange-yellow colour. The solvents are removed under vacuum. The residue is diluted with 10 ml of cyclohexane and then is additionally diluted with cyclohexane up to a volume of 2.00 l. The obtained solution of the catalyst system with the chromium concentration of 4.0 mg/l is used in the trimerization reaction of ethylene. 170 ml of solvent of the catalyst system is added to a 0.5 l reactor, hydrogen is added to achieve a partial pressure of 0.5 bar, and then ethylene is fed, wherein the total pressure of 12 bars (gauge) is maintained in the system for 30 minutes. The ethylene absorption is 36.5 g. Then, the catalyst system solution and hydrogen are fed at a rate of 165 g/h and 0.2 nl/h, respectively, and the reactor is discharge at a rate equal to the sum rate of the rates feeding of ethylene and the catalyst system solution. The output stream of the reactor is passed through a filter and a flow regulator and is directed to a degasser. The liquid phase from the degasser is fed to rectification and a main reaction product (hexene-1), a solvent (cyclohexane) and heavy reaction products together with the catalyst residues are isolated. After the beginning of the discharge of the reactor, the reaction is carried out for 4 hours.
The heavy reaction products are reprocessed in the same way as in example 1. The results of the reaction are presented in table 1.
Example 4
92.5 mg (0.192 mM) of Cr(EH) 3 and 91.5 mg (0.962 raM) of DMP are admixed in 15 ml of ethylbenzene in a dry flask filled with nitrogen. A solution of TEA in toluene (1.9 mole/l) in an amount of 3.75 ml (7.13 mM) is admixed with a DEAC solution in hexanes (1.0 mole/l) in an amount of 2.5 ml (2.50 mM). The obtained mixture of organoaluminum compounds is exposed by SHF-radiation for 6 minutes at a nominal power of 400 W. Then, the solution of TEA and DEAC is added to a mixture of ethylbenzene, DMP and Cr(EH) 3 for 30 seconds, to obtain a brown solution, which after 15 minutes gains orange-yellow colour. The solvents are removed under vacuum. The residue is diluted with 10 ml of cyclohexane and then is additionally diluted with cyclohexane up to the volume of 2.00 l. The obtained solution of the catalyst system having the chromium concentration of 4.0 mg/l is used in the trimerization reaction of ethylene.
150 ml of solvent of the catalyst system is added to a 0.5 l reactor, hydrogen is added to achieve a partial pressure of 0.5 bar, and then ethylene is fed, wherein the total pressure of bars (gauge) is maintained in the system for 30 minutes. Ethylene absorption is 27.7 g. Then, the catalyst system solution and hydrogen are fed at a rate of 165 g/h and 0.2 nl/h, respectively, and the reactor is discharged at a rate equal to the sum rate of the rates feeding of ethylene and the catalyst system solution. The output stream of the reactor is passed through a filter and a flow regulator and is directed to a degasser. The liquid phase from the degasser is fed to rectification and a main reaction product (hexene-1), a solvent (cyclohexane) and heavy reaction products together with the catalyst residues are isolated.
After the beginning of the discharge of the reactor, the reaction is carried out for 3 hours.
The heavy reaction products are reprocessed in the same way as in example 1. The results of the reaction are presented in table 1.
Example 5
Heavy reaction products comprising catalyst residues are taken out from the bottom residue and are admixed with a 3% aqueous solution of nitric acid in an amount of 60 ml per 100 ml of the bottom residue, thereby providing an effective contact of phases. A possible precipitate is filtrated. The aqueous and organic solvents are separated. The aqueous solution is passed through a column having a diameter of 2 cm, filled with a layer of cathionite KU-2-8 in H-form having a height of 30 cm, thus obtaining an aqueous solution purified from chromium and aluminum salts. The content of chromium and aluminum in the initial bottom residue, in the organic layer after the treatment with a nitric acid solution and separation of the aqueous solution, in the aqueous solution before the passing through the column with cathionite, and in the aqueous solution after passing thereof through the column with cathionite are analyzed by an inductively coupled plasma mass-spectrometry (ICP-MS) method. The content of aluminum and chromium in the solutions, in ppm, are presented in table 2.
TABLE 1
Parameter
Example 1
Example 2
Example 3
Example 4
Concentration of Cr
3.0
4.0
4.0
5.0
in the catalyst
solution, mg/1
Cr:DMP:TEA:DEAC
1:5:37:13
1:5:36:14
1:5:36:14
1:5:37:13
Pressure of
15
9
12
9
ethylene, bar
SHF-exposure, min.
6
6
0
6
Hexene-1, %
89.2
87.9
87.1
84.4
Other hexenes, %
0.3
0.2
0.4
0.5
Butenes, %
0.7
1.3
1.2
0.7
Octenes, %
0.4
0.4
0.3
0.5
Decenes, %
8.6
9.2
9.8
12.0
C12+, %
0.8
0.8
1.2
1.9
Hexene-1 purity in
99.68
99.73
99.58
99.43
C6, %
Ethylene
64.2
56.0
79.2
83.4
consumption, g/h
Chromium
0.54
0.64
0.83
1.06
consumption, mg/h
Conversion of
85
91
80
88
ethylene, %
The efficacy of
100.1
79.6
75.9
69.2
catalyst, kg of
olefins/g Cr
Residence time of
0.79
1.00
0.78
0.70
the catalyst, h
The activity of
126.7
79.6
97.3
98.9
catalyst, kg/(g Cr*h)
TABLE 2
The content of aluminum and chromium in solutions, ppm
Solution
Al
Cr
Initial bottom residue
440
18
Organic after the treatment with the diluted
<1
<1
aqueous nitric acid
Aqueous after the treatment of the organic layer
745
30
Aqueous after the cathion-exchanger
<1
<1 | The invention relates to the production of olefin oligomers by a method of oligomerization of olefins, and, in particular, to a method of isolating olefin oligomerization products and decomposing the oligomerization catalyst residues. The method of isolating products of an oligomerization reaction of olefins including a terminal double bond, in which the reaction is carried out by the action of a catalyst having chromium compounds, a nitrogen-containing ligand and organoaluminum compounds, includes a step of isolating independent olefin products and a step of treating catalyst residues. Further, the method includes the following sequential steps:
a) isolating at least one liquid product of the oligomerization reaction of olefins from an output stream of an oligomerization reactor; b) treating a residue with an aqueous solution of an acid; and c) separating an organic layer and an aqueous layer. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to removably mounted attachments for vehicle tires and more particularly to transversely positioned traction treads which grip the tires and the surface of the road to prevent skidding.
This application is an improvement over the subject matter of copending application Ser. No. 130,583 filed Mar. 14, 1980 by Fred C. White now U.S. Pat. No. 4,280,544 and assigned to the applicants of this application.
DESCRIPTION OF THE PRIOR ART
Anti-skid devices of various kinds including chains and individually mounted straps have been known. These devices usually formed of metal have been of limited road gripping value and have caused permanent damage to the road surface causing their use to have been prohibited in some areas. Additionally, these heavy and unwieldy chains have not only seriously injured the tires but failed to form a firm grip between the tire and the road surface to prevent sliding, slipping and skidding of the vehicle.
U.S. Patent Des. 247,291 discloses a transverse traction tread for vehicle tires the outer surface of which includes a plurality of pointed projections which are integrally formed with the traction element and wear rapidly due to road abrasion.
U.S. Pat. No. 923,456 discloses an anti-slip device consisting of an arch formed to fit transversely over the tread of a vehicle tire. Two openings are provided in each leg of the arch to receive a chain by means of which the arches are spaced apart and secured to the wheel rim in a known manner. The arch is provided with a tread having serrated edges.
U.S. Pat. No. 1,326,513 discloses an anti-skid device comprising a pair of draw members disposed along the sides of an automobile tire and a chain extending across the tread of the tire between the draw members. The cross chain comprises a center element from which radiates a series of arms each connected at its free end to one of the draw members. Each arm comprises a multiplicity of similar gripping elements each provided with an inner annular face adapted to lie against the tire for gripping the tire and the surface of the road.
SUMMARY OF THE INVENTION
It is, therefore, one object of this invention to provide a new and improved lightweight wheel mountable traction device for vehicles which increases the traction between a tire and the surface of a road.
Another object of this invention is to provide a new and improved wheel mountable traction device which is easy to install and remove and which will incur substantially less wear and loss of effectiveness than the known structures after prolonged use.
A further object of this invention is to provide a new and improved wheel mountable traction device formed by a plurality of individual treads, the treads being separately replaceable in the event of damage or wear.
A still further object of this invention is to provide a new and improved wheel mountable traction device employing a plurality of individual treads wherein the number of treads used is selected as appropriate to fit a given size of wheel.
A still further object of this invention is to provide a new and improved wheel mountable traction device employing lugs which may be replaced individually or in groups in the event of excessive wear or loss.
A still further object of this invention is to provide such a traction device in which the metal studs or cleats may be employed or conveniently removed as an accessory at the option of the user.
These and other objects and advantages of the invention will become apparent as the following description proceeds and the features of novelty which characterize the invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.
BRIEF DESCRIPTION OF THE DRAWING
The present invention may be more readily described by reference to the accompanying drawing, in which:
FIG. 1 is a perspective view of a first embodiment of the improved wheel mountable traction device of the invention.
FIG. 2 is an enlarged perspective view of a single traction element employed in the device of FIG. 1, the element being shown in FIG. 1 is within the area enclosed by the broken line 2;
FIG. 3 is a cross-sectional view of FIG. 2 taken along the line 3--3;
FIG. 4 is a cross-sectional view of FIG. 2 taken along the line 4--4;
FIG. 5 is an enlarged plan view showing one half of the traction element of FIG. 2;
FIG. 6 is an enlarged plan view of a modification of the traction element shown in FIGS. 1-5 showing one half of a traction element;
FIG. 7 is an enlarged partial plan view showing another variation of a traction element which may be employed in the device of FIG. 1;
FIG. 8 is an enlarged partial view of another variation of the traction element in which a different means is employed for fastening or securing the element to a wheel;
FIG. 9 is a cross-sectional view of FIG. 8 taken along the line 9--9;
FIG. 10 is a partial plan view of another fastening means for a traction element;
FIG. 11 is a cross-sectional view of FIG. 10 taken along the line 11--11;
FIG. 12 is a partial plan view of still another variation of the traction element illustrating a modified form of the traction member;
FIG. 13 is an enlarged view of an individual lug incorporated in the surface of the traction element of FIG. 12;
FIG. 14 is a plan view of still another variation of the traction element in which removable lug assemblies are incorporated;
FIG. 15 is a cross-sectional view of FIG. 14 taken along the line 15--15;
FIG. 16 is an enlarged perspective view showing a part of the lug assembly of FIGS. 14 and 15;
FIG. 17 is a perspective exploded view of an alternate removable lug assembly which may be employed in a manner similar to the application of the lug assembly of FIGS. 14-16;
FIG. 18 is a cross-sectional view of the lug assembly of FIG. 17 as attached to a traction member;
FIG. 19 is a partial perspective view of a device intended to be secured to one of the traction elements for use in holding the end of a fastening strap to prevent it from being thrown about as the wheel revolves;
FIG. 20 is a cross-sectional view of FIG. 19 taken along the line 20--20;
FIG. 21 is a cross-sectional view of FIG. 20 taken along the line 21--21;
FIG. 22 is a plan view of yet another variation of the traction member;
FIG. 23 is a cross-sectional view of FIG. 22 taken along the line 23--23; and
FIG. 24 is another plan view of the device of FIG. 22 as seen from the opposite side.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawing by characters of reference, FIGS. 1-4 disclose an improved wheel mountable traction device 10 comprising a plurality of traction elements 11 secured together in an endless chain by means of two belts 12 encircling the wheel of a vehicle.
As shown more cleary in FIG. 2, each of the traction elements 11 comprises a plastic body 13 molded in the form of an upper-case letter H with metal studs or lugs 14 mounted in a horizontal cross or traction member 15. The two upright members 16 of the H-shaped configuration, functioning as the fastening members 16, are arcuate in shape curving outwardly at their ends. As apparent from FIG. 1, the cross member 15 serving a traction function extends laterally across the surface of the wheel or tire, parallel with the axis of rotation of the wheel. The two fastening members 16 fold around the tire, bending in area 20 of FIG. 5 so that the arcuate portions of member 16 lie against the sidewalls of the tire, their arcuate contours matching the curvature of the sidewalls of the tire over which they are superimposed.
The traction member 15 is rectangular in shape with its edges 17 serrated to aid in providing traction in snow or on other slippery surfaces. A row of holes 18 is provided along the longitudinal centerline of member 15 in which the studs 14 are mounted. These studs may be mounted in one or more of the holes 18 as desired. As shown in FIG. 4, studs 14 may be formed of any suitable hardened metal or ceramics in the form of rivets 19 that are installed from the underside of the traction member 15 and extend beyond the outer surface 21 to make contact with the surface of a road. A retainer collar 22 is press-fitted over the protruding end of the rivet. Alternatively, rivet 19 and collar 22 may be replaced by a suitable screw and nut configuration, respectively. In either case, the protruding end of the rivet or screw is intended to dig into an icy road surface to provide traction.
As best illustrated in FIGS. 1, 2, 3 and 5, the fastening members 16 are provided with a plurality of slots 23 arranged like the rungs of a ladder along the curved portion of member 16. These slots are arranged to receive the flexible belts or straps 12, which are preferably formed of woven nylon. As best illustrated in FIG. 3, belt 12 is recessed within cavities 24 formed in the inner and outer surfaces of member 16 in the areas lying between slots 23. The belt is laced through the slots passing first under member 16, then over, then under etc. as it emerges from successive slots 23. The lacing of belt 12 progresses from each traction member 16 to the next until the total circumferential path around device 10 is completed. The two adjacent ends of belt 12 are then joined by means of a buckle, not shown in the drawing. As noted from FIGS. 1 and 2, two belts are employed, one around the inner side of the wheel of a vehicle and one around the outer side thereof.
Traction device 10 is applied in much the same manner as a conventional tire chain; however, since it is relatively light in weight compared to a metal chain, it may be much more easily installed than a chain. As the wheel on which it is mounted rolls along a road surface, lugs 14 cut into the ice surface and provide the desired traction.
In the variation of FIG. 6 a modified traction element 25 is provided. The bending area 26 is strengthened relative to area 20 of FIG. 5 through the utilization of slanted or cross-braced supports 26A and 26B. By virtue of the strengthened or stiffened support afforded the traction member 27, there will be less tendency for member 27 to be moved out of position under the forces applied to it by the power-driven wheel. A modified edge 28 is also employed in this case utilizing extending integral tabs 29 to afford traction in opposition to lateral motion of the wheel. Instead of a single row of holes, three rows of holes, 31, 32 and 33, are provided for the installation of studs 34. It should again be noted that these studs are not necessarily installed in all of the holes, 18, 31, 32 or 33. Under certain surface conditions the holes themselves are effective in providing traction.
Additional variations of the traction member are shown in FIGS. 7, 12 and 13. In FIG. 7 a flat studded open chain 35 is provided with traction afforded by studs 14 or 34 as well as by the outside edges 36 and by the central openings 37 of the chain 35. In FIGS. 12 and 13 the contours of the open chain are retained, but protruding integral plastic tabs 38 are substituted for the metal or ceramic studs.
FIGS. 8 and 9 illustrate the use of a cable clamp 39 as an alternate means for securing the traction elements to the wheel. The cable clamp 39 is formed by folding a square or rectangular sheet of metal or sturdy plastic back on itself leaving a loop 40 at the fold. The loop 40 provides a substantially cylindrical opening for a cord or cable. Clamps 39 are secured at both ends of traction member 41 by means of rivets 42 with the orientation of clamp 39 being arranged so that the axis of the cylindrical opening through loop 40 is perpendicular to the main axis of element 41. A metal backup plate 43 adds strength to the riveted attachment, the plate 43 being secured to the surface of member 41 opposite clamp 39 by the same rivets 42. In the use of clamp 39 to secure the traction members in position, the ends of the traction elements are again folded over the edge of the tire toward the sidewall of the tire so that loops 40 are in general alignment with the tire sidewalls. A sturdy cable or cord 45 is passed through loops 40 of the several traction elements to complete the assembly of a traction device similar to device 10 of FIG. 1. The two ends of cable 45 are then secured together by means of a cable clamp or other means (not shown) to complete the mounting of the device to the wheel of a vehicle.
FIGS. 10 and 11 illustrate yet another means for securing the traction elements to the wheel of a vehicle. At each end of traction member 46 a plurality of large-headed rivets 47 are installed. These rivets are passed through two reinforcing or back-up plates 48 with the two plates 48 being positioned opposite each other, one on the front and one on the rear surface of member 46. A cable or cord 49 is passed under the extending heads of rivets 47 on the outside surface of member 46 with the cable passing successively in a serpentine fashion under the heads of several of the rivets as shown in FIG. 10. The serpentine path of cable 49 through the formation of rivets causes the cable to wrap partially around each of the rivets thereby assuring a more secure attachment of the cable to the rivets. The ends of the traction members 46 again fold around the tire toward the sidewalls where they are securely held by cable 49 as described earlier in connection with the variation of FIGS. 8 and 9.
FIGS. 14--16 disclose another variation of the traction member wherein traction member 51 utilizes replaceable stud assemblies 52, 53 or 54. Each of the assemblies 52, 53 and 54 comprises a channel-shaped bracket 55 and a set of studs 56. The bracket 55 wraps around the back surface and around the leading and trailing edges of the traction member 51. Several holes 57 (two, three or five as shown, respectively in assemblies 52, 53 and 54) are provided in an appropriate pattern in bracket 55 to receive studs 56, each of which comprises a rivet 58 and a press-fit cap 59. The rivets 58 formed of any suitable metal or ceramics are passed through the brackets 55 from the rear or underside and then through aligned holes in the plastic body of traction member 51. The caps 59 are then installed over the protruding ends of rivets 58 to complete the mounting of assembly 52, 53 or 54 to member 51. The dimensions of brackets 55 and the number of studs 52 may be selected as appropriate for a wheel or tire of a given size. It should be noted that the bracket shown in FIGS. 14-16 may be molded in a surface of the traction member, if so desired.
FIGS. 17 and 18 illustrate a variation of the replaceable stud assembly just described. In the variation of FIGS. 17 and 18 a bracket 61 is equipped with a plurality of sets of posts 62 that are integrally formed with bracket 61. These posts are attached permanently to the bracket in the desired arrangement or pattern using some process such as welding or press-fitting. Bracket 61 is then mounted to traction member 60 by passing the posts through aligned holes in the traction member so that bracket 61 is again positioned on the under or rear side of traction member 60. Caps 63 are then secured over the protruding ends of posts 62. Press-fit or threaded screw attachments of caps 63 to posts 62 also may be employed.
When a belt is employed to secure the traction elements in place over the wheel or tire, the ends of the belts extending from the buckle or other fastener will fly around and become tattered and torn as the wheel turns unless the ends of the belts are secured by some means. FIGS. 19-21 illustrate a simple and convenient means for securing the end of the belts. This means comprises a plastic or metal clip 64 having a flat rectangular body 65 with two attachment posts 66 and a row of pointed projections 67 extending perpendicularly from one surface thereof. The posts 66 are passed through two appropriately spaced holes conveniently located on the fastening member 68 of the traction element and are secured therein by blunting the protruding ends of the posts or by some other suitable means. The loose end of belt 69 is passed under the body 65 of clip 64, between the surface of member 68 and the pointed projections 67, so that the projections 67 bite into the material of the belt 69 and hold it securely in place. One end of body 65 extends beyond the adjacent post 66 and past the edge of member 68 so that its extending end 71 may be raised by finger pressure to disengage belt 69 from projections 67 when it is desired to remove the traction device from the wheel. In a modified design or arrangement the projection 71 may be pressed against member 68 to cause the center of body 65 to be bowed upward as an alternate means for releasing belt 69.
As described in the copending application Ser. No. 130,583, now U.S. Pat. No. 4,280,544, traction may also be achieved by providing suction or vacuum pockets in the traction members. This approach is disclosed in the illustration of FIGS. 22-24 wherein the traction member 75 comprises a generally rectangular strip having scalloped edges 76. The outer surface 77 of the traction member that bears against the road surface is generally planar as shown in FIG. 24. The inner surface 78 as shown in FIG. 22 has formed therein a plurality of suction cavities 79 formed by the walls of the scalloped edges 76, a central longitudinal wall 80, end walls 81, and transverse intermediate walls 82. A plurality of spaced apart apertures 83 are formed in the plastic material and extend from the suction cavities 79 towards the planar outer surface 77 of the traction member 75. Recesses 84 are formed in outer surface 77 of traction member 75 in alignment with apertures 83. The recesses have a substantial diameter and extend to a depth of approximately one-half the thickness of the material between the outer surface and cavities 79. Continuing from the base of each of recesses 84 to the suction cavities 79 are apertures 83 of relatively small diameter. Thus, there is provided a continuing air passage between the outer face 77 of the traction member 75 and suction cavities 79. As the tire rolls along a road surface, traction members 75 contact the road surface, producing a vacuum and maintaining a suction within the suction cavities 79 which, through recesses 84 and apertures 83, provide a relatively high degree of traction between the traction members, the tire and the road surface.
While the embodiment of FIGS. 22-24 are shown to utilize fastening members 85 that are the same as members 16 of FIGS. 1-7, it will be recognized that the variations of FIGS. 8-11 may be applied here as well. It should also be noted that one or more studs or rows of studs may be attached to the traction member 75 thereby combining the benefits of studs 14, 34, 56 and 63 with the suction features of FIGS. 22-24.
An improved wheel mounted traction device is thus disclosed in accordance with the stated objects of the invention, and although but a few embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. | An improved wheel-mounted traction device comprising a plurality of molded plastic traction elements held in place about the periphery of a wheel or tire by belts or cables that engage the individual traction elements. Metal studs, integral plastic projections and suction cavities are disclosed as additional means for aiding in achieving improved traction results. | 1 |
FIELD OF THE INVENTION
The present invention relates to Optical Time Domain Reflectometers, and is directed more particularly to an improved method and apparatus for reducing coherence/polarization noise in such reflectometers.
BACKGROUND OF THE INVENTION
With the increasingly widespread use of fiberoptic cables as wideband data links, it has become increasingly important to have instruments which are able to accurately locate and measure the optical characteristics and parameters of such cables. Among these characteristics and parameters are characteristics such as attenuation, cutoff, and polarization, and parameters such as the length of the fiber, the location of the end of the fiber, and the numbers, magnitudes and locations of lossy features such as couplings, splices, and defects, among others. Instruments which are designed to perform such measurements are referred to as Optical Time Domain Reflectometers or, more commonly, OTDRs. An example of one type of OTDR is described in U.S. Pat. No. 4,794,249 (Beckmann et al). Examples of commercially available ones of such OTDRs are sold under the model designations TD-1000 and TD-3486 OTDRs by the Laser Precision Division of GN Nettest of Utica, N.Y.
The precision and accuracy of OTDR measurements can be affected by various noise sources. Some of these are purely electronic in nature and others are directly related to the production, transmission, reflection and detection of the optical signal. Among the most important types of noise that affect transmission through fiberoptic cables are background or "white" noise and coherence/polarization noise. Background noise is essentially random in character. This type of noise exists in all systems that include electronic circuitry and affects all pulses, without regard to the temporal duration or spectral width thereof. Because optical signals transmitted along fiberoptic cables decrease in amplitude with distance, they tend to become difficult to distinguish from this noise. OTDRs cope with this type of noise by basing final results on the average of the results of many individual measurements. This is because averaging is a process that tends to cancel out the randomly varying components of a signal such as background noise.
Coherence/polarization noise, on the other hand, is not random in character. It is caused by microscopic features in the optic fiber, such as impurities and variations in dopant concentration. Since such features are localized at fixed points along the fiber, they tend to have repeatable effects. The magnitude of this noise is not particularly troublesome for relatively long duration pulses, such as those with a temporal width significantly greater than the coherence time of the source. This is because such noise tends to become "washed out" over the course of a pulse. For relatively short duration pulses, such as those with a temporal width less than the coherence time, on the other hand, the effect is unable to "wash out" over the course of a pulse. Moreover, because the effect is coherent rather than random, it is less subject to being removed by averaging. Prior to the present invention, attempts to reduce the magnitude of coherence/polarization effects have made use of one of two approaches. One of these involves the use of hardware and software implemented filtering applied on a post sampling basis, i.e., on filters applied to signals after they have been both transmitted and received. A second of these approaches involves using lasers with larger than usual cavities, although this approach is effective in some but not all cases.
For the sake of brevity, the phrase "coherence/polarization noise" will hereinafter be abbreviated to "coherence noise".
Attempts to deal with coherence noise by means of the post processing of the received signal have not been entirely successful. This is because the filtering process used in this post processing often has the effect of filtering out weak but significant events. As a result, the filtering process can prevent the detection of the very features that the measurement is performed to detect and, what is worse, prevent such detection on an intermittent and unpredictable basis. It has recently become evident that the degree of this unpredictability can vary from laser to laser within or between manufacturing batches thereof, as well as from fiber to fiber.
In view of the foregoing it will be seen that, prior to the present invention, there has existed a need for a method and apparatus for reducing the effect of coherence noise in OTDRs, and for doing so in a manner that does not effect the stability and repeatability of measurements made with ODTRs.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention, it has been discovered that recently occurring increased difficulties with the coherence effect is caused, paradoxically, by recent improvements in the line widths and the stability of laser diodes. More particularly, it has been discovered that recently occurring increased difficulties with coherence noise are the result of improved quality and design of laser diodes, and in the resultant generation of optical pulses having fewer modes, increased uniformity, narrower spectral widths, and greater spectral stability. The paradoxical nature of these improvements is that, at least for relatively short optical pulses, these improvements increase the coherence component of the total noise to the point where it can no longer be effectively dealt with by the usual averaging and post sampling techniques.
In accordance with a second aspect of the present invention, it has been discovered that recently occurring difficulties with the coherence effect may be substantially reduced by controllably decreasing the spectral stability of the laser output pulses and/or by controllably modifying the phase relationships between the OTDR output pulses and the output pulses of the lasers. As will be explained more fully presently, this may be accomplished in a variety of different ways using control variables that may be any one (or more) of electrical, optical, electrooptical, thermal and thermoelectrical in nature.
In a first embodiment of the method of the invention, the spectral stability of the pulses transmitted by OTDRs is decreased by driving the lasers with a drive signal having a waveform that prevents the laser from rapidly settling into a stable operating state, characterized by a relatively small number of modes and relatively narrow spectral width. In other words, the operation of the laser is controllably destabilized so that optical components having randomly varying frequencies (or phase positions) are introduced into the output of the laser. Because of this destabilization or randomization, the coherence noise that is associated with laser output pulses that are "too good" becomes subject to elimination by conventional techniques such as averaging. As a result, there is less apparent noise in the measured output signal and, consequently, no need to apply the post sampling techniques (such as filtering) which have prior to the present invention, resulted in lost data. Thus, the first embodiment of the method of the invention, and the various apparatuses that enable that method to be put into practice, solves the coherence problems that have recently caused difficulties with the use of OTDRs.
In a second embodiment of the method of the invention, the spectral stability of the pulses transmitted by OTDRs is decreased by the step of redirecting or retroreflecting a portion of the laser output pulse back into the laser. This retroreflection so interferes with the lasing process on the optical level that the laser is again prevented from rapidly settling into an operating state characterized by a relatively small number of modes and a relatively narrow spectral width. For the reasons discussed earlier, this embodiment of the method of the invention also has the effect of introducing components having randomly varying frequencies or phase positions into the output of the laser. Thus, the second embodiment of the method of the invention, and the various apparatuses that enable that method to be put into practice, also solve the coherence problems that have recently caused difficulties with the use of OTDRs.
In a third embodiment of the method of the invention, the spectral content of pulses transmitted by OTDRs is increased by so modulating the phase of the laser output pulses, during or after their generation, that the optical pulses transmitted by an OTDR have a phase position that varies randomly as a function of time. The phase position of the laser output pulses may, for example, be modulated by commercially available optical phase modulators. Thus, for reasons similar to those discussed earlier herein, the third embodiment of the invention, and the various apparatuses that enable that method to be put into practice, also solve the coherence problems that have recently caused difficulties with the use of ODTRs.
In a fourth embodiment of the invention, the desired reduction in coherence noise is produced by thermal means. This may, for example, be accomplished by controllably changing the temperature of the laser and thereby decreasing the spectral stability thereof. This method of destabilizing the laser is broadly similar to the above described electrical destabilization, except that it operates on a very much longer time scale. Alternatively, this may be accomplished by controllably changing or modulating the phase relationship between the output pulses of the laser and the OTDR. This may, for example, be accomplished by controllably changing or modulating the temperature of a spool of fiber and thereby modulating the phase position of the OTDR output pulse by means of the thermal expansion effect. This method or reducing coherence noise is broadly similar to the above described third embodiment, except that it again operates on a very much longer time scale.
In view of the foregoing, it will be seen that, in its most general aspect, the method and apparatus of the present invention contemplates the use of a variety of different methods for controllably decreasing the spectral stability of optical pulses transmitted by OTDRs or modifying the spectral content or distribution. As will be apparent to those skilled in the art of OTDRs, all of these different methods have in common what will be referred to herein as the step of controllably destabilizing, randomizing or modifying the optical content of the laser which generates the desired OTDR output pulse, randomizing the pulse generated by the laser, or modifying the spectral content of a pulse generated by a laser that is operating normally. It will be understood that all such embodiments are within the contemplation of the present invention.
DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will be apparent from the following description and drawings, in which:
FIG. 1 is a block diagram of a first, laser modulating embodiment of an apparatus suitable for use in practicing the method of the invention;
FIGS. 1A and 1B are block diagrams of various exemplary devices that are suitable for use with the embodiment of FIG. 1;
FIG. 2 is a block diagram of a second, induced reflection embodiment of an apparatus suitable for use in practicing the method of the invention;
FIGS. 2A-2D are block diagrams of various exemplary devices that are suitable for use with the embodiment of FIG. 2;
FIG. 3 is a block diagram of a third, phase modulating embodiment of an apparatus suitable for use in practicing the method of the invention;
FIGS. 3A is a fragmentary block diagram of the embodiment of FIG. 3 that shows exemplary waveforms for signals associated therewith;
FIG. 4 is a block diagram of a fourth, thermally operated embodiment of an apparatus suitable for use in practicing the method of the invention;
FIGS. 4A-4C 4A-1, 4A-2 are fragmentary block diagrams of exemplary devices that are suitable for use with the embodiment of FIG. 4; and
FIG. 5 is a simplified representation of information of the type that may be displayed by the apparatuses shown in FIGS. 1-4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a block diagram of an OTDR 10 that is suitable for use in practicing a first, laser modulating embodiment of the method of the invention. Also shown in FIG. 1 is a fiberoptic cable C that may extend for hundreds of kilometers from the output coupling 12 of OTDR 10 to a receiver or other utilization device, not shown. Cable C will typically be made up of a plurality of component fiberoptic segments C1, C2 . . . CN which are joined together by optical connectors or splices S1, S2 . . . SN that are located at distance X1, X2 . . . XN, respectively, from output coupling 12. Fiberoptic features, such as breaks, chips, etc., that give rise to changes in backscatter or reflected light that can be detected by OTDR 10 are shown by black dots labelled D1, D2 . . . DN. As used herein, the term "event" will be understood to apply generically to changes inwardly propagating light caused by normal features, such as couplings or splices, and caused by abnormal features such as fiber defects.
Generally speaking, OTDR 10 includes one or more solid-state lasers, such as 15A and 15B, which operate at different respective nominal wavelengths preferably, but not necessarily, equal to 1310 and 1550 nm, respectively, when driven by respective outputs of a suitable laser driver circuit 20. The output of the driven one of lasers 15A and 15B is applied to cable C, via coupler 12, through a suitable wavelength division multiplexer (WDM) 25 and a coupler or splitter 30 which preferably, but not necessarily, has a 50/50 coupling ratio. In the embodiment of FIG. 1, WDM 25 functions as an optical OR device between lasers 15A and 15B and coupler 30. Coupler 30, on the other hand, serves as a bidirectional optical splitter, directing 50% of laser pulses received from WDM 25 to Cable C, and directing 50% of the light reflected back from features of cable C to a conventional photodetector device 35, such as an avalanche photodiode or PIN diode.
OTDR 10 of FIG. 1 also includes an amplifier 37, which is connected to a suitable A/D converter 40. If desired, a separate amplifier may be provided for use with each laser. As a result of these connections, A/D converter 40 will output, at output 43 thereof, a series of digital signals, each of which is a returned power level at a respective time period. These time periods may be regularly spaced and have a suitable sampling rate, such as 10-12 MHz. Each of these signals will have a multi-bit value indicative of the magnitude of the returned power level for the feature which gave rise thereto.
The first reflective event of a transmission will be the reflection, from OTDR coupling 12, of a tiny fraction of the light from an outgoing optical pulse. This allows the first reflective event to be used as a time reference pulse, shown as pulse R(12) in FIG. 5. The occurrence times of later occurring events, such as R(S1), R(S2), may then be measured with respect to event R(12), as shown by times T1 and T2 of FIG. 5. Since the speed of light in cable C is constant, times T1, T2, etc. may be used to determine the distances, from coupling 12, of the features that gave rise to these events, as shown by distances X1, X2, etc. of FIG. 1.
The overall operation of the above described OTDR components are preferably controlled by a suitable programmable control circuit, such as microprocessor 50 of FIG. 1, which operates in conjunction with a memory 55 that incudes both a program memory space and data memory space. Processor 50 and memory 55 are coupled to one another, and to laser driver 20 and AND converter 40, among others, via a suitable multiconductor bus 60. Also coupled to bus 60 are an I/O interface device through which a user may enter data or commands into OTDR 10, and a display 70 through which data, such as that shown in FIG. 4, may be presented to a user.
Because the structure and operation of the above-described portions of OTDR 10 are well known to those skilled in the art, they will not be described further herein. The portion of OTDR 10 which will now be described are those which modify the structure and operation of OTDR 10 in a manner which makes possible the practice of a first embodiment of the method and apparatus of the present invention.
As explained previously, the present invention contemplates the reduction of coherence noise by preventing the ODTR from applying to cable C optical signals which have a spectral content such that these signals give rise to excessive coherence noise, particularly for optical pulses that have widths that are relatively short compared to their coherence length. As also explained previously, the present invention accomplishes this by any one or more of controllably destabilizing, randomizing or reorganizing the spectral content of the laser which generates the desired OTDR output pulse, randomizing the pulse generated by the laser, or modifying the spectral content of a pulse generated by a laser that is operating normally.
Laser Modulating Embodiments of the Invention
In the embodiment of FIG. 1, the desired spectral destabilization is accomplished by destabilizing or randomizing the operation of lasers 15A and 15B by electrically powered means. This is preferably accomplished by including in OTDR 10 a driver control circuit 75 which is connected to provide laser driver circuit 20 with a modulating signal that causes the latter to drive the driven laser in a manner that prevents it from settling down into a stable steady state operating mode during the generation of a pulse. This modulating signal may, for example, be applied to laser driver 20 via a modulating input 77 which is specially provided for this purpose. It will be understood that it is unimportant for purposes of the invention whether this modulation is introduced by varying the supply voltage of the driver, the gain of the drive transistor, etc., so long as the effect of the modulating signal is to change the excitation of the laser as a function of time.
Examples of circuits that may be used as driver control circuit 75 are shown in FIGS. 1A and 1B. Turning first to the embodiment of FIG. 1A, the driver control circuit may take the form of a pulse generating circuit 79, such as a one-shot multivibrator, that drives modulating input 77 via a pulse shaping circuit 81. Examples of one set of shaped pulses that may be used for this purpose are shown adjacent to circuits 79 and 81, although the actual shapes of these are unimportant so long as they controllably destabilize the operation of the driven laser.
A second embodiment of a driver control circuit is shown in FIG. 1B. In the lafter embodiment, the driver control circuit again includes a suitable pulse generating circuit 79. Instead of a pulse shaping circuit of the type shown in FIG. 1A, however, it includes a pulse shaping circuit that comprises an AM pulse modulator 83, such as an AND gate one input of which is connected to a carrier signal generating oscillator 87. It therefore, produces the amplitude modulated drive waveform shown adjacent to modulator 83. An otherwise suitable frequency modulated (FM) modulator or a duty cycle modulator (e.g. a pulse width modulator) could also be used. Again, the important feature is the step of controllably destabilizing or chaoticizing the operation of the driven laser and not the particulars of the apparatus used to perform that step.
In practicing the embodiment of FIG. 1B, the pulse generating circuit and pulse modulating circuit may be replaced by a programmable pulse generating circuit which is adapted to generate a drive signal having a predetermined shape each time that it receives a command, (e.g. a pulse) from processor 50. Equivalently, processor may itself generate a signal of the desired shape, with the programmable pulse generating circuit being replaced by a simple drive or buffer amplifier. Once again it is the desired controllable laser destabilization and not the particulars of the circuitry which is important.
Retroreflective Embodiments of the Invention
Referring to FIG. 2, there is shown an OTDR 10-2 which is similar to OTDR 10 of FIG. 1, like functioning parts being similarly numbered, except that it uses a different method for changing the spectral content of the pulses output by the OTDR. In the embodiment of FIG. 2 the desired change in spectral content is produced by optically (rather than electrically) altering the operating condition of the lasers. More particularly, in the embodiment of FIG. 2, the method of altering the operating condition of the laser comprises the step of directing part of the light output by the laser back into the laser and thereby controllably changing the spectral content of the optical pulse output by the OTDR. For the sake of brevity this step will be referred to herein as the step of retroreflecting light produced by the laser.
The retroreflective embodiment of the invention may be realized by means of any of a plurality of different retroreflective structures. Any of these different structures may, in turn, be located at any of a plurality of different locations between the lasers and output coupling 12. In order to avoid the needless showing of all permutations and combinations of these retroreflective structures and locations, OTDR 10-2 of FIG. 2 has been shown with a reflective structure in each of a plurality of the different locations at which such a structure may be usefully positioned. In addition, FIGS. 2A-2D show exemplary ones of a plurality of different kinds of retroreflective structures. It will therefore be understood that, in spite of the fact that numerous retroreflector structures are showing in the OTDR of FIG. 2, only one such retroreflector (or one pair of such reflectors) will ordinarily be included for each of the lasers included therein. It will also be understood that any of the retroreflective structures shown in FIG. 2 may comprise any of the retroreflective structures shown in FIGS. 2A-2C.
Referring to FIG. 2, the various locations at which retroreflective structures may be usefully positioned include the following. First, they may be located in proximity to the outputs of lasers 15A and 15B or, more generally, between the outputs of those lasers and respective inputs of WDM 25, as shown by retroreflectors 100A1 and 100B1 of FIG. 2. In these locations, the retroreflectors direct laser light emitted by the lasers directly back into respective outputs thereof and thereby change the spectral content of the light reaching respective inputs of WDM 25. The advantage of this position is that it allows the spectral content of the outputs of lasers 15A and 15B to be set and adjusted independently.
Second, the retroreflective structures may be located in series with the main outputs of WDM 25 and/or coupler 30, as shown by reflectors 100C1 and 100C2 of FIG. 2. The advantages of these locations is that a single retroreflector may be used to modify the spectral content of light generated by both lasers. Ordinarily, but not necessarily, retroreflectors will be located either in the above described first or in the just described second positions, but not in both.
Third, the retroreflectors may be located at the ends of the secondary outputs of WDM 25 and/or coupler 30, as shown by reflectors 100D1 and 100D2 of FIG. 2. The advantages of these locations is that they produce less overall attenuation of the light transmitted between the lasers and output coupling 12. Ordinarily, but not necessarily, retroreflectors will be located in one of the above-described first and second positions, or in the just described third positions, but not in both.
Referring to FIGS. 2A-2D, there are shown a plurality of different retroreflector structures that are suitable for use with the embodiment of FIG. 2. FIG. 2A shows a retroreflector structure in which a predetermined axial misalignment of fibers CA1 and CA2 is used to cause a fraction, X, of forwardly transmitted light F to be reflected backwardly as reflected light R=F(1-X). FIG. 2B shows a retroreflector structure in which the desired reflection is produced by including, between two similar fibers CB1 and CB1', a different and mismatched fiber segment CB2. FIG. 2C shows a retroreflector structure in which the desired reflection is produced by including, between two similar fibers CC1 and CC1', a suitable Bragg diffraction grating G. FIG. 2D shows a retroreflector structure in which the desired reflection is produced by including, in series with a fiber D1, a coupler, such as a 50/50 coupler 101, the secondary output of which is terminated by a suitable reflector 102. If desired, suitable reflectors may be included at both outputs of coupler 101, as suggested by a reflector 104 shown in dotted lines in FIG. 2D. Other suitable reflective structures and arrangements will be apparent to those skilled in the art.
If desired, any of retroreflector embodiments 2A, 2C and 2D may be made mechanically or electrically adjustable in order to render the desired change in spectral content subject to manual or automatic (i.e., closed loop) control. In the case of the embodiments of FIGS. 2A and 2C, for example, the misalignment of the fibers or the orientation of the grating may be adjusted either mechanically or electrically. In the embodiment of FIG. 2D, the coupling ratio may be adjusted mechanically; alternatively, the degree of reflection provided by reflector 102 may be controlled by means of a liquid crystal or other controllably variable element of electrically controllable reflectivity.
Phase Modulating Embodiment of the Invention
Referring to FIG. 3, there is shown an OTDR 10-3 which is similar to OTDR 10 of FIG. 1, like functioning parts being similarly numbered, except that it uses a still different method for randomizing the pulses output by the OTDR. In the embodiment of FIG. 3 the desired coherence noise reduction is produced by modulating the phase of light passing through the OTDR. More particularly, in the embodiment of FIG. 3, a phase modulating signal is used to electrically vary the phase positions of the output pulses of the OTDR with respect to the output pulses of the lasers, thereby causing these outputs to be less subject to coherence effects. For the sake of clarity this step will be referred to herein as the step of phase modulating the light generated by the laser.
The electrical phase modulating embodiment of the invention may be realized by means of any of a plurality of different phase modulating structures. In the preferred embodiment, these phase modulating structures contemplate the introduction, in series with the main optical path through the OTDR, of a controllable phase modulating element, and the inclusion of a user or program controllable phase control signal generator for generating an electrical signal for controlling the modulating element in the desired manner. Together these elements perform the step of controllably varying the phase positions of the output pulses of the OTDR and thereby preventing those pulses from giving rise to coherence noise.
In the embodiment of FIG. 3, the phase modulating structure includes an optical phase modulator 110 which is connected in series between WDM 25 and coupler 30, and a phase control signal generator 120 which is connected between bus 60 and modulator 110. As in the case of the retroreflective structures of the embodiment of FIG. 2, the phase modulating structure of the embodiment of FIG. 3 may be located at other suitable points between the lasers and the output of the OTDR. Because these other locations will be apparent to those skilled in the art, they will not be shown or described in detail herein.
Referring to FIG. 3A, there is shown a phase modulating embodiment of the invention in which the phase modulator is an electrically operated phase modulator 110A that is modulated by an electrical signal generated by an electrical phase control signal generator 120A. Phase modulator 110A may comprise a phase modulator of any of a plurality of commercially available types such as, for example, those manufactured by UTP Corporation. Phase control signal generator 120A may comprise of any of a plurality of different pulse generating and shaping circuits, such as those described in connection with the embodiment of FIG. 1. Alternatively, phase signal generator 120A may be eliminated as a discrete circuit, with its function being served directly by microprocessor 50, via bus 60 and suitable amplifying or buffer circuits. It will be understood that all such variants are equivalents for purposes of the present invention.
In operation, the electrical phase modulator introduces, into the optical path between the laser and the OTDR output, a medium having phase retardant properties which vary as a function of electric field intensity. Accordingly, when this electric field is made to vary as a function of time, the phase retardant effect of this modulator will also vary as a function of time. In accordance with the present invention, the parameters of phase modulator and signal generator are selected so that the magnitude of this effect is large enough to change the spectral content of the OTDR output pulse sufficiently to substantially decrease the level of coherence noise in the system.
Thermally Modulated Embodiments of the Invention
Referring to FIG. 4, there is shown an OTDR 10-4 which is similar to OTDR 10 of FIG. 1, like functioning parts being similarly numbered, except that it uses yet another different method for randomizing or changing the spectral content of the light output by the OTDR. More particularly, in the embodiment of FIG. 4, a phase modulating signal is used to thermally or electrothermally destabilize the operation of the driven laser and/or to randomize the phase positions of the output of the OTDR. For the sake of clarity, these steps will be referred to herein generically as the step of thermally modulated the light generated by the OTDR.
In the preferred embodiment, the laser destabilizing variants of the thermally modulated embodiment of the invention, may take one or both of two forms. A first of these variants is based on the addition to OTDR 10 of a heat generating control circuit 90 and a pair of heat generating devices 92A and 92B as shown in FIG. 4. The latter are preferably located in thermal proximity to lasers 15A and 15B, respectively. This embodiment differs from the electrically modulated embodiments and 1B, firstly, in that the randomizing signal is a thermal randomizing signal, and secondly, that the randomizing signal is used to change the temperatures of the lasers rather than their excitation.
Examples of embodiments of circuits that may be used in practicing thermally induced destabilization of the lasers are shown in FIGS. 4A and 4B. In FIG. 4A, heat generating control circuit 90 comprises a pair of pulse generating circuits 90A and 90B that are able to controllably generate an output pulse having sufficient power to drive heat generating devices 92A and 92B, respectively, thereby vary the temperatures of lasers 15A and 15B, respectively. Since the frequency of the light emitted by a laser is a function of temperature in response to heat applied thereto, the effect of this method of destabilizing the lasers is generally similar to that shown in FIG. 1A, except that the time scale is more aptly expressed in seconds than microseconds. As will be apparent to those skilled in the art, the pulses generated by pulse generators 90A and 90B may have any of a variety of different shapes, including but not limited to those shown in FIGS. 1A and 1B.
Included with FIG. 4A are two specific examples of thermally based circuits that may be used in practicing the invention. A first of these, shown in FIG. 4A-1, includes a resistive heating element 93 which is driven by a variable conducting device 94, such as an FET. A second of these, shown in FIG. 4A-2, includes a thermoelectric heating and/or cooling device 96 which is driven by either a variable conducting or an on-off switching element 96. Other examples of circuits of this type will be apparent to those skilled in the art.
In addition to the above-described thermally based embodiments of the invention, it is also possible to produce an electrothermal embodiment thereof. More particularly, the present invention may be practiced by an embodiment in which the desired degree of destabilization of the laser is produced by raising the temperature of the lasers by controlling the current that laser driver 20 applies to the lasers. In FIG. 4 this embodiment might take the form of an OTDR that includes a heat generating control circuit 90 that is connected to laser driver circuit 20 via a conductor 97, but that does not include either of heat generators 92A and 92B. With this embodiment, the variation of the degree of self heating of the lasers by the modulation of their drive currents produces the desired change in their spectral content. An example of a heat generating control circuit that may be used for his purpose is shown in FIG. 4B as a programmable pulse generating circuit 99. This circuit may be used to generate a variety of modulated waveforms that are similar to those discussed in connection with FIG. 1B, except that they use a longer time scale. Because the structure and operation of such embodiments will be apparent to those skilled in the art, they will not be described in detail herein.
Referring to FIG. 4, there is shown an embodiment of the invention in which the phase of the output light of the OTDR is randomized by a phase modulator that is controlled by a thermal phase control signal rather than an electrical phase control signal. With this embodiment the desired phase modulation may be produced by a thermosensitive phase modulator 110 which is controlled by a heat generating control circuit 90 that may be of the type shown in FIG. 4C. Phase modulator 110 may comprise a spool of fiberoptic fiber several meters in length which is wound around a thermally conducting core. Heat generating control circuit 90 may include a heat generator circuit 125, such as one of those described earlier in connection with FIGS. 4A-1 and 4A-2, which is positioned within the thermally conducting core of the spool to transmit heat thereto. The amount of heat generated by heat generator 125 may be controlled by a suitable driver control circuit 130, similar to one of the pulse generating and shaping circuits described earlier in connection with FIGS. 1A and 1B, except for their use of a longer time scale. Other driver control circuits will be apparent to those skilled in the art.
In operation, the thermal phase modulator introduces, into the optical path between the laser and the OTDR output, a medium having phase retardant properties which vary as a function of temperature. Accordingly, when the temperature of this medium is made to vary as a function of time, the phase retardant effect of the fiber will also vary as a function of time. In accordance with the present invention, the parameters of the phase modulators and signal generators are selected so the magnitude of this effect is large enough to randomize the ODTR output pulse sufficiently to substantially decrease the level of coherence noise in the system.
SUMMARY
In view of the forgoing, it will be seen that in its positive aspect, the present invention contemplates both a variety of different methods for so changing the spectral content of the output of an OTDR that coherence noise is maintained within acceptable limits, and a variety of different apparatuses for practicing those methods. It will also be seen that, in its negative aspect, the present invention contemplates the elimination of previously used methods (such as post sampling filtering) for reducing the effect of coherence noise, and thereby increasing the signal-to-noise ratio of the OTDR. Accordingly, it will be seen that the method and apparatus of the invention represent significant advances in the field of OTDR measurements.
While the invention has been described with reference to a number of particular specific embodiments, it will be understood that the true spirit and scope of the invention should be determined only with reference to the following claims. | Apparatus (OTDR) for accurately locating and measuring the optical parameters and characteristics of fiberoptic cables which reduces the adverse effects of coherence noise without effecting the stability and repeatability of the acquired locating and measuring information. | 6 |
This application claims priority to Korean Patent application no. 10-2011-0108754 filed Oct. 24, 2011, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fabric dryer and a method of controlling the fabric dryer.
2. Description of the Related Art
Generally, a fabric dryer is an apparatus that dries wet clothes, bedclothes, etc. (hereinafter, referred to as ‘laundry’). The fabric dryer includes a drum receiving laundry and a motor for driving the drum, and a heater for supplying hot air into the drum. The fabric dryer supplies dry hot air heated by the heater into the drum holding laundry and rotates the drum to dry laundry.
Since a typical fabric dryer is configured to dry only wet laundry, when spots or other contaminants are found in wet laundry to be dried, a washing machine needs to be separately driven to remove the spots and the contaminants. Also, when the quantity of laundry having spots or other contaminants is small, it is inefficient to separately drive the washing machine to remove the spots or other contaminants in terms of time and cost.
SUMMARY OF THE INVENTION
Thus, an object of the present invention is to provide a fabric dryer and a method of controlling the fabric dryer, which can remove contaminants from laundry without operating a separate washing machine.
According to an aspect of the present invention, there is provided a fabric dryer including: a drum rotatably disposed and receiving laundry; a driving unit rotating the drum; a steam supply unit supplying steam into the drum; a radical supply unit for supplying radical into the drum; a contamination removal function selector for selecting a water-soluble contaminant or a fat-soluble contaminant; and a controller configured to control the steam supply unit to supply steam in response to selection of the water-soluble-contaminant by the contamination removal function selector, and control the radical supply unit to supply radical in response to selection of fat-soluble contaminant by the contamination removal function selector.
According to another aspect of the present invention, there is provided a method of controlling a fabric dryer, including: selecting a water-soluble contaminant or a fat-soluble contaminant through a contamination removal function selector; and removing the contaminant from laundry in a drum according to the selected contaminant, wherein steam is supplied into the drum when the selected contaminant is water-soluble, and radical is supplied into the drum when the selected contaminant is fat-soluble.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a perspective view illustrating a fabric dryer according to an embodiment of the present invention;
FIG. 2 is a view illustrating a control panel of FIG. 1 ;
FIG. 3 is a view illustrating a main configuration of a fabric dryer according to an embodiment of the present invention;
FIG. 4 is a flowchart illustrating a method of controlling a fabric dryer according to an embodiment of the present invention;
FIG. 5 is a view illustrating a control panel according to another embodiment of the present invention; and
FIG. 6 is a view illustrating a main configuration of a fabric dryer according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings. Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as being 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, the shapes and dimensions may be exaggerated for clarity, and the same reference numerals will be used throughout to designate the same or like components.
Hereinafter, exemplary embodiments of a fabric dryer according will be described in detail with reference to the accompanying drawings.
FIG. 1 is a perspective view illustrating a fabric dryer according to an embodiment of the present invention. FIG. 2 is a view illustrating a control panel of FIG. 1 . FIG. 3 is a view illustrating a main configuration of a fabric dryer according to an embodiment of the present invention.
Referring to FIG. 1 , the fabric dryer may include a cabinet 2 defining the exterior, a top cover 4 for covering the upper side of the cabinet 2 , and a control panel 10 disposed at a front upper side of the cabinet 2 .
A drum 8 may be rotatably disposed in the cabinet 2 to hold laundry. Also, a motor (not shown) for driving the drum 8 and a hot air supply unit 80 for supplying hot air or cool air into the drum 8 may be disposed in the cabinet 2 .
The hot air supply unit 80 may include a heater (not shown) and a blowing fan (not shown) for blowing air heated by the heater into the drum 8 .
A steam supply unit 60 may be disposed in the cabinet 2 to supply steam into the drum 8 . The steam supply unit 60 may supply steam generated by heating water into the drum 8 .
Also, a radical supply unit 70 may be disposed in the cabinet 2 to generate radical into the drum 8 . The radical supply unit 70 may include an air pumping unit (not shown), an ozone generating unit (not shown), and a molecular conversion unit (not shown). The air pumping unit (not shown) may supply air for generating ozone to the ozone generating unit, and the ozone generating unit (not shown) may generate ozone by applying a high voltage to supplied air or irradiating ultraviolet rays. The molecular conversion unit may react supplied ozone with a radical conversion catalyst to generate OH radical. The generated radical can sterilize bacteria or virus living in water or clothes through a strong and rapid oxidation process.
Referring to FIG. 2 , the control panel 10 may include a plurality of drying operation input unit 20 manipulated to select a dry operation condition and a contamination removal function selecting unit 40 for removing predetermined contaminants.
The plurality of drying operation input unit 20 may include a course selection dial 21 for selecting drying courses that are programmed and a plurality of selection buttons 22 for selecting detail drying operation condition other than the drying course. The plurality of selection buttons 22 may include a dry level button for selecting the degree of the drying, a temperature control button for selecting the temperature of hot air supplied upon drying, a drying time selection button for selecting the drying time, and a beep sound selection button for selecting a beep alarming a user.
Also, the control panel 10 may include a power button 12 and a pause button 14 for resuming the operation of each course or pausing the operation of each course
Also, the control panel 10 may include a display unit 30 for displaying the input conditions or the operation state of the fabric dryer.
The contamination removal function selecting unit 40 may be disposed at one side of the control panel 10 separately from the drying operation input unit 20 . The contamination removal function selecting unit 40 may include a plurality of contamination selecting units 43 and 44 such that a user can select one from predetermined contaminants. In this embodiment, the predetermined contaminants may include water-soluble contaminants, fat-soluble contaminants such as sebum, liquid contaminants, solid contaminants such as dust and soil.
The contamination removal function selecting unit 40 may be configured to select one from the plurality of contamination selecting units 43 and 44 according to the push number of one pushable button or the rotation angle of a rotatable dial. Alternatively, the plurality of contamination selection units 43 and 44 may include a corresponding button, respectively. When buttons are provided to the plurality of contamination selecting units 43 and 44 , respectively, two or more buttons can be selected.
The contamination removal function selecting unit 40 may include a contamination removal function selecting button 42 that is a push-type button. The plurality of contamination selecting units 43 and 44 may be selected according to the push number of the contamination removal function selecting button 42 . For example, when the contamination removal function selecting unit 40 is pushed once, the water-soluble contamination selecting unit 43 may be selected, and when the contamination removal function selecting unit 40 is pushed twice, the fat-soluble contamination selecting unit 44 may be selected.
Referring to FIGS. 2 and 3 , the plurality of contamination selecting units 43 and 44 may include the water-soluble contamination selecting unit 43 for removing water-soluble contaminants and the fat-soluble contamination selecting unit 44 for removing fat-soluble contaminants. In this embodiment, the plurality of contamination selecting units 43 and 44 are described as being divided into two kinds, but embodiments are not limited thereto. For example, the plurality of contamination selecting units may be divided into more kinds according to the kinds of contaminants, and may also be configured to select a combination of two or more contaminants.
The plurality of contamination selecting units may include entries corresponding to each contaminant and indicating lamps for indicating whether or the entries are selected. For example, when the contamination removal function selecting button 42 is pushed once, the water-soluble contamination selecting unit 43 may be selected and the indicating lamp corresponding to the water-soluble contamination selecting unit 43 may be lighted. Referring to FIG. 2 , although in the control panel 10 , the plurality of contamination selecting units are written in English, embodiments are not limited thereto. For example, the plurality of contamination selecting units may be written in other languages or symbols.
The fabric dryer may include a controller 50 for controlling the operation of the fabric dryer according to signals inputted into the control panel 10 .
When the drying operation input unit 20 and the contamination removal function selecting unit 40 are both selected, the controller 50 may control to perform the drying operation after a contamination removing course for removing contaminants.
The controller 50 may control the operation of the driving unit 9 , the steam supply unit 60 and the radical supply unit 70 according to signals inputted into the drying operation input unit 20 and the contamination removal function selecting unit 40 .
When the water-soluble contamination selecting unit 43 is selected, the controller 50 may control the operation of the steam supply unit 60 to supply steam to laundry in the drum 8 .
When the fat-soluble contamination selecting unit 44 is selected, the controller 50 may control the operation of the radical supply unit 70 to supply radical to laundry in the drum 8 .
FIG. 4 is a flowchart illustrating a method of controlling a fabric dryer according to an embodiment of the present invention. Hereinafter, the operation of the fabric dryer will be described with reference to FIG. 4 .
When a user intends to use the fabric dryer, the user may push the power button 12 , and then input a desired drying course using the course selecting dial 21 , or may input a desired drying operation condition using the plurality of selection buttons 22 .
When power is applied through the power button 12 , the controller 50 may check whether the contamination removal function is selected (S 1 ).
When a user finds contaminants from laundry during the drying of laundry or intends to remove contaminants of laundry using a fabric dryer instead of a separate washing machine, the user may use the contamination removal function of the fabric dryer.
When a user intends to use the contamination removal function of the fabric dryer, the user may manipulates the contamination removal function selecting button 42 . As described above, since the contamination removal function selecting button 42 is a push-type button, a user may push the contamination removal function selecting button 42 .
When a user pushes the contamination removal function selecting button 42 , a push signal may be inputted into the controller 50 . Then, the controller 50 may determine that the contamination removal function has been selected.
When the controller 50 determines that the contamination removal function has been selected, the controller 50 may determine whether or not the kind of contaminants is selected (S 2 and S 4 ). That is, after the contamination removal function selecting butting 42 is pushed, the controller 50 may wait such that the kind of contaminant can be selected within a predetermined duration.
When the controller 50 determines that the water-soluble contamination selecting unit 43 has been selected (S 2 ), the controller 50 may operate the steam supply unit 60 to supply steam to laundry in the drum 8 . As described above, while steam is being supplied to laundry in the drum 8 , the controller 50 may control the operation of the driving unit 9 to rotate the drum 8 . Also, the controller 50 may operate the hot air supply unit 80 to increase the temperature of laundry wetted by steam. As the temperature of wet laundry increases, the degradation of contaminants by water may be facilitated. Particularly, a user can process laundry with detergent, and then load laundry into the drum 8 . In this case, the activity of detergent can be improved through the hot air supply process, and thus the washing performance can be improved.
When the controller 50 determines that the fat-soluble contamination selecting unit 44 has been selected (S 4 ), the controller 50 may operate the radical supply unit 70 to supply radical to laundry in the drum 8 (S 5 ). Since fat-soluble contaminants such as sebum are difficult to remove, radical having good washing efficiency may be used to remove the contaminants. As described above, while radical is being supplied to laundry in the drum 8 , the controller 50 may control the operation of the driving unit 9 to rotate the drum 8 .
After the contamination removing course is completed, the controller 50 may perform a drying cycle according to conditions preset through the control panel 10 (S 6 ).
In this embodiment, since contaminants can be removed from the fabric dryer without operating a separate washing machine, convenience for use can be improved.
FIG. 5 is a view illustrating a control panel according to another embodiment of the present invention. FIG. 6 is a view illustrating a main configuration of a fabric dryer according to another embodiment of the present invention.
Referring to FIGS. 5 and 6 , a control panel 80 according to this embodiment may differ from the control panel 10 according to the previous embodiment in that the control panel 80 includes a plurality of course selecting units 121 , 122 and 123 , but other configurations and operations are similar to those of the previous embodiment, and thus a detail description thereof will be omitted below.
The plurality of course selecting units 121 , 122 and 123 may include a tumble course selecting unit 121 for tumbling laundry in a drum 8 by driving a driving unit 9 , a steam course selecting unit 122 for generating steam into the drum 8 by operating a steam supply unit 60 , and a radical course selecting unit 123 for generating radical into the drum 8 .
When one of the plurality of course selecting units 121 , 122 and 123 is selected, the selected contamination removing course may proceed.
When the tumble course selecting unit 121 is selected, a controller 50 may control the operation of the driving unit 9 to tumble laundry in the drum 8 .
When the steam course selecting unit 122 is selected, the controller 50 may control the operation of the steam supply unit 60 to supply steam to laundry in the drum 8 .
When the radical course selecting unit 123 is selected, the controller 50 may control the operation of a radical supply unit 70 to supply radical to laundry in the drum 8 .
Although the preferred embodiments of the invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Provided are a fabric dryer and a method of controlling the fabric dryer. The fabric dryer includes a drum, a driving unit, a steam supply unit, a radical supply unit, a contamination removal function selector, and a controller. The drum is rotatably disposed and receives laundry. The driver rotates the drum. The steam supply unit supplies steam into the drum. The radical supply unit supplies radical into the drum. The contamination removal function selector selects a water-soluble contaminant or a fat-soluble contaminant. The controller controls the steam supply unit to supply steam in response to selection of the water-soluble-contaminant by the contamination removal function selector, and controls the radical supply unit to supply radical in response to selection of fat-soluble contaminant by the contamination removal function selector. | 3 |
[0001] This is a divisional application of U.S. application Ser. No. 09/347,302.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a combined pronation and supination control plantar insert for shoes.
[0003] From a functional point of view, the foot behaves like a propeller whose blades are constituted by the hindfoot and the forefoot.
[0004] The rolling action of a step can be seen as consisting of three phases: a first contact phase, a second resting phase and a third propulsion phase.
[0005] During the first contact phase, the foot tends to pronate and therefore arrange itself inward; during the second resting phase, the foot stiffens and tends to supinate, so that the weight tends to shift toward the outer part of the foot; during the third propulsion phase, the foot is in a central position with a slight pronation in order to give impetus to the step.
[0006] All these movements of the foot can be considered equivalent to the motion of a propeller.
[0007] Therefore, depending on the motion of the blades, the foot relaxes and flattens or stiffens and therefore becomes hollow.
[0008] These two relaxation and stiffening phases are the two movements that occur alternatively in the foot during upright posture, running and jumping, and are known as pronation and supination respectively.
[0009] The deformities commonly known as flatfoot and hollow foot are due to predominant or persistent pronation (flatfoot) or supination (hollow foot).
[0010] Ready-made plantar inserts are commercially available in order to control the movement of the foot but they are usually scarcely useful.
[0011] Their use is often discretionary and can cause damage if said plantar inserts are incautiously worn by careless users.
[0012] Customizable plantar inserts manufactured by specialized technicians are an altogether different matter.
[0013] In this case, the final product is customized and perfectly matches the foot of the patient.
[0014] However, this requires the aid of labor-intensive techniques (plaster cast of the foot and creation of a complementary shape, assembly of different materials, refinement of the complementary shape according to the defect to be corrected, etcetera) and accordingly entails long production times.
[0015] Costs are high and it is impossible to modify the configuration of said plantar inserts if changes in the foot and/or in the structure of the bones, joints and muscles occur.
[0016] All these are only some of the main problems of this kind of plantar inserts.
[0017] It should also be noted that the bad posture of the feet does not affect only the bone, joint and muscle structures of said foot, causing various localized disorders; it also affects the entire supra- and subsegmental posture; accordingly, alterations can occur which affect not only the foot and the joints closest to it (talocrural joint, coxofemoral joint, knee joint) but also more distal articulations (interchondral joints, costovertebral joints, etcetera).
[0018] Many of the alterations affecting the cervical column and related symptoms, reaching as far as the temporomandibular joint with consequences for mastication, can in all likelihood originate from the incorrect static and dynamic posture of the foot.
SUMMARY OF THE INVENTION
[0019] The aim of the present invention is to solve the above-described problem, eliminating the drawbacks of the cited prior art and thus providing a plantar insert which allows to correct the main defects or problems of the foot.
[0020] Within the scope of the above aim, an important object is to provide a plantar insert which not only allows to compensate and correct flat feet and hollow feet by controlling and/or correcting pronation and supination but also allows this correction in a progressive and gradual form, so as to make it more acceptable to the patient and adapted for the current configuration of his bone, joint and muscle structures, said gradualness of the correction being more important during the developmental period.
[0021] Another important object is to provide a plantar insert which can be manufactured in a short time and can be equally applied to the various cases of correction of the cited defects, thus allowing accurate customization for any possible specific case.
[0022] Another object is to provide a plantar insert which has low manufacturing costs and can be customized in a short time to the specific defect to be corrected for a single and specific user.
[0023] This aim, these objects and others which will become apparent hereinafter are achieved by a combined pronation and supination control plantar insert for shoes, characterized in that it comprises posture control means adapted to correct and/or modify the posture of the entire tendon, bone and muscle structure of the body.
[0024] Advantageously, said means are constituted by one or more elements which can move on one or more adjustable planes arranged in a chosen point of the plantar insert.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Further characteristics and advantages of the invention will become apparent from the following detailed description of a particular but not exclusive embodiment, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
[0026] [0026]FIG. 1 is a first partially sectional lateral perspective view of the heel region of the plantar insert, on which the posture control means are associated;
[0027] [0027]FIG. 2 is a second side perspective view of the heel region;
[0028] [0028]FIGS. 3 and 4 are two side perspective views of the heel region without the sliding blocks;
[0029] [0029]FIG. 5 is a bottom view of the heel region of the plantar insert;
[0030] [0030]FIG. 6 is a top view of the heel region of the plantar insert;
[0031] [0031]FIG. 7 is a sectional view, taken along the plane VII-VII of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] With reference to the above figures, an example is given of a particular application of the posture control means for correcting and/or modifying the posture of the entire tendon, bone and muscle structure of the body by placing it in the heel region 1 ; as an alternative, said posture control means can be placed not only in the hindfoot but also in the midfoot or also in the forefoot or can be placed exclusively in the hindfoot or in the midfoot or in the forefoot.
[0033] In the illustrated solution, therefore, the plantar insert has, in the heel region 1 , posture control means which are adapted to correct and/or modify the posture of all of the bone and tendon structure of the body; this placement may be preferred for the problem of pronation and supination and therefore may be aimed at hollow or flat feet.
[0034] Said posture control means provide, at the heel region 1 , a rigid base 2 having a perimetric ridge 3 which forms two first lateral arc-like wings 4 a and 4 b blended, in a rear region, to a second wing 5 which has a concave upper surface 6 which is blended with the base 2 by way of a first wall 7 which is perpendicular thereto and lies on an axis which is approximately transverse with respect to the axis of the heel region 1 or is conveniently inclined with respect to it.
[0035] The first lateral wings 4 a and 4 b are instead blended, in a front region, with a pair of third wings 8 a and 8 b which blend with the base 2 , forming second walls 9 a and 9 b which are inclined with respect to an axis which runs transversely to the heel region 1 .
[0036] Both the first wall 7 and the second walls 9 a and 9 b have tips which protrude beyond the upper perimetric edge 10 a and 10 b of the first lateral wings 4 a and 4 b so as to form guiding seats for elements which can move with respect to the base 2 and can be adjusted; said elements are constituted by two sliding blocks 11 a and 11 b.
[0037] Each one of said blocks has an external lateral surface 12 a and 12 b which has a step-like discontinuity 13 a and 13 b which is shaped complementarily to the first lateral wings 4 a and 4 b , and the dimensions of the blocks are such as to allow them to slide between the first wall 7 and the second walls 9 a and 9 b of the second wing 5 and of the third wings 8 a and 8 b respectively.
[0038] Each block also has an internal lateral surface 14 a and 14 b which is shaped conveniently and therefore arc-like and is blended with the concave upper surface 6 of the second wing 5 so as to constitute supporting regions for the overlying part of the foot.
[0039] Adjustment of the position of the movable elements, and therefore the possibility to adjust them in terms of their position with respect to the base 2 , is provided by means of at least one pair of screws 15 a and 15 b which are freely rotatably associable at suitable seats formed transversely with respect to the first lateral wings 4 a and 4 b along axes, designated by the reference numerals 16 a and 16 b , which do not coincide with the axis that runs transversely to the heel region 1 .
[0040] The blocks slide with respect to the base 2 because the ends of the screws 15 a and 15 b are rotatably associable at complementarily threaded seats 17 a and 17 b formed at the facing external lateral surfaces 12 a and 12 b of the blocks 11 a and 11 b.
[0041] The simple adjustment of the position of the blocks with respect to the base 2 therefore allows to customize, according to the specific defect to be corrected and therefore to the specific anatomical shape of the user, the configuration of the plantar insert, varying the position of the blocks at the level of the hindfoot in the medial and lateral region, so as to control, for example, pronation and supination.
[0042] These adjustments are performed rapidly and easily.
[0043] It has thus been found that the invention has achieved the intended aim and objects, a combined pronation and supination control plantar insert having been obtained which allows to correct the main defects or problems affecting the position of the foot by varying the position of the movable elements with respect to the base of the plantar insert in the chosen region of the foot.
[0044] The invention is of course susceptible of numerous modifications and variations, all of which are within the scope of the same inventive concept.
[0045] Thus, for example, the posture control means adapted to correct and/or modify the posture of the entire tendon, bone and muscle structure of the body may be constituted not only by blocks but also by wedges, sliders or other equivalent means, and their position may be adjusted by virtue of means which are equivalent to the screws, allowing to use optional flexible interposed elements, such as springs or blocks made of plastics or other suitable material.
[0046] To spatially orientate the posture control means, a ball joint being positionable and lockable at various manners and locations, may be used.
[0047] Moreover, as an alternative, the wedge system may instead use a different system which allows the foot resting surface to tilt, and therefore be adjusted, in the various spatial planes by way of a spherical articulation (solid or hollow spherical segment) which inherently has many degrees of freedom.
[0048] The system can then be locked in a given position, compensating and/or correcting the configuration of the sole of the foot.
[0049] Likewise, said system can be an independent object which can be fitted in conventional shoes or in specifically provided shoes or can be an integral part of shoes designed specifically for this purpose and marketed as such.
[0050] The materials and the dimensions that constitute the individual components of the plantar insert and said elements may of course be the most pertinent according to specific requirements.
[0051] The disclosures in Italian Patent Application No. TV98A000101 from which this application claims priority are incorporated herein by reference. | A combined pronation and supination control plantar insert for shoes comprising posture control elements adapted to correct and/or modify the posture of the entire tendon, bone and muscle structure of the body, both laterally and medially and both for talipes equinus and for talipes calcaneus. The plantar insert allows to correct the main postural defects involving mastication, cervical structures, the spinal column, hips, ankles and feet. | 0 |
RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. Section 119(e) of U.S. Provisional Patent Application No. 60/402,661 filed Aug. 12, 2002.
FIELD OF THE INVENTION
[0002] The present invention includes assays useful for identifying inhibitors of Hepatitis C virus (HCV) activity. Particularly, the present invention includes a dual HCV assay useful for high throughput screening that quantifies both the amount of HCV RNA replication inhibitory activity associated with a test compound and the amount of cytotoxicity associated with the test compound. As such, an assay of the present invention permits the determination of both inhibitory activity associated with a test compound and selectivity of that test compound in a single well. The present invention also includes a reporter assay utilizing at least one enzyme associated with HCV RNA replication. The present invention also includes a cell line useful in assay of the present invention.
BACKGROUND OF THE INVENTION
[0003] Hepatitis C virus (HCV) is the major etiological agent of 90% of all cases of non-A, non-B hepatitis (Dymock, B. W. Emerging Drugs 6:13-42 (2001)). The incidence of HCV infection is becoming an increasingly severe public health concern with 2-15% individuals infected worldwide. While primary infection with HCV is often asymptomatic, most HCV infections progress to a chronic state that can persist for decades. Of those with chronic HCV infections, it is believed that about 20-50% will eventually develop chronic liver disease (e.g. cirrhosis) and 20-30% of these cases will lead to liver failure or liver cancer. As the current HCV-infected population ages, the morbidity and mortality associated with HCV are expected to triple.
[0004] Known treatments for HCV infection include the use of interferon-α (IFN), which indirectly effects HCV infection by stimulating the host antiviral response. IFN treatment is largely ineffective, however, as a sustained antiviral response is produced in less than 30% of treated patients. Further, IFN treatment induces an array of side effects of varying severity in upwards of 90% of patients (e.g. acute pancreatitis, depression, retinopathy, thyroiditis). Therapy with a combination of IFN and ribavirin has provided a slightly higher sustained response rate, but has not alleviated the IFN-induced side effects.
[0005] One research area of active interest includes the development of antiviral agents which inactivate virally encoded protein products essential for HCV viral replication. Examples of such agents include various tripeptide compounds, which act as selective HCV NS3 serine protease inhibitors. However, many of these compounds do not sufficiently inhibit HCV protease activity or do not have sufficient potency, and thus, may not provide optimal treatment of HCV-infected patients. Accordingly, there is an ongoing need for the development of HCV assays for the identification of agents effective for inactivating viral replication proteins.
[0006] Known cell-based assays for screening compounds for HCV inhibitory activity rely upon the detection of viral RNA replication using RT-PCR (Ito et al., Hepatology 34(3):566-572 (2001); Bartenschlager R. and V. Lohman, Antiviral Res. 52(1):1-17 (2001)). Such cell-based systems often yield variable results, making reproducibility a major problem and the use of such system for the screening of compounds impractical, particularly for use in high throughput screening (HTS). HCV assays which rely on the inhibition of viral enzymes essential for viral replication and which may be suitable for HTS are known (Bianchi et al., Analytical Biochemistry 237, 239-244 (1996); Taliani et al., Analytical Biochemistry 240, 60-67 (1996)), but such assays measure only in vitro activity.
[0007] Accordingly, there exists a need for an accurate and reproducible cell-based HCV assays which permits the screening of compounds for HCV replication inhibitory activity. The present invention is directed towards such assays.
SUMMARY OF THE INVENTION
[0008] The present invention includes a cell-based HCV assay which measures the inhibitory activity of compounds on HCV RNA replication. The present invention may include a dual assay useful for high throughput screening that quantifies both: (i) the amount of HCV RNA replication inhibitory activity associated with a test compound; and (ii) the amount of cytotoxicity associated with the test compound. Desirably, both steps are conducted in a single well. Assays of the present invention permit the determination of both the inhibitory activity as well as the selectivity of a test compound in a HTS.
[0009] In one aspect, the present invention includes an assay for identifying a compound that inhibits HCV RNA replication. The assay comprising the steps of: (a) providing a cell which expresses at least one enzyme associated with HCV RNA replication; (b) contacting the cell with a test compound; (c) determining whether the test compound inhibits HCV RNA replication; and (d) determining whether the test compound is cytotoxic to the cell. The cell expressing at least one enzyme associated with HCV RNA replication may include a HCV replicon which is a polynucleotide having the nucleic acid sequence set forth in SEQ ID NO:1 and encoding a polypeptide having the amino acid sequence set forth in SEQ ID NO:2. Further, the HCV replicon may be the molecular construct set forth in FIG. 1. A cell useful in the present invention has the ATTC Accession No. PTA-4583.
[0010] Both steps of an assay of the present invention are desirably conducted in a single well, or may be conducted in two or more wells. The enzyme associated with HCV RNA replication may be any enzyme associated with HCV RNA replication, and is desirably a protease, such as a serine protease. The serine protease is desirably NS3 protease. The protein may also be NS4A. The step of determining whether the test compound inhibits HCV RNA replication is desirably conducted by contacting the cell with a fluorescence substrate, and the step of determining whether the test compound is cytotoxic to the cell is desirably conducted by contacting the cell with an Alamar Blue solution.
[0011] The present invention also includes compounds and pharmaceutical compositions containing such compounds identified by the inventive assay. Further, the present invention includes a method for treating hepatitis-C by administering to a mammalian species in need thereof a therapeutically effective amount of such a compound.
[0012] In another aspect, the present invention includes an assay for identifying a compound that inhibits HCV RNA replication, which comprises the steps of: (a) providing a cell which expresses at least one enzyme associated with HCV RNA replication; (b) contacting the cell with a test compound; (c) contacting the cell with a compound which permits the determination of whether the test compound inhibits HCV RNA replication; and (d) contacting the cell with an indicator solution which permits the determination of whether the test compound is cytotoxic to the cell. The compound which permits the determination of whether the test compound inhibits HCV RNA replication is desirably a FRET peptide, and the indicator solution which permits the determination of whether the test compound is cytotoxic to the cell is desirably an Alamar Blue solution.
[0013] In another aspect, the present invention includes an assay for identifying a compound that inhibits HCV RNA replication. The assay comprises the steps of: (a) providing a cell which expresses at least one enzyme associated with HCV RNA replication, the cell comprising a HCV replicon; (b) contacting the cell with a test compound; (c) contacting the cell with a FRET peptide for determining whether the test compound inhibits HCV RNA replication; and (d) contacting the cell with an indicator solution for determining whether the test compound is cytotoxic to the cell.
[0014] In another aspect, the present invention includes a reporter assay for identifying a compound that modulates that activity of a gene of interest. The reporter assay, comprises the steps of: (a) providing an expression system, the expression system comprising (i) a cell and (ii) a construct comprising a promoter region associated with said gene of interest operably linked to an enzyme associated with HCV RNA replication; (b) contacting the expression system with a test compound; and (c) contacting the expression system with a compound capable of detecting expression of the enzyme associated with HCV RNA replication. The enzyme associated with HCV RNA replication is desirably NS3 protease, and the compound capable of detecting expression of the enzyme associated with HCV RNA replication is desirably a FRET peptide.
[0015] In another aspect, the present invention includes a cell having ATCC Accession No. PTA-4583.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 shows the molecular construct of the HCV Replicon used in an assay of the present invention.
[0017] [0017]FIG. 2 shows the nucleic acid sequence of the HCV Replicon used in an assay of the present invention.
[0018] [0018]FIG. 3 shows the amino acid sequence of the HCV Replicon used in an assay of the present invention.
[0019] [0019]FIG. 4 shows the 96-well layout used in an assay of the present invention.
[0020] [0020]FIG. 5 shows the results of Interferon Titration in the HCV Replicon cell line used in an assay of the present invention.
[0021] [0021]FIG. 6A shows an EC50 comparison of typical values determined by FRET, RT-PCR or Western analysis for titration of interferon in the HCV replicon cell line.
[0022] [0022]FIG. 6B shows a Western immunoblot using an anti-NS3 protease serum for the determination of EC 50 of IFN-α.
[0023] [0023]FIG. 7A shows the enzyme activity in each well after contact with test compounds.
[0024] [0024]FIG. 7B shows the cytotoxicity activity in each well after contact with test compounds.
[0025] [0025]FIG. 8 shows a graphical representation of the variation within an assay of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention includes a cell-based HCV assay for measuring the ability of compounds to inhibit HCV RNA replication. An assay of the present invention desirably include a first cytotoxicity assay step which measures the conversion of an indicator solution to a fluorescent product, to determine if a test compound is cytotoxic to a cell; and a second inhibition assay step, to determine if the test compound inhibits HCV RNA replication. Desirably, an assay of the present invention includes the use of cells transfected with a HCV replicon.
[0027] The ability of the HCV replicon to replicate is highly dependent on the amounts or activity of host cell factors. Therefore, any slight toxicity may have significant effects on viral protein expression and ultimately on any assay which examines the effect of compounds on HCV replication. As such, the use of an indicator to assess cytotoxicity in an HCV replicon cell line in an assay of the present invention provides a significant advantage in the ability to address the issue of whether HCV inhibition is due to a specific compound-virus interaction or due to a subtle but toxic effect on the cellular replication machinery.
[0028] Accordingly, the present invention includes a dual assay useful for HTS that quantifies both the amount of HCV RNA replication inhibitory activity associated with a test compound, and the amount of cytotoxicity associated with that test compound. The dual assay is desirably conducted in a single well. Assays of the present invention permit for the mass screening of compounds specifically directed towards HCV replication, and permit viral RNA as well as viral proteins to be produced at levels consistently detectable using standard immunological and molecular biology methods. These consistent levels are amendable for HTS of compounds specific for the HCV replicon since effects either toxic to the cell or specific to the replicon can be differentiated and quantitated.
[0029] In an assay of the present invention, a first cytotoxicity assay step measures the conversion of an Alamar Blue solution to a fluorescent product while a second inhibition assay step that uses a fluorescence resonance energy transfer (FRET) protease substrate specifically measures the amount of HCV NS3 protease activity present and relates that activity to HCV RNA amounts. The first cytotoxicity assay step permits the determination of selectivity of the test compound under consideration for the cells in the assay. The use of Alamar Blue solution permits the assay steps to be run in the same well, as the Alamar Blue solution is non-lethal to the cells. An assay of the present invention has been validated and compared with quantitative reverse-transcriptase polymerase chain reaction (qRT-PCR) and western blot analysis using interferon-α, a known HCV inhibitor. An assay of the present invention yielded fifty-percent effective concentration (EC50) values of 1.9, 2.9 and 5.3 units for the western, FRET and qRT-PCR assays, respectively. Assays of the present invention are amenable for HTS to identify compounds which inhibit HCV RNA replication, providing a convenient and economical assay comparable to qRT-PCR.
[0030] HCV is a plus (+) strand RNA virus which is well characterized, having a length of approximately 9.6 kb and a single, long open reading frame (ORF) encoding an approximately 3000-amino acid polyprotein (Lohman et al., Science 285:110-113 (1999), expressly incorporated by reference in its entirety). The ORF is flanked at the 5′ end by a nontranslated region that functions as an internal ribosome entry site (IRES) and at the 3′ end by a highly conserved sequence essential for genome replication (Lohman, supra). The structural proteins are in the NH 2 -terminal region of the polyprotein and the nonstructural proteins (NS) 2 to 5B in the remainder.
[0031] In an assay of the present invention, a HCV replicon was used in a cell culture system and was made as set forth below in Materials and Methods. The HCV replicon was based on a full-length consensus genome cloned from viral RNA isolated from an infected human liver. As shown in the molecular construct set forth in FIG. 1, a HCV replicon useful in an assay of the present invention includes a neomycin (neo) selectable marker protein translated from the native HCV internal ribosome entry site (IRES) element and non-structural proteins translated by the IRES from encephalomyocarditis virus (Lohman, supra). The known viral specific enzymatic activities provided by the replicon include the protease (NS3) and activator of the protease (NS4A), helicase (NS3), ATPase (NS3) and RNA dependent RNA polymersase (NS5B). Expression of neo is solely dependent on active HCV RNA replication in cells, and the viral gene products NS3 to NS5B are believed to be essential for HCV RNA replication and are the primary targets for inhibitor identification. For purposes of the present invention, viral gene products which are “associated” with HCV RNA replication include any and all viral gene products believed to be essential for HCV RNA replication.
[0032] Methods used to quantitate HCV can be applied to the replicon and include quantitative RT-PCR (qRT-PCR) for RNA levels and immunological methods for proteins such as ELISA (Rodriguez-Lopez et. al., J. Gen. Virol. 80:727-738 (1999), expressly incorporated by reference in its entirety) or Western analysis (Pietschmann et al., J. Virol. 75:1253-1264 (2001), expressly incorporated by reference in its entirety).
[0033] An assay of the present invention consists of two parts. The first part is a cytotoxicity assay step which quantitates the amount of cytotoxicity associated with a test compound, as determined by the conversion of Alamar Blue dye. The second part is an inhibition assay step which quantitates the amount of NS3 protease activity associated with the test compound. Both measurements are then compared relative to control wells. This method provides a measure of cytotoxicity for each well and an indirect measure of HCV RNA levels. Inhibition of HCV RNA replication is expected to reduce the amount of viral proteins present, including NS3 protease. As such, inhibitory activity of test compounds on HCV RNA replication is indirectly measured by quantitating NS3 protease levels using a FRET assay. The results obtained with the FRET assay have been shown to be comparable to those obtained from qRT-PCR.
[0034] The following section sets forth materials and methods used in the present invention, and which were utilized in the Example set forth hereinbelow.
Materials and Methods
[0035] 1. HCV Replicon Cell Line Preparation
[0036] The HCV replicon cell line was isolated from colonies as described by Lohman et al. al. (Lohman, supra) and used for all experiments. The HCV replicon has the nucleic acid sequence set forth in FIG. 2 (EMBL Accession No.: AJ242652; SEQ ID NO:1), the coding sequence of which is from 1801 nt-7758 nt. The coding sequence encodes the polypeptide having the sequence set forth in FIG. 3 (SEQ ID NO:2).
[0037] The cell line used in the present invention has been deposited as ATCC Accession No. PTA-4583 in the American Type Culture Collection, 10801 University Boulevard, Manassas, Va. 20110-2209 U.S.A. under the terms of the Budapest Treaty on the International Recognition of Deposits of Microorganisms for Purposes of Patent Procedure and the Regulations promulgated under this Treaty. Samples of the deposited material are and will be available to industrial property offices and other persons legally entitled to receive them under the terms of the Treaty and Regulations and otherwise in compliance with the patent laws and regulations of the United States of America and all other nations or international organizations in which this application, or an application claiming priority of this application, is filed or in which any patent granted on any such application is granted.
[0038] The coding sequence of the published HCV replicon was synthesized by Operon Technologies, Inc. (Alameda, Calif.), and the full-length replicon was then assembled in plasmid pGem9zf(+) (Promega) using standard molecular biology techniques. The replicon consists of (i) the HCV 5′ UTR fused to the first 12 amino acids of the capsid protein, (ii) the neomycin phosphotransferase gene (neo), (iii) the IRES from encephalomyocarditis virus (EMCV), and (iv) HCV NS3 to NS5B genes and the HCV3′ UTR. Plasmid DNAs were linearized with ScaI and RNA transcripts were synthesized in vitro using the T7 MegaScript transcription kit (Ambion) according to manufacturer's directions.
[0039] To generate cell lines, 4×10 6 Huh-7 cells (kindly provided by R. Bartenschlager and available from Health Science Research Resources Bank, Japan Health Sciences Foundation) were electroporated (GenePulser System, Bio-Rad) with 10 ug of RNA transcript and plated into 100-mm dishes. After 24 h, selective media containing 1.0 mg/ml G418 was added and media was changed every 3 to 5 days. Approximately 4 weeks after electroporation, small colonies were visible which were isolated and expanded for further analysis. These cell lines were maintained at 37° C., 5% CO 2 , 100% relative humidity in DMEM (Life Technologies #11965-084) with 110% heat inactivated calf serum (Sigma #F-2442), 100 U/ml of penicillin/streptomycin (Life Technologies #15140-122), Geneticin at 1 mg/ml (Life Technologies #10131-027). One of the cell lines which had approximately 3,000 copies of HCV replicon RNA/cell was used for development of the assay.
[0040] Other HCV replicons, as well as different genotypes, are suitable for use in assays of the present invention, and it is to be understood that assays of the present invention are not limited to any particular HCV replicon or cell line created therefrom. For example, in addition to the HCV replicon described above, HCV replicons suitable for use in assays of the present invention include, but are not limited to, those available from Apath, LLC. Also, it is understood that modifications of such HCV replicons may be made such that the replicon is useful in assays of the present invention.
[0041] 2. RNA Detection
[0042] HCV RNA detection was conducted using RT-PCR, according to the manufacturer's instructions, using a Gibco-BRL Platinum Quantitative RT-PCR Thermoscript One-Step Kit on a Perkin-Elmer ABI Prism Model 7700 sequence detector. The primers for TaqMan were selected for use following analysis of RNA sequences with Primer Express Software from ABI. Primers used for detection of the plus strand RNA were 131F-5′ GGGAGAGCCATAGTGGTCTGC 3′ (SEQ ID NO:3) and 231R-5′ CCCAAATCTCCAGGCATTGA 3′ (SEQ ID NO:4) which amplify the HCV 5′UTR from nucleotides 131 to 231. The probe used for detection, 5′ FAM-CGGAATTGCCAGGACGACCGG-BHQ1 3′ (SEQ ID NO:5) was obtained from Biosearch Technologies. RNA's were purified from 96-wells using the RNAeasy 96 kit from Qiagen.
[0043] 3. Western Analysis
[0044] Experiments were done in duplicate. Western analysis was performed according to the instructions for Amershams Chemiluminescence Immunology Kit (NEL105 Renaissance) using a Molecular Dynamics Storm 860 phosphoimager and associated software. The primary and secondary antibody dilutions were at 1 to 5,000. Antisera was generated by immunizing rabbits with purified NS3 protease made from an E. Coli expression vector encoding the first 181 amino acids of HCV 1a NS3 with subsequent boosts.
[0045] Bleeds were tested weekly and boosts continued until a positive signal on a control western was seen. Secondary antibody was a BioRad (#170-6515) Goat anti-Rabbit IgG HRP Conjugate. The protein samples for western analysis were from the same wells used for the FRET assay and were prepared by the addition of an equal volume of 2×SDS-PAGE buffer to the FRET assay mixture, heating and loading on a 10% gel for SDS-PAGE. Interferon alpha (IFN-α) was obtained from Sigma (#I-4276) and stored as recommended.
[0046] 4. FRET Assay Preparation
[0047] To perform the HCV FRET screening assay, 96-well cell culture plates were used. The FRET peptide (Anaspec, Inc.) (Taliani et al. Anal. Biochem. 240:60-67 (1996), expressly incorporated by reference in its entirety) contains a fluorescence donor, EDANS, near one end of the peptide and an acceptor, DABCYL, near the other end. The fluorescence of the peptide is quenched by intramolecular resonance energy transfer (RET) between the donor and the acceptor, but as the NS3 protease cleaves the peptide the products are released from RET quenching and the fluorescence of the donor becomes apparent.
[0048] The assay reagent was made as follows: 5×cell Luciferase cell culture lysis reagent from Promega (#E153A) diluted to 1× with dH 2 O, NaCl added to 150 mM final, the FRET peptide diluted to 20 uM final from a 2 mM stock. Cells were trypsinized, placed into each well of a 96-well plate and allowed to attach overnight. The next day, the test compounds were added to columns 1 through 10; column 11 was media only, and column 12 contained a titration of interferon as a control (1000 units for A12, B12, 100 units for C12, D12, 10 units for E12, F12 and 1 unit for G12, H12). In addition, replicon cells in A12, B12 can be replaced, if desired, with naïve Huh-7 cells as a negative background control. The plates were then placed back in the incubator. FIG. 4 shows the layout for HTS of the replicon cell line in a 96-well plate. In FIG. 4, labels are as followed: “Screen” denotes wells with test compound; “1-HCV” denotes control replicon wells (100% activity), “Inhibited” denotes wells containing the highest amount of control inhibitor (100% inhibition), and was used to determine background for each plate; “Titration” denotes the titration of interferon, and was used as a sensitivity control. Units of interferon from the top of row 12 in duplicate are 1000, 100, 10, and 1.
[0049] 5. FRET Assay and Cytotoxicity Assay Steps
[0050] Subsequent to addition of the test compounds described above (FRET Assay Preparation), at various times the plate was removed and Alamar Blue solution (Trek Diagnostics, #00-100) was added per well as a measure of cellular toxicity. After reading in a Cytoflour 4000 instrument (PE Biosystems), plates were rinsed with PBS and then used for FRET assay by the addition of 30 ul of the FRET peptide assay reagent described above (FRET Assay Preparation) per well. The plate was then placed into the Cytoflour 4000 instrument which had been set to 340 excite/490 emission, automatic mode for 20 cycles and the plate read in a kinetic mode. Typically, the signal to noise using an endpoint analysis after the reads was at least three-fold.
[0051] Compound analysis was determined by quantification of the relative HCV replicon inhibition and the relative cytotoxicity values. To calculate cytoxicity values, the average Alamar Blue fluorescence signals from the control wells in row 11 (FIG. 4) were set as 100% non-toxic. The individual signals in each of the compound test wells were then divided by the average control signal and multiplied by 100% to determine percent cytotoxicity. To calculate the HCV replicon inhibition values, an average background value FRET signal was obtained from the two wells containing the highest amount of interferon at the end of the assay period. These numbers were similar to those obtained from naïve Huh-7 cells.
[0052] The background numbers were then subtracted from the average FRET signal obtained from the control wells in row 11 (FIG. 4) and this number was used as 100% activity. The individual signals in each of the compound test wells were then divided by the averaged control values after background subtraction and multiplied by 100% to determine percent activity. EC 50 values for an interferon titration were calculated as the concentration which caused a 50% reduction in HCV RNA, HCV protein amounts or FRET activity. The two numbers generated for the compound plate, percent cytoxicity and percent activity were used to determine compounds of interest for further analysis.
[0053] 6. Calculation of Assay Variation
[0054] The following formula was used to calculate the variation in the FRET assay. Z′ is a measure of the distance between the standard deviations for the signal versus the noise of the assay:
Z′= 1−((3* asds+ 3* asdb )/( as−ab ))
[0055] Asds=standard deviation of the signal
[0056] Asdb=standard deviation of the background
[0057] As=average signal
[0058] Ab=average background signal
[0059] (Zhang et al., J. Biomolecular Screening (4) 2:67-73 (1999), expressly incorporated by reference in its entirety).
EXAMPLE
[0060] An assay of the present invention was prepared and conducted in the manner set forth above in Materials and Methods. The HTS assay was designed to indirectly measure RNA levels through the use of a specific NS3 protease fluorescence substrate which yields a fluorescent signal upon cleavage. To ensure that the NS3 protease substrate could only be cleaved by the NS3 protease and not by any cellular proteases present in the replicon cell lysates, the substrate was added to individual wells containing crude lysates made from either naive Huh-7 cells, HepG-2 cells or HeLa cells. The substrate was found to only yield a substantial increase in fluorescence in cells containing either the HCV replicon or in cells expressing the NS3 enzyme, indicating that the assay was specific for HCV protease.
[0061] Prior to the FRET assay step, a solution of Alamar Blue was added to the same plates in a cytotoxicity assay step, allowing direct quantification of the level of toxicity in that well. Only compounds which show no apparent toxicity but significantly decrease the amount of NS3 protease activity were further analyzed for HCV inhibitory activity.
[0062] In order to validate the FRET assay for HTS, the relationship between viral RNA levels and the amount of NS3 activity present was quantitated. One consideration of using the NS3 protease as a general indicator of RNA levels is that the t 1/2 life of the RNA compared to the protein may be substantially different (Lohman, supra). This could result in a substantial drop in RNA levels rather quickly compared to protein amounts. To compensate for this difference, the cells were exposed to interferon alpha (IFN-α), a known HCV inhibitor (Lauer G. M. and B. D. Walker, N. Engl. J. Med. 345(1):41-52 (2001); Blight et al., Science, 290:1972-1974 (2000); Collier J. and R. Chapman, BioDrugs, 15(4):225-238 (2001), each of which is expressly incorporated by reference in its entirety), for a period of days, allowing the cells to magnify the effect and let the amount of NS3 present decrease relative to controls.
[0063] The validation of the assay was accomplished by the use of quantitative RT-PCR (qRT-PCR) for viral RNA levels, quantification of the amount of NS3 present by scanning of a Western blot for protein levels and measurement of NS3 protease activity using the FRET assay. The samples for these measurements were from 2 plates prepared the same day and treated at the same time with a titration of IFN-α. One plate was used for preparation of RNA for quantitative RT-PCR while the other plate was used for FRET. Samples from the same wells after the FRET assay were used for Western analysis. Compound plates were then used to ensure that the procedure was applicable under conditions of HTS.
[0064] The results of a FRET assay with IFN-α titration following 96 hours of incubation are shown in FIG. 5 as a continuous kinetic graph. FIG. 5 shows the measurement of the increase in fluorescence of the HCV FRET peptide in the HCV cell line and the effect of exposure to various interferon concentrations. The units per ml of IFN-α used for the different wells are listed to the right of the pertinent graphs. The assay is linear over a period of 40 minutes. As seen in FIG. 5, in the absence of IFN-α, the FRET signal is increased with time and is linear for at least 30 minutes. A decrease in the rate of FRET activity is clearly evident in the graph with increasing IFN-α concentration. The titration was from 0.1 units to 1,000 units per milliliter with control wells containing IFN-α dilution buffer only.
[0065] Calculations involved subtracting the final background fluorescence signal while using the control wells as 100% activity. These numbers from the linear range are required for determination of the IFN-α EC 50 . Similarly, RNA levels were measured by qRT-PCR while the amount of NS3 protein present in each well was quantitated by scanning a Western immunoblot. An EC 50 was determined for all three methods by normalizing to the controls for each measurement. FIG. 6A shows a comparison of typical values determined by FRET, RT-PCR or scanning of a western blot for titration of interferon in the HCV replicon cell line, and also shows values for quantification of NS3 protease specific bands (FIG. 6B) by phosphorimaging. Each value in FIG. 6A represents a well of a 96-well plate at a single interferon concentration relative to a control value. Data at the lowest concentration of interferon tended to contain more variation. FIG. 6B shows the Western immunoblot using an anti-NS3 protease serum for the determination of EC 50 of IFN-α.
[0066] The results shown in FIG. 6A indicate EC 50 values (in units of IFN-α per milliliter) of 1.9 for the Western, 2.9 for the FRET and 5.3 for RT-PCR. These values are within 3-fold of one another and indicate equivalency between the assay methods. This demonstrates the utility of the FRET assay method for inhibitor titration in an assay of the present invention and provides a comparison of a HTS format to the conventional qRT-PCR method of HCV quantification.
[0067] A random compound plate was used in a method test of both the Alamar Blue assay and the FRET HCV replicon assay steps. The results are presented in FIGS. 7A and 7B for both the FRET and Alamar Blue assay as diagrammed in FIG. 4. FIG. 7A shows the percentage of activity in each well following FRET readings and performing the calculations described above for the endpoint reading from cycle 21 of the FRET assay. In FIG. 7A, lower numbers represent less activity present and indicate that the HCV replicon is inhibited. Wells F2 and G5 (underlined and enlarged) indicate that the compounds present in these wells inhibited the HCV replicon approximately 73% and 99% respectively.
[0068] [0068]FIG. 7B shows Alamar Blue readings from the random compound plate expressed as a measure of cytoxicity. Wells corresponding to F2 and G5 (underlined and enlarged) indicate that compound present in F2 shows very little toxicity while compound in G5 has substantial toxicity. Comparing the results of the FRET assay with the Alamar assay it is likely that the inhibition of the HCV replicon for G5 is due to a toxic mechanism while the inhibition due to compound in F2 is not toxic in this assay, suggesting the compound may be specific for HCV.
[0069] In general, the majority of compounds did not cause a significant variation in either the FRET or Alamar Blue assay indicating acceptable results amenable to HTS. The FRET activity yielded a 12.7% standard deviation in wells containing control media (FIG. 7A, column 11). In the IFN-α control samples, a clear inhibition was observed, the EC 50 was close to or slightly lower than the lowest concentration of IFN-α used (FIG. 7A, column 11). The Alamar Blue measurements in this plate yielded a variation of 4% for the cytotoxicity measurements in wells containing control media (FIG. 7B, column 11). Approximately 18% cytotoxicity was observed in the wells with the highest concentration of IFN-α (1000 units, FIG. 7B, columns A12 and B12), but no apparent Alamar Blue staining change was seen at lower concentrations of IFN-α. In the compound test area, two compounds showed a noticeable reduction in FRET activity, down to 27% and 1% detectable activity, respectively, of the control level (FIG. 7A, columns F2 and G5).
[0070] Inspection of the numbers and comparison of FIGS. 7A and 7B indicate a toxic compound is present in well G5 due to the decrease in FRET activity along with a corresponding decrease for the Alamar assay. Well F2, however, was seen to have a noticeable decrease in FRET activity without a corresponding decrease in the Alamar Blue measurement, indicating HCV replicon inhibition without measurable toxicity for this compound. Therefore, this compound was chosen for further evaluation.
[0071] To confirm that the variation in the FRET assay would remain acceptable, 40 additional compound plates were used to quantitate the variation using a statistical analysis to measure the Z′ statistic (Materials and Methods). The Z′ statistic is a measure of the distance between the standard deviations for the signal versus the noise of the assay. This analysis was used since the signal to noise in the assay was usually only 3-fold which is less than the Alamar signal to noise of approximately 8-fold indicating less tolerance for variation in the assay. An assay is considered acceptable if the Z′ statistic is 0.5 or greater indicating acceptable signal to noise scatter in the plates.
[0072] Forty plates were used to measure the standard deviations and the number distribution between the endpoint signal obtained for the controls and the signal obtained for the background. FIG. 8 shows a graphical representation of the averaged numbers from 40 separate compound plates used in the Z′ calculation. The numbers at a signal of approximately 500 are the readings from the wells containing 1000 units of interferon and are considered to have 0% FRET activity. The numbers at a signal of approximately 1500 are from wells containing buffer only and are considered as 100% FRET activity. The Z′ measurement calculates the distance as a fraction between the two number distributions in terms of the means of those distributions.
[0073] Using this calculation, a Z′ of 0.62 was obtained indicating a plate to plate variation acceptable for HTS. In addition, this measurement can be used on individual plates to determine if the controls were acceptable validating the data for a particular plate.
Discussion
[0074] Assays of the present invention may be conducted in a 96-well format, as demonstrated by the dose response curve generated by IFN-α and yields results comparable to qRT-PCR, and are amenable to an even greater degree of miniaturization, such as a 384 or smaller based cell culture assay.
[0075] As illustrated in FIGS. 7A and 7B, assays of the present invention are capable of measuring toxicity associated with a test compound as well as inhibitory activity associated with the test compound in the same well, thereby providing a method to prioritize compounds according to their inhibitory profile versus HCV as well as according to their toxicity profile. The variation associated with such assays is also statistically acceptable, as illustrated in FIG. 8. The cytotoxicity assay reagents, such as Alamar Blue, are desirably easily removed and are not deleterious to the cells.
[0076] Assays of the present invention have distinct advantages when compared to qRT-PCR or other methods in that assays of the present invention may take place in-situ in a detergent based crude cell lysate, which requires no further preparation prior to performing the assays. Assays of the present invention do not involve numerous manipulations to add or subtract reagents after addition of test compounds, and are desirably based on a viral protein which is required by the HCV replicon for replication. The FRET protease substrate peptide, which is resistant to cleavage by endogenous Huh-7 cellular proteases over the assay time period, is efficiently recognized by the replicon-based NS3 enzyme. Given that the original purpose of the substrate was to monitor the in-vitro cleavage (Taliani, supra) of this substrate by purified rather than crude enzyme, it is probable that the substrate can still be cleaved by the many different genotypes of HCV NS3, thereby providing greater utility.
[0077] The present invention also includes reporter assays. Reporter assays of the present invention include the use of a HCV protease and FRET peptide combination. The FRET substrate is relatively resistant to Huh-7, HeLa and HepG2 cellular proteases, indicating that it is very specific for HCV protease and therefore likely resistant to cellular proteases in other cell types. Placement of the HCV NS3 protease in a mammalian or bacterial expression system, or in the context of other viruses, allows the FRET assay to provide a sensitive method to use the viral protein in a wider cell repertoire. Such a reporter system is useful in a similar manner to known luciferase/beta-galactosidase systems, and are useful for the measurement of protein production, promoter strength, cell viability or other combinations. Adaptation of this method of assay is also possible with other viral proteases, provided a suitable and specific assay substrate is synthesized. The present invention also includes a cell line having ATCC Accession No. PTA-4583.
[0078] While the invention has been described in connection with specific embodiments therefore, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth and as follows in the scope of the appended claims. All references cited herein are expressly incorporated in their entirety.
1
5
1
7989
DNA
Artificial
HCV Replicon
1
gccagccccc gattgggggc gacactccac catagatcac tcccctgtga ggaactactg 60
tcttcacgca gaaagcgtct agccatggcg ttagtatgag tgtcgtgcag cctccaggac 120
cccccctccc gggagagcca tagtggtctg cggaaccggt gagtacaccg gaattgccag 180
gacgaccggg tcctttcttg gatcaacccg ctcaatgcct ggagatttgg gcgtgccccc 240
gcgagactgc tagccgagta gtgttgggtc gcgaaaggcc ttgtggtact gcctgatagg 300
gtgcttgcga gtgccccggg aggtctcgta gaccgtgcac catgagcacg aatcctaaac 360
ctcaaagaaa aaccaaaggg cgcgccatga ttgaacaaga tggattgcac gcaggttctc 420
cggccgcttg ggtggagagg ctattcggct atgactgggc acaacagaca atcggctgct 480
ctgatgccgc cgtgttccgg ctgtcagcgc aggggcgccc ggttcttttt gtcaagaccg 540
acctgtccgg tgccctgaat gaactgcagg acgaggcagc gcggctatcg tggctggcca 600
cgacgggcgt tccttgcgca gctgtgctcg acgttgtcac tgaagcggga agggactggc 660
tgctattggg cgaagtgccg gggcaggatc tcctgtcatc tcaccttgct cctgccgaga 720
aagtatccat catggctgat gcaatgcggc ggctgcatac gcttgatccg gctacctgcc 780
cattcgacca ccaagcgaaa catcgcatcg agcgagcacg tactcggatg gaagccggtc 840
ttgtcgatca ggatgatctg gacgaagagc atcaggggct cgcgccagcc gaactgttcg 900
ccaggctcaa ggcgcgcatg cccgacggcg aggatctcgt cgtgacccat ggcgatgcct 960
gcttgccgaa tatcatggtg gaaaatggcc gcttttctgg attcatcgac tgtggccggc 1020
tgggtgtggc ggaccgctat caggacatag cgttggctac ccgtgatatt gctgaagagc 1080
ttggcggcga atgggctgac cgcttcctcg tgctttacgg tatcgccgct cccgattcgc 1140
agcgcatcgc cttctatcgc cttcttgacg agttcttctg agtttaaaca gaccacaacg 1200
gtttccctct agcgggatca attccgcccc tctccctccc ccccccctaa cgttactggc 1260
cgaagccgct tggaataagg ccggtgtgcg tttgtctata tgttattttc caccatattg 1320
ccgtcttttg gcaatgtgag ggcccggaaa cctggccctg tcttcttgac gagcattcct 1380
aggggtcttt cccctctcgc caaaggaatg caaggtctgt tgaatgtcgt gaaggaagca 1440
gttcctctgg aagcttcttg aagacaaaca acgtctgtag cgaccctttg caggcagcgg 1500
aaccccccac ctggcgacag gtgcctctgc ggccaaaagc cacgtgtata agatacacct 1560
gcaaaggcgg cacaacccca gtgccacgtt gtgagttgga tagttgtgga aagagtcaaa 1620
tggctctcct caagcgtatt caacaagggg ctgaaggatg cccagaaggt accccattgt 1680
atgggatctg atctggggcc tcggtgcaca tgctttacat gtgtttagtc gaggttaaaa 1740
aacgtctagg ccccccgaac cacggggacg tggttttcct ttgaaaaaca cgataatacc 1800
atggcgccta ttacggccta ctcccaacag acgcgaggcc tacttggctg catcatcact 1860
agcctcacag gccgggacag gaaccaggtc gagggggagg tccaagtggt ctccaccgca 1920
acacaatctt tcctggcgac ctgcgtcaat ggcgtgtgtt ggactgtcta tcatggtgcc 1980
ggctcaaaga cccttgccgg cccaaagggc ccaatcaccc aaatgtacac caatgtggac 2040
caggacctcg tcggctggca agcgcccccc ggggcgcgtt ccttgacacc atgcacctgc 2100
ggcagctcgg acctttactt ggtcacgagg catgccgatg tcattccggt gcgccggcgg 2160
ggcgacagca gggggagcct actctccccc aggcccgtct cctacttgaa gggctcttcg 2220
ggcggtccac tgctctgccc ctcggggcac gctgtgggca tctttcgggc tgccgtgtgc 2280
acccgagggg ttgcgaaggc ggtggacttt gtacccgtcg agtctatgga aaccactatg 2340
cggtccccgg tcttcacgga caactcgtcc cctccggccg taccgcagac attccaggtg 2400
gcccatctac acgcccctac tggtagcggc aagagcacta aggtgccggc tgcgtatgca 2460
gcccaagggt ataaggtgct tgtcctgaac ccgtccgtcg ccgccaccct aggtttcggg 2520
gcgtatatgt ctaaggcaca tggtatcgac cctaacatca gaaccggggt aaggaccatc 2580
accacgggtg cccccatcac gtactccacc tatggcaagt ttcttgccga cggtggttgc 2640
tctgggggcg cctatgacat cataatatgt gatgagtgcc actcaactga ctcgaccact 2700
atcctgggca tcggcacagt cctggaccaa gcggagacgg ctggagcgcg actcgtcgtg 2760
ctcgccaccg ctacgcctcc gggatcggtc accgtgccac atccaaacat cgaggaggtg 2820
gctctgtcca gcactggaga aatccccttt tatggcaaag ccatccccat cgagaccatc 2880
aaggggggga ggcacctcat tttctgccat tccaagaaga aatgtgatga gctcgccgcg 2940
aagctgtccg gcctcggact caatgctgta gcatattacc ggggccttga tgtatccgtc 3000
ataccaacta gcggagacgt cattgtcgta gcaacggacg ctctaatgac gggctttacc 3060
ggcgatttcg actcagtgat cgactgcaat acatgtgtca cccagacagt cgacttcagc 3120
ctggacccga ccttcaccat tgagacgacg accgtgccac aagacgcggt gtcacgctcg 3180
cagcggcgag gcaggactgg taggggcagg atgggcattt acaggtttgt gactccagga 3240
gaacggccct cgggcatgtt cgattcctcg gttctgtgcg agtgctatga cgcgggctgt 3300
gcttggtacg agctcacgcc cgccgagacc tcagttaggt tgcgggctta cctaaacaca 3360
ccagggttgc ccgtctgcca ggaccatctg gagttctggg agagcgtctt tacaggcctc 3420
acccacatag acgcccattt cttgtcccag actaagcagg caggagacaa cttcccctac 3480
ctggtagcat accaggctac ggtgtgcgcc agggctcagg ctccacctcc atcgtgggac 3540
caaatgtgga agtgtctcat acggctaaag cctacgctgc acgggccaac gcccctgctg 3600
tataggctgg gagccgttca aaacgaggtt actaccacac accccataac caaatacatc 3660
atggcatgca tgtcggctga cctggaggtc gtcacgagca cctgggtgct ggtaggcgga 3720
gtcctagcag ctctggccgc gtattgcctg acaacaggca gcgtggtcat tgtgggcagg 3780
atcatcttgt ccggaaagcc ggccatcatt cccgacaggg aagtccttta ccgggagttc 3840
gatgagatgg aagagtgcgc ctcacacctc ccttacatcg aacagggaat gcagctcgcc 3900
gaacaattca aacagaaggc aatcgggttg ctgcaaacag ccaccaagca agcggaggct 3960
gctgctcccg tggtggaatc caagtggcgg accctcgaag ccttctgggc gaagcatatg 4020
tggaatttca tcagcgggat acaatattta gcaggcttgt ccactctgcc tggcaacccc 4080
gcgatagcat cactgatggc attcacagcc tctatcacca gcccgctcac cacccaacat 4140
accctcctgt ttaacatcct ggggggatgg gtggccgccc aacttgctcc tcccagcgct 4200
gcttctgctt tcgtaggcgc cggcatcgct ggagcggctg ttggcagcat aggccttggg 4260
aaggtgcttg tggatatttt ggcaggttat ggagcagggg tggcaggcgc gctcgtggcc 4320
tttaaggtca tgagcggcga gatgccctcc accgaggacc tggttaacct actccctgct 4380
atcctctccc ctggcgccct agtcgtcggg gtcgtgtgcg cagcgatact gcgtcggcac 4440
gtgggcccag gggagggggc tgtgcagtgg atgaaccggc tgatagcgtt cgcttcgcgg 4500
ggtaaccacg tctcccccac gcactatgtg cctgagagcg acgctgcagc acgtgtcact 4560
cagatcctct ctagtcttac catcactcag ctgctgaaga ggcttcacca gtggatcaac 4620
gaggactgct ccacgccatg ctccggctcg tggctaagag atgtttggga ttggatatgc 4680
acggtgttga ctgatttcaa gacctggctc cagtccaagc tcctgccgcg attgccggga 4740
gtccccttct tctcatgtca acgtgggtac aagggagtct ggcggggcga cggcatcatg 4800
caaaccacct gcccatgtgg agcacagatc accggacatg tgaaaaacgg ttccatgagg 4860
atcgtggggc ctaggacctg tagtaacacg tggcatggaa cattccccat taacgcgtac 4920
accacgggcc cctgcacgcc ctccccggcg ccaaattatt ctagggcgct gtggcgggtg 4980
gctgctgagg agtacgtgga ggttacgcgg gtgggggatt tccactacgt gacgggcatg 5040
accactgaca acgtaaagtg cccgtgtcag gttccggccc ccgaattctt cacagaagtg 5100
gatggggtgc ggttgcacag gtacgctcca gcgtgcaaac ccctcctacg ggaggaggtc 5160
acattcctgg tcgggctcaa tcaatacctg gttgggtcac agctcccatg cgagcccgaa 5220
ccggacgtag cagtgctcac ttccatgctc accgacccct cccacattac ggcggagacg 5280
gctaagcgta ggctggccag gggatctccc ccctccttgg ccagctcatc agctagccag 5340
ctgtctgcgc cttccttgaa ggcaacatgc actacccgtc atgactcccc ggacgctgac 5400
ctcatcgagg ccaacctcct gtggcggcag gagatgggcg ggaacatcac ccgcgtggag 5460
tcagaaaata aggtagtaat tttggactct ttcgagccgc tccaagcgga ggaggatgag 5520
agggaagtat ccgttccggc ggagatcctg cggaggtcca ggaaattccc tcgagcgatg 5580
cccatatggg cacgcccgga ttacaaccct ccactgttag agtcctggaa ggacccggac 5640
tacgtccctc cagtggtaca cgggtgtcca ttgccgcctg ccaaggcccc tccgatacca 5700
cctccacgga ggaagaggac ggttgtcctg tcagaatcta ccgtgtcttc tgccttggcg 5760
gagctcgcca caaagacctt cggcagctcc gaatcgtcgg ccgtcgacag cggcacggca 5820
acggcctctc ctgaccagcc ctccgacgac ggcgacgcgg gatccgacgt tgagtcgtac 5880
tcctccatgc ccccccttga gggggagccg ggggatcccg atctcagcga cgggtcttgg 5940
tctaccgtaa gcgaggaggc tagtgaggac gtcgtctgct gctcgatgtc ctacacatgg 6000
acaggcgccc tgatcacgcc atgcgctgcg gaggaaacca agctgcccat caatgcactg 6060
agcaactctt tgctccgtca ccacaacttg gtctatgcta caacatctcg cagcgcaagc 6120
ctgcggcaga agaaggtcac ctttgacaga ctgcaggtcc tggacgacca ctaccgggac 6180
gtgctcaagg agatgaaggc gaaggcgtcc acagttaagg ctaaacttct atccgtggag 6240
gaagcctgta agctgacgcc cccacattcg gccagatcta aatttggcta tggggcaaag 6300
gacgtccgga acctatccag caaggccgtt aaccacatcc gctccgtgtg gaaggacttg 6360
ctggaagaca ctgagacacc aattgacacc accatcatgg caaaaaatga ggttttctgc 6420
gtccaaccag agaagggggg ccgcaagcca gctcgcctta tcgtattccc agatttgggg 6480
gttcgtgtgt gcgagaaaat ggccctttac gatgtggtct ccaccctccc tcaggccgtg 6540
atgggctctt catacggatt ccaatactct cctggacagc gggtcgagtt cctggtgaat 6600
gcctggaaag cgaagaaatg ccctatgggc ttcgcatatg acacccgctg ttttgactca 6660
acggtcactg agaatgacat ccgtgttgag gagtcaatct accaatgttg tgacttggcc 6720
cccgaagcca gacaggccat aaggtcgctc acagagcggc tttacatcgg gggccccctg 6780
actaattcta aagggcagaa ctgcggctat cgccggtgcc gcgcgagcgg tgtactgacg 6840
accagctgcg gtaataccct cacatgttac ttgaaggccg ctgcggcctg tcgagctgcg 6900
aagctccagg actgcacgat gctcgtatgc ggagacgacc ttgtcgttat ctgtgaaagc 6960
gcggggaccc aagaggacga ggcgagccta cgggccttca cggaggctat gactagatac 7020
tctgcccccc ctggggaccc gcccaaacca gaatacgact tggagttgat aacatcatgc 7080
tcctccaatg tgtcagtcgc gcacgatgca tctggcaaaa gggtgtacta tctcacccgt 7140
gaccccacca ccccccttgc gcgggctgcg tgggagacag ctagacacac tccagtcaat 7200
tcctggctag gcaacatcat catgtatgcg cccaccttgt gggcaaggat gatcctgatg 7260
actcatttct tctccatcct tctagctcag gaacaacttg aaaaagccct agattgtcag 7320
atctacgggg cctgttactc cattgagcca cttgacctac ctcagatcat tcaacgactc 7380
catggcctta gcgcattttc actccatagt tactctccag gtgagatcaa tagggtggct 7440
tcatgcctca ggaaacttgg ggtaccgccc ttgcgagtct ggagacatcg ggccagaagt 7500
gtccgcgcta ggctactgtc ccaggggggg agggctgcca cttgtggcaa gtacctcttc 7560
aactgggcag taaggaccaa gctcaaactc actccaatcc cggctgcgtc ccagttggat 7620
ttatccagct ggttcgttgc tggttacagc gggggagaca tatatcacag cctgtctcgt 7680
gcccgacccc gctggttcat gtggtgccta ctcctacttt ctgtaggggt aggcatctat 7740
ctactcccca accgatgaac ggggagctaa acactccagg ccaataggcc atcctgtttt 7800
tttccctttt tttttttctt tttttttttt tttttttttt tttttttttt ttctcctttt 7860
tttttcctct ttttttcctt ttctttcctt tggtggctcc atcttagccc tagtcacggc 7920
tagctgtgaa aggtccgtga gccgcttgac tgcagagagt gctgatactg gcctctctgc 7980
agatcaagt 7989
2
1985
PRT
Artificial
HCV Replicon
2
Met Ala Pro Ile Thr Ala Tyr Ser Gln Gln Thr Arg Gly Leu Leu Gly
1 5 10 15
Cys Ile Ile Thr Ser Leu Thr Gly Arg Asp Arg Asn Gln Val Glu Gly
20 25 30
Glu Val Gln Val Val Ser Thr Ala Thr Gln Ser Phe Leu Ala Thr Cys
35 40 45
Val Asn Gly Val Cys Trp Thr Val Tyr His Gly Ala Gly Ser Lys Thr
50 55 60
Leu Ala Gly Pro Lys Gly Pro Ile Thr Gln Met Tyr Thr Asn Val Asp
65 70 75 80
Gln Asp Leu Val Gly Trp Gln Ala Pro Pro Gly Ala Arg Ser Leu Thr
85 90 95
Pro Cys Thr Cys Gly Ser Ser Asp Leu Tyr Leu Val Thr Arg His Ala
100 105 110
Asp Val Ile Pro Val Arg Arg Arg Gly Asp Ser Arg Gly Ser Leu Leu
115 120 125
Ser Pro Arg Pro Val Ser Tyr Leu Lys Gly Ser Ser Gly Gly Pro Leu
130 135 140
Leu Cys Pro Ser Gly His Ala Val Gly Ile Phe Arg Ala Ala Val Cys
145 150 155 160
Thr Arg Gly Val Ala Lys Ala Val Asp Phe Val Pro Val Glu Ser Met
165 170 175
Glu Thr Thr Met Arg Ser Pro Val Phe Thr Asp Asn Ser Ser Pro Pro
180 185 190
Ala Val Pro Gln Thr Phe Gln Val Ala His Leu His Ala Pro Thr Gly
195 200 205
Ser Gly Lys Ser Thr Lys Val Pro Ala Ala Tyr Ala Ala Gln Gly Tyr
210 215 220
Lys Val Leu Val Leu Asn Pro Ser Val Ala Ala Thr Leu Gly Phe Gly
225 230 235 240
Ala Tyr Met Ser Lys Ala His Gly Ile Asp Pro Asn Ile Arg Thr Gly
245 250 255
Val Arg Thr Ile Thr Thr Gly Ala Pro Ile Thr Tyr Ser Thr Tyr Gly
260 265 270
Lys Phe Leu Ala Asp Gly Gly Cys Ser Gly Gly Ala Tyr Asp Ile Ile
275 280 285
Ile Cys Asp Glu Cys His Ser Thr Asp Ser Thr Thr Ile Leu Gly Ile
290 295 300
Gly Thr Val Leu Asp Gln Ala Glu Thr Ala Gly Ala Arg Leu Val Val
305 310 315 320
Leu Ala Thr Ala Thr Pro Pro Gly Ser Val Thr Val Pro His Pro Asn
325 330 335
Ile Glu Glu Val Ala Leu Ser Ser Thr Gly Glu Ile Pro Phe Tyr Gly
340 345 350
Lys Ala Ile Pro Ile Glu Thr Ile Lys Gly Gly Arg His Leu Ile Phe
355 360 365
Cys His Ser Lys Lys Lys Cys Asp Glu Leu Ala Ala Lys Leu Ser Gly
370 375 380
Leu Gly Leu Asn Ala Val Ala Tyr Tyr Arg Gly Leu Asp Val Ser Val
385 390 395 400
Ile Pro Thr Ser Gly Asp Val Ile Val Val Ala Thr Asp Ala Leu Met
405 410 415
Thr Gly Phe Thr Gly Asp Phe Asp Ser Val Ile Asp Cys Asn Thr Cys
420 425 430
Val Thr Gln Thr Val Asp Phe Ser Leu Asp Pro Thr Phe Thr Ile Glu
435 440 445
Thr Thr Thr Val Pro Gln Asp Ala Val Ser Arg Ser Gln Arg Arg Gly
450 455 460
Arg Thr Gly Arg Gly Arg Met Gly Ile Tyr Arg Phe Val Thr Pro Gly
465 470 475 480
Glu Arg Pro Ser Gly Met Phe Asp Ser Ser Val Leu Cys Glu Cys Tyr
485 490 495
Asp Ala Gly Cys Ala Trp Tyr Glu Leu Thr Pro Ala Glu Thr Ser Val
500 505 510
Arg Leu Arg Ala Tyr Leu Asn Thr Pro Gly Leu Pro Val Cys Gln Asp
515 520 525
His Leu Glu Phe Trp Glu Ser Val Phe Thr Gly Leu Thr His Ile Asp
530 535 540
Ala His Phe Leu Ser Gln Thr Lys Gln Ala Gly Asp Asn Phe Pro Tyr
545 550 555 560
Leu Val Ala Tyr Gln Ala Thr Val Cys Ala Arg Ala Gln Ala Pro Pro
565 570 575
Pro Ser Trp Asp Gln Met Trp Lys Cys Leu Ile Arg Leu Lys Pro Thr
580 585 590
Leu His Gly Pro Thr Pro Leu Leu Tyr Arg Leu Gly Ala Val Gln Asn
595 600 605
Glu Val Thr Thr Thr His Pro Ile Thr Lys Tyr Ile Met Ala Cys Met
610 615 620
Ser Ala Asp Leu Glu Val Val Thr Ser Thr Trp Val Leu Val Gly Gly
625 630 635 640
Val Leu Ala Ala Leu Ala Ala Tyr Cys Leu Thr Thr Gly Ser Val Val
645 650 655
Ile Val Gly Arg Ile Ile Leu Ser Gly Lys Pro Ala Ile Ile Pro Asp
660 665 670
Arg Glu Val Leu Tyr Arg Glu Phe Asp Glu Met Glu Glu Cys Ala Ser
675 680 685
His Leu Pro Tyr Ile Glu Gln Gly Met Gln Leu Ala Glu Gln Phe Lys
690 695 700
Gln Lys Ala Ile Gly Leu Leu Gln Thr Ala Thr Lys Gln Ala Glu Ala
705 710 715 720
Ala Ala Pro Val Val Glu Ser Lys Trp Arg Thr Leu Glu Ala Phe Trp
725 730 735
Ala Lys His Met Trp Asn Phe Ile Ser Gly Ile Gln Tyr Leu Ala Gly
740 745 750
Leu Ser Thr Leu Pro Gly Asn Pro Ala Ile Ala Ser Leu Met Ala Phe
755 760 765
Thr Ala Ser Ile Thr Ser Pro Leu Thr Thr Gln His Thr Leu Leu Phe
770 775 780
Asn Ile Leu Gly Gly Trp Val Ala Ala Gln Leu Ala Pro Pro Ser Ala
785 790 795 800
Ala Ser Ala Phe Val Gly Ala Gly Ile Ala Gly Ala Ala Val Gly Ser
805 810 815
Ile Gly Leu Gly Lys Val Leu Val Asp Ile Leu Ala Gly Tyr Gly Ala
820 825 830
Gly Val Ala Gly Ala Leu Val Ala Phe Lys Val Met Ser Gly Glu Met
835 840 845
Pro Ser Thr Glu Asp Leu Val Asn Leu Leu Pro Ala Ile Leu Ser Pro
850 855 860
Gly Ala Leu Val Val Gly Val Val Cys Ala Ala Ile Leu Arg Arg His
865 870 875 880
Val Gly Pro Gly Glu Gly Ala Val Gln Trp Met Asn Arg Leu Ile Ala
885 890 895
Phe Ala Ser Arg Gly Asn His Val Ser Pro Thr His Tyr Val Pro Glu
900 905 910
Ser Asp Ala Ala Ala Arg Val Thr Gln Ile Leu Ser Ser Leu Thr Ile
915 920 925
Thr Gln Leu Leu Lys Arg Leu His Gln Trp Ile Asn Glu Asp Cys Ser
930 935 940
Thr Pro Cys Ser Gly Ser Trp Leu Arg Asp Val Trp Asp Trp Ile Cys
945 950 955 960
Thr Val Leu Thr Asp Phe Lys Thr Trp Leu Gln Ser Lys Leu Leu Pro
965 970 975
Arg Leu Pro Gly Val Pro Phe Phe Ser Cys Gln Arg Gly Tyr Lys Gly
980 985 990
Val Trp Arg Gly Asp Gly Ile Met Gln Thr Thr Cys Pro Cys Gly Ala
995 1000 1005
Gln Ile Thr Gly His Val Lys Asn Gly Ser Met Arg Ile Val Gly
1010 1015 1020
Pro Arg Thr Cys Ser Asn Thr Trp His Gly Thr Phe Pro Ile Asn
1025 1030 1035
Ala Tyr Thr Thr Gly Pro Cys Thr Pro Ser Pro Ala Pro Asn Tyr
1040 1045 1050
Ser Arg Ala Leu Trp Arg Val Ala Ala Glu Glu Tyr Val Glu Val
1055 1060 1065
Thr Arg Val Gly Asp Phe His Tyr Val Thr Gly Met Thr Thr Asp
1070 1075 1080
Asn Val Lys Cys Pro Cys Gln Val Pro Ala Pro Glu Phe Phe Thr
1085 1090 1095
Glu Val Asp Gly Val Arg Leu His Arg Tyr Ala Pro Ala Cys Lys
1100 1105 1110
Pro Leu Leu Arg Glu Glu Val Thr Phe Leu Val Gly Leu Asn Gln
1115 1120 1125
Tyr Leu Val Gly Ser Gln Leu Pro Cys Glu Pro Glu Pro Asp Val
1130 1135 1140
Ala Val Leu Thr Ser Met Leu Thr Asp Pro Ser His Ile Thr Ala
1145 1150 1155
Glu Thr Ala Lys Arg Arg Leu Ala Arg Gly Ser Pro Pro Ser Leu
1160 1165 1170
Ala Ser Ser Ser Ala Ser Gln Leu Ser Ala Pro Ser Leu Lys Ala
1175 1180 1185
Thr Cys Thr Thr Arg His Asp Ser Pro Asp Ala Asp Leu Ile Glu
1190 1195 1200
Ala Asn Leu Leu Trp Arg Gln Glu Met Gly Gly Asn Ile Thr Arg
1205 1210 1215
Val Glu Ser Glu Asn Lys Val Val Ile Leu Asp Ser Phe Glu Pro
1220 1225 1230
Leu Gln Ala Glu Glu Asp Glu Arg Glu Val Ser Val Pro Ala Glu
1235 1240 1245
Ile Leu Arg Arg Ser Arg Lys Phe Pro Arg Ala Met Pro Ile Trp
1250 1255 1260
Ala Arg Pro Asp Tyr Asn Pro Pro Leu Leu Glu Ser Trp Lys Asp
1265 1270 1275
Pro Asp Tyr Val Pro Pro Val Val His Gly Cys Pro Leu Pro Pro
1280 1285 1290
Ala Lys Ala Pro Pro Ile Pro Pro Pro Arg Arg Lys Arg Thr Val
1295 1300 1305
Val Leu Ser Glu Ser Thr Val Ser Ser Ala Leu Ala Glu Leu Ala
1310 1315 1320
Thr Lys Thr Phe Gly Ser Ser Glu Ser Ser Ala Val Asp Ser Gly
1325 1330 1335
Thr Ala Thr Ala Ser Pro Asp Gln Pro Ser Asp Asp Gly Asp Ala
1340 1345 1350
Gly Ser Asp Val Glu Ser Tyr Ser Ser Met Pro Pro Leu Glu Gly
1355 1360 1365
Glu Pro Gly Asp Pro Asp Leu Ser Asp Gly Ser Trp Ser Thr Val
1370 1375 1380
Ser Glu Glu Ala Ser Glu Asp Val Val Cys Cys Ser Met Ser Tyr
1385 1390 1395
Thr Trp Thr Gly Ala Leu Ile Thr Pro Cys Ala Ala Glu Glu Thr
1400 1405 1410
Lys Leu Pro Ile Asn Ala Leu Ser Asn Ser Leu Leu Arg His His
1415 1420 1425
Asn Leu Val Tyr Ala Thr Thr Ser Arg Ser Ala Ser Leu Arg Gln
1430 1435 1440
Lys Lys Val Thr Phe Asp Arg Leu Gln Val Leu Asp Asp His Tyr
1445 1450 1455
Arg Asp Val Leu Lys Glu Met Lys Ala Lys Ala Ser Thr Val Lys
1460 1465 1470
Ala Lys Leu Leu Ser Val Glu Glu Ala Cys Lys Leu Thr Pro Pro
1475 1480 1485
His Ser Ala Arg Ser Lys Phe Gly Tyr Gly Ala Lys Asp Val Arg
1490 1495 1500
Asn Leu Ser Ser Lys Ala Val Asn His Ile Arg Ser Val Trp Lys
1505 1510 1515
Asp Leu Leu Glu Asp Thr Glu Thr Pro Ile Asp Thr Thr Ile Met
1520 1525 1530
Ala Lys Asn Glu Val Phe Cys Val Gln Pro Glu Lys Gly Gly Arg
1535 1540 1545
Lys Pro Ala Arg Leu Ile Val Phe Pro Asp Leu Gly Val Arg Val
1550 1555 1560
Cys Glu Lys Met Ala Leu Tyr Asp Val Val Ser Thr Leu Pro Gln
1565 1570 1575
Ala Val Met Gly Ser Ser Tyr Gly Phe Gln Tyr Ser Pro Gly Gln
1580 1585 1590
Arg Val Glu Phe Leu Val Asn Ala Trp Lys Ala Lys Lys Cys Pro
1595 1600 1605
Met Gly Phe Ala Tyr Asp Thr Arg Cys Phe Asp Ser Thr Val Thr
1610 1615 1620
Glu Asn Asp Ile Arg Val Glu Glu Ser Ile Tyr Gln Cys Cys Asp
1625 1630 1635
Leu Ala Pro Glu Ala Arg Gln Ala Ile Arg Ser Leu Thr Glu Arg
1640 1645 1650
Leu Tyr Ile Gly Gly Pro Leu Thr Asn Ser Lys Gly Gln Asn Cys
1655 1660 1665
Gly Tyr Arg Arg Cys Arg Ala Ser Gly Val Leu Thr Thr Ser Cys
1670 1675 1680
Gly Asn Thr Leu Thr Cys Tyr Leu Lys Ala Ala Ala Ala Cys Arg
1685 1690 1695
Ala Ala Lys Leu Gln Asp Cys Thr Met Leu Val Cys Gly Asp Asp
1700 1705 1710
Leu Val Val Ile Cys Glu Ser Ala Gly Thr Gln Glu Asp Glu Ala
1715 1720 1725
Ser Leu Arg Ala Phe Thr Glu Ala Met Thr Arg Tyr Ser Ala Pro
1730 1735 1740
Pro Gly Asp Pro Pro Lys Pro Glu Tyr Asp Leu Glu Leu Ile Thr
1745 1750 1755
Ser Cys Ser Ser Asn Val Ser Val Ala His Asp Ala Ser Gly Lys
1760 1765 1770
Arg Val Tyr Tyr Leu Thr Arg Asp Pro Thr Thr Pro Leu Ala Arg
1775 1780 1785
Ala Ala Trp Glu Thr Ala Arg His Thr Pro Val Asn Ser Trp Leu
1790 1795 1800
Gly Asn Ile Ile Met Tyr Ala Pro Thr Leu Trp Ala Arg Met Ile
1805 1810 1815
Leu Met Thr His Phe Phe Ser Ile Leu Leu Ala Gln Glu Gln Leu
1820 1825 1830
Glu Lys Ala Leu Asp Cys Gln Ile Tyr Gly Ala Cys Tyr Ser Ile
1835 1840 1845
Glu Pro Leu Asp Leu Pro Gln Ile Ile Gln Arg Leu His Gly Leu
1850 1855 1860
Ser Ala Phe Ser Leu His Ser Tyr Ser Pro Gly Glu Ile Asn Arg
1865 1870 1875
Val Ala Ser Cys Leu Arg Lys Leu Gly Val Pro Pro Leu Arg Val
1880 1885 1890
Trp Arg His Arg Ala Arg Ser Val Arg Ala Arg Leu Leu Ser Gln
1895 1900 1905
Gly Gly Arg Ala Ala Thr Cys Gly Lys Tyr Leu Phe Asn Trp Ala
1910 1915 1920
Val Arg Thr Lys Leu Lys Leu Thr Pro Ile Pro Ala Ala Ser Gln
1925 1930 1935
Leu Asp Leu Ser Ser Trp Phe Val Ala Gly Tyr Ser Gly Gly Asp
1940 1945 1950
Ile Tyr His Ser Leu Ser Arg Ala Arg Pro Arg Trp Phe Met Trp
1955 1960 1965
Cys Leu Leu Leu Leu Ser Val Gly Val Gly Ile Tyr Leu Leu Pro
1970 1975 1980
Asn Arg
1985
3
21
DNA
Artificial
Primers
3
gggagagcca tagtggtctg c 21
4
20
DNA
Artificial
Primers
4
cccaaatctc caggcattga 20
5
21
DNA
Artificial
Probe
5
cggaattgcc aggacgaccg g 21 | The present invention includes an assay useful for identifying inhibitors of Hepatitis C virus (HCV) activity. Particularly, the present invention is directed to a dual HCV assay useful for high throughput screening that quantifies both the amount of HCV RNA replication inhibitory activity associated with a test compound and the amount of cytotoxicity associated with that test compound. The present invention also includes compounds discovered using this assay, compositions containing such compounds and methods of treating Hepatitis C by the administration of such compounds. The present invention also includes reporter assays using enzymes associated with HCV RNA replication, as well as a cell line having ATTC Accession No. PTA-4583. | 2 |
This application is a continuation of application Ser. No. 291,228, filed 08/10/81, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to high pressure valves, particularly to high pressure valves which operate by directing flow to a dump outlet. With still greater particularity, this invention pertains to high pressure dump valves that are usable as a rotary joint.
2. Description of the Prior Art
Water jet cutting equipment requires the use of extremely high fluid pressures. Pressures in the range of 20,000-100,000 psi are not uncommon. At such pressures, conventional valves are useless, due to erosion at the seals, and, leakage. Accordingly, a number of valves have been devised which use the compression characteristics of materials at high pressures and counter balancing forces. Valves of this type, however, require high actuation forces to overcome the hydrostatic forces on the operating parts to actuate the valve. For this reason valves for high pressure use have required auxiliary activator systems, such as, solenoids or pneumatic activators to provide sufficient force to operate valves. Accordingly, a need has arose for a valve that may be constantly subjected to ultra high pressures, and requires a small actuation force.
Recent advances in high pressure technology have made water jet drilling of hard surfaces a reality. In such drilling, a high pressure jet at an angle to the surface face is rotated and advanced. A high pressure rotary joint is required for this device, to allow supply of high pressure fluid to the rotating jet. The joint is subjected to constant high pressure and movement. The swivel must still seal under these conditions.
In water jet drilling apparatus it is desirable that the assembly be as simple as possible. First, the simpler the apparatus is, the more lightweight, and, therefore, portable. Second, simplification of the apparatus reduces the chance of malfunctions, and increases durability. For these reasons it would be desirable to combine the functions of rotary joint and on-off valve in one piece of apparatus.
SUMMARY OF THE INVENTION
An improved high pressure valve is provided by the present invention. The device can be activated by a relatively low force such as could be provided by hand or foot force. The low activation force is needed even if the valve is operating at very high pressures. The valve is capable of substained operation at high pressures without leakage or scoring of the seal materials. These design ends are achieved by balancing of forces and the characteristics of materials under high pressures.
The device is comprised of a body suitable for containment of high pressures. The body has openings for entry and exit of fluids, and the activator. A valve spool is located within the valve body. The valve spool is hollow to equalize forces, and also acts as the activator. The valve spool is also provided with a series of ports that give access to the interior cavity. When the valve is in the on position, flow is through these ports and into the cavity which also serves as an exit in a load. When the valve is turned off, one set of ports are pushed through a seal into a second chamber in the valve body. The fluid now flows into the spool through one set of ports and out the other set. The other set of ports exit into a cavity connected to the outside, thus diverting pressure from the load. The valve is unusual in that ports having pressure on them pass through a seal. This is possible due to the high pressures which prevent seal materials from being eroded.
The device is also capable of operation as a high pressure rotary joint. Due to the symmetrical design of the device the valve spool may be rotated relative to the valve body. The ability to function as a rotary joint is also possible because the hydrostatic forces are balanced and no large forces are needed to produce movement. Combination of the valve and rotary joint functions results in simplicity of the apparatus and a savings in weight.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional plan view of the invention in the on position.
FIG. 2 is a sectional plan view of the invention in the off position.
FIG. 3 is a detail sectional view of the FIG. 1 embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a sectional plan view of the invention in the on position. The device is generally cylindrical in shape, and, since this is a sectional view, it is realized that all rectangles are actually cylinders unless otherwise noted.
The outer surface of the invention is formed by the valve body 1 which in this embodiment is a cylinder, although it is realized that for other applications valve body 1 could be shaped otherwise. Valve body 1 is hollow to provide for valve cavities, and the passage of a spool 2. Spool 2 is an elongated member that is provided with a hollow core 4. One end 3 of cavity 4 serves as the outlet of the invention. Outlet 3 may be connected to a load, or may serve as an extention of the supply tube to a load. The load is not shown, but may be a cutting jet nozzle. The end of spool 2, opposite outlet 3, is sealed and acts as an activator for the invention. Spool 2 is provided with a first set of ports 6, and a second set of ports 7, which communicate between core 4 and the outer surface of spool 2. When the valve is in the on position, both ports 6 and 7 connect core 4 to the valve chamber 8 in valve body 1. Valve cavity 8 of the invention is connected to the outer surface of valve body 1 by the inlet passage 9, which may be a single hole. Inlet passage 9 is adapted to receive a high pressure connector, which along with a supply tube (not shown), connects inlet passage 9 to a source of ultra high pressure fluid, such as a pump or hydraulic intensifier. Valve cavity 8 is defined by the outer surface of spool 2, the inner surface of valve body 1, and two seals 11 and 14. Seals 11 and 14 may be comprised of a tapered seal plug combined with a back up ring 12, 16. If it is desired to operate the invention as a swivel, bearings 13 and 17 are provided. Bearings 13 and 17 may be constructed of a bearing material such as, bronze. For some applications it may be desirable to place a compression spring (not shown) between seal 11 and seal 14 to urge said seals outward, if the invention is used for intermittent service. Under normal conditions, cavity 8 is filled with high pressure fluid so no spring is necessary. The interior of valve body 1 is divided into two sections by the seal retainer 18. The first section already described is those components associated with valve cavity 8. The second section is the dump chamber 21. Seal retainer 18 is provided with a hole 19 allowing passage of spool 2. Hole 19 is of such dimension as to provide a small clearance between seal retainer 18 and spool 2. Dump chamber 21 is defined by the outer surface of spool 2, the inner surface of valve body 1, seal retainer 18, and the spool retainer 24. Spool retainer 24 closes the interior of valve body 1, and provides a hole for passage of spool 2. Spool 2 is provided with a flange 22, which limits the motion of spool 2, and retains spool 2 in valve body 1. Dump chamber 21 is connected to the outer surface of valve body 1 by the dump outlet passage 23, which may be a single hole. Dump outlet passage 23 may connect directly with the outside environment, or may receive a tube to connect it to an area, where it is desired to place excess fluid.
In the FIG. 1 position, high pressure fluid enters through a supply tube (not shown), connected to inlet 9. The fluid then flows through inlet 9 into valve chamber 8. In valve chamber 8 the difference between the pressure in valve chamber 8 and dump chamber 22 urges seal 11 toward bearing 13. In a similar manner, seal 14 is urged toward bearing 17. The only outlet from valve chamber 8 is ports 6 and 7 in spool 2. The fluid thus flows into core 4 in spool 2. Since spool 2 contains core 4, filled with very high pressure fluid, spool 2 is expanded in a direction away from its axis. This expansion forms a tight seal between the exterior of spool 2 and the interiors of seals 11 and 14, preventing any leakage out of chamber 8. Additionally when the seal is pressurized the taper of rings 12 & 16 forces seals 11 & 14 onto spool 2.
FIG. 2 is a sectional plan view of the FIG. 1 valve in the off or dump position. The parts are the same as in FIG. 1 and are identified by the same numbers. The position of ports are different as described below. As in FIG. 1, all parts are cylindrical except as noted.
In FIG. 2, spool 2 has been moved into the off or dump position. In this position it will be noted that the extension of core 4 is still surrounded by seals 11 and 14, and bearings 13 and 17. The second set of ports 7 is still in valve chamber 8, but has been moved toward seal 11. The first set of ports 6 has been moved to a position adjacent to seal retainer 18. Dump passage 19 is thus adjacent to the first set of ports 6. Dump passage 19 is formed by the clearance between the outer surface of spool 2 and the inner surface of seal retainer 18. Dump passage 19 is not to be confused with a hex key opening that forms part of passage 19, and is still visible in this view. Stop 22 has been moved into contact with a cavity in spool retainer 24. Spool 2 is thus at the limit of its travel toward the direction of spool retainer 24. In FIG. 1, stop 22 butted up against the surface of seal retainer 18 for the other limit of its movement.
In the FIG. 2 position, high pressure fluid enters by a supply tube (not shown) connected to inlet 9 as in FIG. 1. The fluid flows through inlet 9 to valve chamber 8. The same forces as in FIG. 1 are present in FIG. 2. From valve chamber 8 the fluid flows through the second set of ports 7 into core 4 in spool 2. The force in core 4 is still sufficent to operate seals 11 and 14. Next, the fluid flows through core 4 to the first set of ports 6. Since the pressure in dump cavity 21 is much lower than that in core 4, the fluid flows through the first set of ports 6 into passage 19. The clearance between seal retainer 18 and spool 2 is sufficient to accommodate this flow. At this point the fluid exits from passage 19 into dump chamber 21. The excess fluid is removed from dump chamber 21 via outlet 23. An outlet tube (not shown) may connect outlet 23 to a reservoir if it is desired to recycle the fluid.
It will be noted that in moving spool 2 from the FIG. 1 position to the FIG. 2 position, the first set of ports 6 must pass through seal 11 and bearing 13. As the first set of ports 6 contain fluid at high pressure, it would be expected that this passage would result in severe erosion of the interior of seal 11 and bearing 13. It has been found that at the high operating pressures of this valve that there is no erosion, even at pressures above 50,000 p.s.i. The explanation is believed to be that the high pressure fluid forces the material of seal 11 away from ports 6 and prevents the erosion. It will also be noted that the valve does not actually switch fluid from from outlet 3 to outlet 23 as a conventonal two-port valve, but rather acts by providing an alternative flow path that relieves the pressure. Due to the balanced construction of the valve, very little force is required to move spool 2 from the FIG. 1 to the FIG. 2 position. In fact, only sufficient force to overcome the friction between seals 11 and 17, and spool 2, need be applied. For this reason the valve may be operated by hand or foot pressure without the use of wheels, or other pressure increasing devices.
FIG. 3 is a sectional detail drawing that illustrates the operation of the seals of the invention. While FIG. 3 illustrates the area around seal 14, it will be realized that the area around seal 11 is similar and operates in the same manner. It will be noted that seal 14 is shaped like a hollow truncated cone with the base in contact with the high pressure fluid in valve chamber 8 and the top in contact with bearing 17. Seal 14 is constructed from a material that deforms and actually extrudes at a controlled rate under the influence of high pressure. It has been found that high molecular weight polyethylene is a suitable material for use in seal 14, but it is realized that other substances having similar properties may be substituted. The area between the tapered portion of seal 14 and valve body 1 is occupied by a back-up ring 16. Back-up ring 16 is constructed of a rigid material, such as stainless steel. Back-up ring 16 is shaped as a tapered annulus with a cylindrical outer surface and a conical inner surface. The taper of the inner surface of back-up ring 16 is chosen to match the taper of the outer surface of seal 14. It is crucial that the junction of the inner and outer surfaces of ring 16 form a sharp point. If the point is not sharp, back-up ring 16 will hang up on seal 14, and, impair the operation of the seal. It will also be noted, that a small gap 25 is formed between one end of back-up ring 16 and bearing 17. Gap 25 is also essential to operation of the seal. While the size of gap 25 must vary in different applications, it has been found that a suitable dimension for gap 25 in many applications is about 0.008 inches. The hole in the center of seal 14 is selected to conform closely to the outer diameter of spool 2.
In operation there is high pressure fluid in valve chamber 8 of the valve. As there is no fluid in the area of bearing 17, there is a large pressure differential between these two areas. This pressure differential produces a resultant force in the direction of the arrows in FIG. 3. The force pushes seal 14 toward bearing 17, but since seal 14 is tapered, the force is converted into a force that tends to increase the diameter of back-up ring 16. The expansion of ring 16 results in an increase of sealing force. The result is that the greater the pressure in valve cavity 8, the more effective the seal becomes. Since the sliding of seal 14, relative to back-up ring 16 is necessary to this operation, the importance of the sharp point on back-up ring 16 and gap 25 is readily appreciated. As was described above, the junction between the outer surface of spool 2 and the inner surface of seal 14 is sealed because the high pressure fluid present in core 4 expands the diameter of spool 2. This expansion is transferred into an outward force on valve body 1, which is constructed sufficiently strong to stake up the force. By use of this seal construction, continuous operation at pressures in excess of 50,000 pounds per square inch is possible. At pressures such as these, conventional hydraulic valves are useless, as the very distortion of materials that makes the operation of this valve possible, results in the destruction of the seals or jamming of moving parts.
The unique construction of the valve also allows use as a high pressure rotary joint. In a similar way, the device is usable as a combination on-off valve rotary joint. As is apparent in FIGS. 1 and 2, spool 2 is supported by bearings 13 and 17. The holes in retainers 24 and 18 are of sufficiently high clearance to allow rotation of spool 2 relative to valve body 1, even if core 4 of spool 2 is filled with high pressure fluid. As a result, it is possible to rotate spool 2 relative to valve body 1. In a water jet drilling application this may be accomplished by effectively connecting a motor to an extension of one end of spool 2 and a nozzle to the other end of spool 2. When the motor is started, the nozzle revolves, and high pressure fluid may be supplied to inlet 9 to ultimately emerge at the nozzle. For this application the use of a combination joint valve results in a great reduction of weight and simplification of the apparatus.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit of the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not be to limited to the details thereof, but may be modified within the scope of the appended claims. | This invention relates to a high pressure valve of the dump type. The valve body contains a slideable, hollow spool with ports connecting its interior and exterior. When the valve is in the on position, all ports are located in the pressurized portion of the valve body, and fluid flows to an outlet connected to the hollow spool. In the off position, at least one port is outside the pressurized area of the valve body, thereby relieving fluid pressure. The ports slide through a seal of self-pressurizing construction. The valve may also be used as a high pressure swivel, or combination valve swivel, by rotating the spool, if the spool is supported by bearings. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 61/365,961, filed Jul. 20, 2010, the contents of which are incorporated fully herein by reference.
FIELD OF THE INVENTION
The invention relates to rotary boring and, in particular to an improved joint for connecting two rotatable components of a boring system.
SUMMARY OF THE INVENTION
The present invention is directed to a pipe joint for use in rotary boring operations. The pipe joint comprises a first member, a second member, and a ground engaging member. The first member has a non-circular exterior surface and a threaded socket. The second member comprises a threaded end portion for mating engagement with the threaded socket and a non-circular exterior surface portion corresponding to the non-circular exterior surface of the first member. The ground engaging member has a non-circular internal surface and an outer surface for enlarging a borehole. The non-circular internal surface corresponds to the non-circular exterior surface of both the first member and the second member for slidably mounting the ground engaging member on the non-circular exterior surfaces of the first member and the second member when the threaded socket of the first member is engaged with the threaded end portion of the second member and to transmit torque between the first member and the second member. Alignable holes are formed in the ground engaging member and the second member for receiving a fastener to secure the ground engaging member to the second member.
The present invention is further directed to a rotary boring system comprising a rotary machine, a drill string, and a downhole tool. The drill string has a first end and a second end. The first end is operatively connected to the rotary drive machine to drive rotation of the drill string. The downhole tool comprises a first member, a second member, and a ground-engaging member. The first member is connected to the second end of the drill string and comprises a non-circular exterior surface and a connector socket. The second member comprises a connector portion for mating engagement with the connector socket and a non-circular exterior surface portion corresponding to the non-circular exterior surface of the first member. The ground engaging member has a non-circular internal surface and an outer surface for enlarging a borehole. The non-circular internal surface corresponds to the non-circular surface of both the first member and the second member for slidably mounting the ground engaging member on the non-circular surfaces of the first member and the second member when the connector end portion is engaged with the connector socket and to transmit torque between the first member and the second member. The downhole tool further comprises alignable holes in the ground engaging member and the second member for receiving a fastener to secure the ground engaging member to the second member.
Further still, the present invention is directed to a method for making boreholes using a boring machine having a rotary drive system capable of rotating and axially advancing or retracting a downhole tool attached to a drill string. The method comprises the steps of connecting a first end of an elongate first member to the drill string, wherein the first member comprises a first end and a second end, the second end comprising a socket and a non-circular outer surface. A ground engaging member having a correspondingly non-circular internal surface is slid over the second end of the first member. A second member is engaged to the socket of the first member and oriented such that a non-circular surface formed thereon fits within the non-circular internal surface of the ground engaging member to pass rotation of the drill string and the first member to the ground engaging member and the second member by means of the non-circular surfaces.
Still yet, the present invention is directed to an adapter for connecting a pair of drilling components. The adapter comprises a first member, a second member, and a ground engaging member. The first member has a non-circular exterior surface and threaded socket. The second member has a threaded end portion and a non-circular exterior surface rearward of the threaded end portion. The threaded end portion is engagable with the threaded socket of the first member. The ground engaging member has a non-circular profile on an inner surface thereof whereby the ground engaging member is slidably mounted on the non-circular exterior profiles of the first and second members when such profiles are brought into alignment by rotation of one member relative to the other in a manner effective to pass torque from one member to the other by means of the non-circular profiles.
The present invention is further directed to a pipe joint for use in rotary boring operations. The pipe joint comprises a first member, a second member, and a ground engaging member. The first member has a non-circular exterior surface and a first connector. The second member comprises a second connector for mating engagement with the first connector and a non-circular exterior surface portion corresponding to the non-circular exterior surface of the first member. The ground engaging member has a non-circular internal surface and an outer surface for enlarging a borehole. The non-circular internal surface corresponds to the non-circular exterior surface of both the first member and the second member for slidably mounting the ground engaging member on the non-circular exterior surfaces of the first member and the second member when the first connector is engaged with the second connector and to transmit torque between the first member and the second member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a first pipe joint according to the invention including a first member, a pulling adapter, and a ground engaging member.
FIG. 2 is a longitudinal section view along line A-A of FIG. 1 .
FIG. 3 is a cross section view of the device of FIG. 2 along section line B-B showing details of engaged non-circular profiles.
FIG. 4 is an isometric view of the pipe joint of FIGS. 1-3 in exploded view.
FIG. 5 is a side view of the device shown FIGS. 1-3 having an additional backreaming tool in a stacked arrangement to provide progressive upsizing.
FIG. 6 is an isometric view of the device of the present invention showing a boring tool connected to the first member.
DESCRIPTION OF THE INVENTION
Rotary boring systems for making holes through soil are well known. The boring system generally includes drill string comprising a series of drill pipes joined end to end. The drill string is rotated by a rotary drive machine and pushed or pulled through the ground by means of a powerful hydraulic device such as a hydraulic cylinder or a gear rack actuated by a hydraulic motor. A boring head for boring in soil, rock or both is disposed at the end of the drill string and may include an ejection nozzle for water or other drilling fluid to assist in boring. In other applications, tools such as pipe bursters, impactors, slitters and pullers are used to slit, burst and replace existing underground pipelines. Reamers may be used along or in combination with any of the aforementioned tools to upsize a borehole.
In most horizontal boring operations a pilot bore is drilled between a starting point and an end point. Once the boring tool reaches the end point, whether the surface of the ground or a pit, the boring tool is removed and a backreamer may be attached to the drill string. The backreamer is used to upsize the borehole to meet or slightly exceed the outer diameter of the product pipe towed into the bore during pullback. Easy attachment of the product pipe to a backreamer assembly in a small access pit is disclosed in U.S. Patent application number 2002/0112890, the contents of which are incorporated herein by reference. If attempting to make a switch out in a pit, the swap will require enlargement of the access pit lengthwise to accommodate the length of the backreamer and its connection components. Ideally, the operator would like the change of tools to occur rapidly and be easily accomplished without the need to dig a large access pit. The present invention allows an operator to change tools at the downhole end of a drill string in a small access pit.
Turning now to the figures and specifically to FIG. 1 , there is shown therein a pipe joint 10 of the present invention. As used herein the term “pipe joint” may mean a downhole tool used in rotary boring operations, an adapter used to connect various drilling tools to the downhole end of a drill string, or the connection of two drilling system components. The pipe joint 10 of FIG. 1 comprises a first member 12 , a second member 14 , and a ground engaging member 16 . The first member 12 has a first end 18 and a second end 20 ( FIG. 2 ). The first end 18 of the first member 12 may have a diametral upset 22 for a yet to be described purpose. The second end 20 of the first member 12 may be disposed within the ground engaging member 16 .
The ground engaging member 16 shown in FIG. 1 comprises a frustoconical outer surface 24 having a plurality of carbide cutting teeth 26 and a helical groove 28 . A plurality of orifices 30 may be spaced about the outer surface 24 to eject fluid from the member into the borehole. The ground engaging member 16 further comprises alignable holes 32 used to connect the ground engaging member to either the first member 12 or the second member 14 using a fastener 33 . In FIG. 1 the alignable holes 32 are shown positioned to connect the ground engaging member to the second member 14 . The second member 14 will be discussed in more detail hereinafter, but as shown in FIG. 1 the second member may comprise a clevis 34 formed for receiving any generic connection to a swivel and product pulling device as may be required to install a utility in the borehole. Cross holes 36 formed in the clevis are on a common axis to allow use of a pin or bolt (not shown) to carry shear forces during towing of the utility behind the pipe joint 10 .
Turning now to FIG. 2 , there is shown a longitudinal section view of the pipe joint 10 of FIG. 1 along section line A-A. The first member 12 may be elongate and comprise the first end 18 having coupling member 38 for coupling the first member to the drill string (not shown). The second end 20 of the first member 12 may comprise a non-circular exterior surface 40 ( FIG. 4 ) and a first connector comprising a threaded socket 42 . The first connector 42 and non-circular exterior surface 40 may form an upset at the second end 20 of the first member 12 . Likewise, the coupling member 38 may form an upset 22 at the first end 18 of the first member 12 . A fluid passage 44 may extend from the first end 18 to the second end 20 to carry fluid such as drilling mud to the ground engaging member 16 .
The second member 14 comprises a second connector, depicted as a threaded end portion 46 for mating engagement with the first connector 42 . When threads are used, as shown in FIG. 2 , the first member 12 and second member 14 are rotated relative to each other to matingly engage the threaded end portion 46 of the second member 14 within the threaded socket 42 of the first member 12 . One skilled in the art will appreciate that the first connector 42 and second connector 46 may include any conventional coupling or joint used to connect drilling tools and may comprise part of such a tool. One such coupling system is known commercially as Splinelok™ wherein interlocking splines that pass torque from the drill string to a tool is described in Wentworth et al., published U.S. Patent Application Serial No. 2001/0017222, the disclosure of which is incorporated herein by reference for all purposes.
As illustrated, the second connector 42 is a tapered threaded end portion disposed between a central collar 48 and a front face 50 of the second member 14 . The second member 14 also comprises a hole 52 that is alignable with a corresponding hole 32 in ground engaging member 16 . Alignable holes 52 and 32 allow the second member to be locked in position relative to the ground engaging member 16 with fastener 33 . A first stop member 53 is formed on the second member 14 to abut the ground engaging member 16 and defines a first boundary of the central collar 48 . A second stop member 62 defines a second boundary of the central collar 48 and abuts a front face 64 of the first member 12 .
An O-ring 54 may be positioned adjacent front face 50 of the second member 14 and against a wall 56 of the first member 12 in a groove 58 . The O-ring 54 protects the socket 42 , wall 56 and threads 46 from ingress of abrasive materials that would exacerbate wear during operations. The O-ring 54 also prevents the egress of drilling fluid as it passes from passage 44 into passage 60 formed in the second member 14 . A radial passage 65 is formed in the second member 14 allow fluid to flow from the internal passage 60 into the cross-sectional clearance area 68 ( FIG. 3 ) to a circumferential gallery 70 . The fluid then flows through the discharge ports 30 ( FIG. 1 ) to mix with the soil thereby facilitating the ground engagement operation. The cross-sectional clearance area 68 continues forward for the length of the ground engaging member 16 and a fraction of the fluid delivered will flow to the front end 72 of the ground engaging member to reduce wear on the edge when engaged with the soil. Carbide teeth 26 and the tapered helical groove 28 produce shearing and mixing between soil and drill fluid as the drill string and ground engaging member are rotated.
FIGS. 2 and 3 illustrate the ground engaging member 16 comprises a non-circular internal surface 66 positioned over the central collar 48 of the second member 14 . The outer surface 24 may be frustoconical for enlarging the borehole. The non-circular internal surface 66 corresponds to the non-circular exterior surface 40 ( FIG. 4 ) of the both the first member 12 and the second member 14 for slidably mounting the ground engaging member 16 on the non-circular exterior surfaces of the first member and the second member when the first connector 42 is coupled to the second connector 46 to transmit torque between the first member 12 and the second member 14 .
In operation, joint 10 is assembled by sliding ground engaging member 16 over the first member 12 . Threaded end portion 46 of second member 14 is then screwed into threaded socket 42 and tightened to the desired level. After threaded end portion 46 of second member 14 has been tightened to the desired degree in threaded socket 42 , the alignment of exterior surfaces 48 and 40 is checked. If the profiles of the non-circular exterior surfaces 48 and 40 are not aligned ground engaging member 16 will not slide over second member 14 , consequently, the second member is unscrewed or backed off until the profiles of exterior surfaces 48 and 40 are aligned. The ground engaging member 16 is then slid along first member 12 and over non-circular exterior surface 48 of the second member 14 . In the event that the profiles of exterior surfaces 48 and 40 are not aligned when second member 14 is tightened to the desired level, the degree to which the second member will have to be backed off or loosened to align the profiles depends upon the selected profile. For example, in the case of an octagonal profile, the angle between the centers of each flat surface is 360/8 or 45°. Thus, in case of octagonal profile, the maximum number of degrees that second member 14 may have to be backed off after tightening to align the octagonal profiles of exterior surfaces 48 and 40 is the rotational difference between successive surfaces, or 45°.
After the ground engaging member has been positioned over the second member 14 , a retaining bolt or screw 33 is passed through hole 32 in the ground engaging member and engaged with bolt hole 52 in the second member, locking the ground engaging member onto the second member. Shoulder 53 prevents the ground engaging member 16 from sliding rearward as ground engagement forces are applied. Bolts 33 retain ground engaging member 16 should the normal direction of the drill string be reversed. Preferably, one or more of alignable holes 52 and 32 and bolt 33 are provided with NPT (National Pipe Thread) threads which provide improved retention and greater shear area than convention straight threads.
Continuing in FIGS. 2 and 3 , fluid such as drilling mud is passed along central bore 44 of first member 12 , continuing flow into internal passage 60 of the second member 14 . The fluid will then pass through the wall of the second member 14 through radial passage 65 . The flow rate of such fluid may be metered through an orifice formed in passage 65 . Threading of passage 65 helps to maintain the position of the orifice so as not to maintain offset between the orifice and the inner surface of the ground engaging member 16 . After flowing through passage 65 , the fluid may make its way through a cross sectional clearance 68 along the length of the ground engaging member to the circumferential gallery 70 . Finally, the fluid flows through the discharge port 30 ( FIG. 1 ) to mix with the soil thereby facilitating the ground engagement operation. The sectional clearance may continue forward for the length of the ground engaging member and a fraction of the fluid delivered will flow to the front end 72 , thereby reducing wear on this edge when engaged with the soil.
Turning now to FIG. 4 , an embodiment of the pipe joint of the present invention is shown in exploded view. First member 12 comprises an elongate tubular member having a first end 18 and a second end 20 . The first end 18 has an upset 22 having a threaded connector 38 ( FIG. 2 ) for connecting the first member to the drill string (not shown). The second end 20 may comprise the non-circular exterior surface 40 and a connector socket. The second member 14 comprises the connector portion for mating engagement with the connector socket 42 and a non-circular surface 48 corresponding to the non-circular exterior surface 40 of the first member 12 . The second member 14 may comprise a front face 50 and a central collar formed by the non-circular exterior surface 48 . The connector end portion 46 is disposed between the front face 50 and the central collar.
The ground engaging member 16 comprises a frustoconical backreaming member having a plurality of helical grooves 28 and carbide teeth 26 for enlarging the borehole. The ground engaging member 16 comprises a non-circular internal surface that corresponds to the non-circular exterior surfaces of the first member and the second member for slidably mounting the ground engaging member on the non-circular surfaces of the first member and the second member when the connector end portion 46 is engaged with the connector socket 42 . Such connection allows for the transmission of torque between the first member and the second member.
Alignable holes 32 and 52 are formed in the ground engaging member 16 and the second member 14 receive fasteners 33 to secure the ground engaging member 16 to the second member 14 . One skilled in the art will appreciate that alignable holes may alternatively be formed in the first member to secure the ground engaging member to the first member instead of the second member or in addition to the holes formed in the second member.
FIG. 5 demonstrates a use of the pipe joint of the present invention with an alternative large reamer weldment 74 sized to continue ground engagement work to open the bore while permitting fluid flow from the ground engagement member 16 as well as ports 82 formed in the exterior surface of the reamer 74 . Reamer 74 may be joined to the second member 14 by a weld 76 . A product pipe (not shown) is towed at product connector 34 behind the combination of stacked reamers. Connector 34 is joined to reamer 74 by weld 78 . As shown in FIG. 5 , the fluid flow passage of the second member 14 may continue, in fluid communication with internal passage 80 formed in reamer 74 so that fluid may be injected into the borehole from the reamer through radial ports 82 formed in the reamer.
Turning now to FIG. 6 , a downhole tool constructed in accordance with the present invention is shown. The downhole tool comprises the previously described first member 12 , second member 14 and ground engaging member 16 of FIGS. 1-5 . However, the second member 14 of FIG. 6 comprises a boring tool 84 . The boring tool 84 shown in FIG. 5 comprises a directional drill bit commonly used in horizontal drilling operations. One skilled in the art will appreciate the second member 14 may comprise several different boring tools used either to cut a pilot bore or to upsize the borehole and tow in product pipe.
In the method for making boreholes in accordance with the present invention, a boring machine having a rotary drive system capable of rotating and axially advancing or retracting a downhole tool attached to a drill string is used. The method comprises connecting the first end 18 of the first member 12 to the drill string. The first member 12 may be connected to the drill string by rotating the first member in a first direction to thread the first member 12 to the drill string. The ground engaging member 16 is slid over the second end 18 of the first member 12 so that the non-circular exterior surface 40 of the first member is positioned with the interior non-circular surface 66 of the ground engaging member. The non-circular surfaces 40 and 66 may comprise a geometric profile. For purposes of illustration only, an octagonal profile will be described. The octagonal profiles of the first member and the ground engaging member 16 are aligned before sliding the ground engaging member over the second end 20 of the first member.
The second member 14 is engaged to the socket 42 of the first member 12 and the second member is oriented, by rotation, such that the non-circular surface 66 of the second member fits within the ground engaging member 16 to pass rotation of the drill string and the first member to the ground engaging member and the second member. The second member 14 may comprise a threaded end portion 46 and the socket 42 may comprise corresponding threads. The method comprises threading the threaded end portion into the socket until the external non-circular surface of the second member is adjacent to the ground engaging member. The second member may then be rotated slightly to align the external non-circular surface 48 with the internal non-circular surface of the ground engaging member. The ground engaging member 16 is then moved axially to substantially cover the external non-circular surface of the second member. The holes 32 and 52 are aligned and the fastener 33 is inserted into the holes to fasten the second member 14 to the ground engaging member 16 .
As will be appreciated, the joint of the invention is applicable to a variety of applications wherein tools used in horizontal directional drilling are connected to a drill string. Joints in accordance with the invention are particularly useful in coupling drill bits, sonde housings, reamers, back reamers, starter rods, impactors and similar drilling tools to a drill string or together in a manner that facilitates rapid replacement of such components while simultaneously providing joints and couplings with an increased usable lifetime and enhanced reliability.
Various modifications can be made in the design and operation of the present invention without departing from the spirit thereof. Thus, while the principal preferred construction and modes of operation of the invention have been explained in what is now considered to represent its best embodiments, as herein illustrated and described, it should be understood that the invention may be practiced otherwise than as specifically illustrated and described. | A joint connecting a pair of members rotatable about a common axis end to end includes a first member having a threaded end portion and a non-circular exterior surface rearwardly of the threaded end portion, a second member having a threaded socket wherein the threaded end portion of the second member can be engaged, and a non-circular exterior surface, a ground engagement sleeve having a non-circular profile on an inner surface thereof whereby the sleeve can be slidably mounted on the non-circular exterior profiles of the first and second members when such profiles are brought into alignment by rotation of one member relative to the other in a manner effective to pass torque from one member to the other by means of the non-circular profiles, a first pair of alignable holes in the sleeve and first member to receive a fastener to secure the sleeve to the first member and a hole in the second member penetrating the threaded socket and positioned to receive a fastener to secure the second member to a third member in place of the first member, the third member having a hole in a threaded end portion thereof alignable with the hole in the second member. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional patent application to Bottjer entitled “WRITING DEVICE FOR SINGLE-DIGIT USE,” Ser. No. 61/877,412, filed Sep. 13, 2013, the disclosure of which is hereby incorporated entirely herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The following relates generally to writing instruments, and in particular to a writing device that may be operated by single-digit use.
[0004] 2. State of the Art
[0005] In many work environments, a writing instrument is integral to the completion of one's job. However, a problem arises when the job requires occasional, rather than continuous, use of the writing instrument. This is because, in most cases, both cannot be used at the same time—the complexities of the job require, at times, that the fingers are used without the burden of holding the writing instrument and, at other times, that the fingers manipulate the writing instrument to write.
[0006] Such a situation introduces inefficiency into the job to be completed. For example, when a writing instrument must be set down and picked back up time and time again, significant time and effort may be wasted. When setting the writing instrument down, so that it does not roll away, one must turn away from the work being done and purposefully place the writing instrument on a level surface or other object. Moreover, every time the writing instrument is needed again, one must turn away from the task at hand, find the writing instrument to be used, and thereafter refocus on the task at hand. This transition between using the writing instrument, putting the writing instrument down to use one's fingers and hands without the writing instrument, and picking back up the writing instrument can be wasteful of one's time and inefficient in one's efforts. It is also cumbersome, repetitive, and even irritating in its monotony.
[0007] It would therefore be very desirable and useful to have a new and improved writing device that can be deployed by a user without having to set it down or pick it back up. And, in addition thereto, the writing device should not impede one's efforts in performing the task at hand that requires occasional use of a writing instrument.
SUMMARY
[0008] The present disclosure relates to writing instruments, and in particular to a writing device that may be operated by single-digit use.
[0009] A first general aspect relates to an adjustable holder for a writing instrument, the holder comprising a digit engaging member, wherein the digit engaging member has an axis and an adjustable diameter for functionally engaging a portion of a user's digit without substantially impeding articulation of the digit, and an instrument engaging member functionally coupled to the digit engaging member, the instrument engaging member configured to receive the writing instrument, wherein under the condition the writing instrument is functionally engaged by the instrument engaging member, a length of the writing tip of the writing instrument is oriented substantially orthogonally to the axis of the digit engaging member.
[0010] Another general aspect relates to wherein the digit engaging member is configured to repeatedly and releasably engage the portion of the user's digit.
[0011] Another general aspect relates to wherein the digit engaging member engages the user's digit between neighboring joints of the digit without impeding articulation of the digit.
[0012] Another general aspect relates to wherein the instrument engaging member is configured to rotate with respect to the digit engaging member between an orthogonal position wherein the length of the writing tip and the axis of the digit engaging member are substantially orthogonal to one another and a parallel position wherein the length of the writing tip and the axis of the digit engaging member are substantially parallel with one another.
[0013] Another general aspect relates to wherein the instrument engaging member is configured to releasably and repeatedly couple to the digit engaging member.
[0014] Another general aspect relates to wherein the instrument engaging member is configured to releasably and repeatedly engage the writing instrument.
[0015] Another general aspect relates to wherein the length of the writing tip of the writing instrument is fixedly oriented substantially orthogonally to the axis of the digit engaging member.
[0016] Another general aspect relates to wherein the writing device is inserted on a thumb of the user.
[0017] Another general aspect relates to an adjustable writing device, the writing device comprising a digit engaging member, wherein the digit engaging member has an adjustable diameter for functionally engaging a portion of a user's digit without substantially impeding articulation of the digit, an instrument engaging member functionally coupled to the digit engaging member, a writing tip functionally coupled to the instrument engaging member, and a cartridge adapted to communicate with the instrument engaging member to allow ink within the cartridge to be dispensed from the writing tip.
[0018] Another general aspect relates to wherein the digit engaging member is configured to repeatedly and releasably engage the portion of the user's digit.
[0019] Another general aspect relates to wherein the digit engaging member engages the user's digit between neighboring joints of the digit without impeding articulation of the digit.
[0020] Another general aspect relates to wherein the instrument engaging member is configured to rotate with respect to the digit engaging member.
[0021] Another general aspect relates to wherein the instrument engaging member is configured to releasably and repeatedly couple to the digit engaging member.
[0022] Another general aspect relates to wherein the writing tip is configured to releasably and repeatedly couple to the instrument engaging member.
[0023] Another general aspect relates to wherein the cartridge is configured to releasably and repeatedly couple to the instrument engaging member on an opposing end of the instrument engaging member from the writing tip.
[0024] Another general aspect relates to wherein the writing device is inserted on a thumb of the user.
[0025] Another general aspect relates to a method of utilizing a writing device, the method comprising coupling a writing instrument to the writing device, coupling the writing device to a digit on a hand of a user such that a length of the writing instrument is oriented substantially orthogonally to an axis of the digit on which the device is coupled, and operating the writing instrument by movement of the digit.
[0026] Another general aspect relates to a digit engaging member defining an opening and the opening defining an axis, wherein the coupling the writing device on a digit on a hand of a user further comprises inserting the digit into the opening, the opening being configured to repeatedly and releasably couple the writing device to the digit.
[0027] Another general aspect relates to wherein the coupling a writing instrument to the writing device further comprises inserting the writing instrument through a sleeve defined by the writing device, the sleeve being configured to engage the writing instrument.
[0028] Another general aspect relates to wherein the operating the writing device further comprises: inserting the writing device on a user's thumb; moving the thumb to make one or more markings on a first object; and operating a second object in the user's hand having the device thereon between the one or more markings without removing the device from the user's thumb.
[0029] The foregoing and other features, advantages, and construction of the present disclosure will be more readily apparent and fully appreciated from the following more detailed description of the particular embodiments, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members.
[0031] FIG. 1 is a side perspective view of an embodiment of an adjustable writing device in accordance with the present disclosure.
[0032] FIG. 2 is a side view of an embodiment of an adjustable writing device in accordance with the present disclosure.
[0033] FIG. 3 is a rear perspective view of an embodiment of an adjustable writing device in accordance with the present disclosure.
[0034] FIG. 4 is a front perspective view of an embodiment of an adjustable writing device in accordance with the present disclosure.
[0035] FIG. 5 is a side perspective view of an embodiment of an adjustable writing device being utilized by a user in accordance with the present disclosure.
[0036] FIG. 6 is a side perspective view of an embodiment of an adjustable writing device being utilized by a user in accordance with the present disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
[0037] A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures listed above. Although certain embodiments are shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present disclosure will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of embodiments of the present disclosure.
[0038] As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
[0039] Referring to the drawings, FIG. 1 depicts an embodiment of an adjustable writing device 10 in accordance with the present disclosure. The writing device 10 may further comprise various structural components that complement one another to provide the unique functionality and performance of the writing device 10 , the structure and function of which will be described in greater detail herein. For example, embodiments of the writing device 10 may comprise, among other components, a digit engaging member 20 , an instrument engaging member 30 , and a writing utensil 40 .
[0040] Embodiments of the adjustable writing device 10 may comprise a digit engaging member 20 . The digit engaging member 20 may comprise an engagement body 22 that defines an engagement opening 24 that may be configured to be releasably and repeatedly coupled to and disengaged from a digit of a user.
[0041] Embodiments of the engagement body 22 may be comprised of a rigid materials, such as metal, plastic, or composite materials of similar properties that may retain the shape of the engagement body 20 as it functionally engages the digit of the user. The engagement opening 24 may have a diameter that can be adjusted by altering or otherwise changing a length of the engagement body 22 . The diameter of the engagement opening 24 may be adjusted as needed to functionally engage the digit of the user. For larger diameter digits, the diameter of the engagement opening 24 may be enlarged accordingly. Similarly, for smaller diameter digits, the diameter of the engagement opening 24 may be reduced accordingly. The engagement opening 24 may be configured to be slid onto the digit of the user. In other words, the engagement opening 24 may functionally engage the digit of a user much like a ring might engage the digit of a user. The engagement opening 24 may provide a friction fit with the digit, so as to secure the device 10 onto the digit. In addition, the diameter of the engagement opening 24 may be adjusted after the device 10 is placed on the digit to securely snug the device 10 onto the digit and substantially prevent unwanted movement of the device 10 . The diameter of the engagement opening 24 may be altered by such means as are now known in the art or later developed, such as for example, but not limited thereto, by straps, buttons, hooks, hook and loop fasteners, belts, loops, zippers, elastic, adhesive, worm gears, clamps, etc. In addition, the diameter of the engagement opening 24 may be altered by adjusting the length of the engagement body 22 with respect to itself by such means as those described above, for example, but not limited thereto, by straps, buttons, hooks, hook and loop fasteners, belts, loops, zippers, elastic, adhesive, worm gears, clamps, etc. The engagement opening 24 may define an axis 26 .
[0042] Embodiments of the adjustable writing device 10 may further comprise the engagement body 22 being made of flexible material, such as stretch material or elastic material. Under these conditions, the engagement body 22 may be stretched from its normal diameter and placed onto the digit of the user. Once over the digit, the flexible engagement body 22 may be released so as to return to its normal diameter and snugly engage the digit of the user and remain in place on the digit.
[0043] Embodiments of the adjustable writing device 10 may further comprise the engagement body 22 having an axial width that is large enough to resist and substantially prevent the engagement body 22 from axially advancing along, radially spinning about, or pivoting on the digit of the user in response to forces acting on the device 10 . In other words, the engagement body 22 may have a width that provides sufficient stability, support, and friction to prevent undesired movement of the engagement body 22 on the digit. Moreover, the width of the engagement body 22 may yet be small enough to fit onto the proximal phalanges, the intermediate phalanges, and/or the distal phalanges of the user. In this way, the width of the engagement body 22 may allow the user to place the writing device 10 on one of the phalanges and thereafter use the normal articulation of the hand, and especially the fingers and thumb of the hand, despite the presence of the writing device 10 on the fingers and/or thumb. In other words, the width of the engagement body 22 may be configured to be less than the distance between neighboring joints of the digit on which the device 10 is placed so as to not interfere with the articulation of the joints between the phalanges.
[0044] Embodiments of the adjustable writing device 10 may further comprise the engagement body 22 having slits, gaps, openings, slots and/or holes to allow the user's skin under the engagement body 22 to breathe with the ambient air. These slits, gaps, openings, slots and/or holes may be positioned haphazardly around the body 22 or may be placed intermittently on the body 22 . In this way, moisture from the user's skin can ventilate with the ambient air and thus evaporate without causing build-up of moisture and sweat that might otherwise cause the engagement body 22 to slip or displace on the user's digit.
[0045] Embodiments of the adjustable writing device 10 may further comprise an instrument engaging member 30 . The instrument engaging member 30 may be configured to functionally engage a writing instrument 40 . Embodiments of the instrument engaging member 30 may be configured to be coupled to the digit engaging member 20 , such that the digit engaging member 20 may support the instrument engaging member 30 thereon and/or thereby. The instrument engaging member 30 may be configured to releasably and repeatedly couple to and disengage from the digit engaging member 20 by the coupling means 38 , so as to possibly be exchanged with other or additional instrument engaging members 30 . The coupling means 38 may be cooperating brackets, adhesive, hook and loop fastener, snaps, belts, slide on clips, ties, or other releasable coupling means known in the art. Alternatively, the instrument engaging member 30 may be configured to be fixedly coupled to the digit engaging member 20 by coupling means 38 . The coupling means 38 may further comprise welds, seals, permanent adhesive, or other permanent coupling mechanisms known in the art. Embodiments of the device 10 may further comprise the digit engaging member 20 and the instrument engaging member 30 being comprised of a single integral piece, wherein the digit engaging member 20 and the instrument engaging member 30 are a unitary body that yet permits the diameter of the digit engaging member 20 to be adjusted.
[0046] As depicted clearly in FIG. 4 , embodiments of the device 10 may further comprise the instrument engaging member 30 defining an axial sleeve or slot 36 running through the entire axial length of the instrument engaging member 30 , the slot 36 being configured to receive therein and there through the writing instrument 40 , such that a tip 42 of the writing instrument 40 may be inserted into the axial slot 36 and pushed through the axial slot 36 so as to extend out one side of the instrument engaging member 30 . A body 44 of the writing instrument 40 may extend out the other side of the instrument engaging member 30 . The body 44 may be configured to hold ink, pigments, dyes, liquids, pastes, or other marking material that may facilitate the tip 42 being able to leave marks, designs, text or images, on objects such as paper and the like. The axial slot 36 may be configured to functionally engage the writing instrument 40 by friction fit. The axial slot 36 may be configured to permit the writing instrument 40 to be removed from the axial slot 36 so as to permit the user to insert another or a different writing instrument 40 into the axial slot 36 to be engaged thereby. In this way, a set of writing instruments 40 may be utilized by the user of the writing device 10 , as desired. For example, the set of writing instruments 40 may include each instrument 40 in the set providing a different color, different font size (i.e, tip size), and/or different ink consistency.
[0047] Embodiments of the adjustable writing device 10 may further comprise the instrument engaging member 30 being configured to position the writing instrument 40 substantially orthogonal to the axis 26 of the finger engaging member 20 , such that an axis 46 of the writing instrument 40 is substantially orthogonal to the axis 26 of the digit engaging member 20 . In this way, the writing instrument 40 may be positioned substantially orthogonally to the axis of the digit, and thus the axis of the phalange (or finger), upon which the device 10 is deployed by the user 60 , as depicted in FIGS. 5 and 6 . As depicted in FIG. 5 , the device 10 may be coupled to the phalange of the thumb so as to not interfere with the distal end of the thumb and the fingers combining to utilize a tool, such as a pen, pencil, or other writing instrument, not depicted. At any rate, FIG. 5 demonstrates that the device 10 may not interfere with other normal operations of the thumb and fingers. As depicted in FIG. 5 , the device 10 may be coupled to the phalange of the thumb so as to not prevent the thumb, fingers, and hand of the user 60 from resting in a comfortable position, such as a resting position with portions of the palm, thumb, and fingers resting on the surface. As depicted in FIG. 6 , the device 10 may be coupled to the phalange of the thumb so as to not prevent the thumb, fingers, and hand of the user 60 from utilizing and competently operating components such as a mouse of a computer system, from typing on a keyboard of a computer system, or from other similar hand-required, or finger-manipulation tasks.
[0048] Embodiments of the adjustable writing device 10 may further comprise the instrument engaging member 30 being configured to twist, spin, rotate, or otherwise pivot with respect to the digit engaging member 20 to reposition the writing instrument 40 such that the axial length of the writing instrument 40 is substantially parallel with the axis 26 of the finger engaging member 20 , or substantially parallel with the axial length of the digit on which the device 10 is configured. The instrument engaging member 30 may be configured to “click” into place in either the orthogonal or parallel configurations described above. In other words, once positioned at either the parallel or orthogonal configuration, the instrument engaging member 30 may be prevented from pivoting or releasing therefrom without user input, user operation, or user release.
[0049] With particular reference now to FIGS. 2-4 , embodiments of the device 10 may further comprise the writing utensil 40 being comprised of a writing tip 42 and a cartridge 44 . The cartridge 44 may be configured to house ink, pigments, dyes, liquids, pastes, or other marking material that may be utilized by the device 10 to write or otherwise mark on objects. The cartridge 44 may be configured to functionally communicate with the instrument engaging member 30 to pass the ink, pigments, dyes, liquids, pastes, or other marking material to the writing tip 42 that may be configured to receive the material from the cartridge and write or otherwise mark on objects and/or surfaces, as desired by the user. The writing tip 42 may be configured to functionally communicate with the opposing end of the instrument engaging member 30 to receive the ink, pigments, dyes, liquids, pastes, or other marking material from the cartridge 44 through the instrument engaging member 30 .
[0050] Accordingly, embodiments of the adjustable writing device 10 may further comprise the instrument engaging member 30 further comprising a writing tip engaging member 32 and a cartridge engaging member 34 . The writing tip engaging member 32 may be configured to functionally engage the writing tip 42 . Likewise the cartridge engaging member 34 may be configured to functionally engage the cartridge 44 . In this way, the writing tip 42 may be releasably and repeatedly coupled to the instrument engaging member 30 via the writing tip engaging member 32 . Further, the cartridge 44 may be releasably and repeatedly coupled to the instrument engaging member 30 via the cartridge engaging member 34 . In this way, different cartridges 44 holding ink, pigments, dyes, liquids, pastes, or other marking material of various quantity, quality, color, consistency, or other characteristic may be coupled to or removed from the instrument engaging member 30 , as desired by the user. In like manner, different writing tips 42 of different size, font, type, or shape may be coupled to or removed from the instrument engaging member 30 , as desired by the user. As a result, the user may customize the adjustable writing device 10 according to the specific want or need.
[0051] Embodiments of the adjustable writing device 10 may be worn on the thumb of the user, such that marks can be made on surfaces without the need for the user to pick up a writing utensil every time a mark must be made on the surface. Further, the user may move his/her hand in such a way as to mark text, letters, images, and/or designs on the same surface as needed. To do so, the user may desire to place the thumb against the palm of the hand, or other proximate surface of the hand, to hold the device 10 in place between the thumb and the hand while exerting force on the device 10 to cause the writing tip 42 to move in such a motion as to leave the desired leave marks, text, images, or designs.
[0052] The components defining the above-described adjustable writing device 10 may be formed of any of many different types of materials or combinations thereof that can readily be formed into shaped objects provided that the components selected are consistent with the intended operation of a writing instrument of the type disclosed herein. For example, and not limited thereto, the components may be formed of: rubbers (synthetic and/or natural) and/or other like materials; glasses (such as fiberglass) carbon-fiber, aramid-fiber, any combination thereof, and/or other like materials; polymers such as thermoplastics (such as ABS, Fluoropolymers, Polyacetal, Polyamide; Polycarbonate, Polyethylene, Polysulfone, and/or the like), thermosets (such as Epoxy, Phenolic Resin, Polyimide, Polyurethane, Silicone, and/or the like), any combination thereof, and/or other like materials; composites and/or other like materials; metals, such as zinc, magnesium, titanium, copper, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, aluminum, any combination thereof, and/or other like materials; alloys, such as aluminum alloy, titanium alloy, magnesium alloy, copper alloy, any combination thereof, and/or other like materials; any other suitable material; and/or any combination thereof.
[0053] Furthermore, the components defining the above-described adjustable writing device 10 may be purchased pre-manufactured or manufactured separately and then assembled together. However, any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, 3-D printing and/or the like. If any of the components are manufactured separately, they may then be coupled with one another in any manner, such as with adhesive, a weld, a fastener (e.g. a bolt, a nut, a screw, a nail, a rivet, a pin, and/or the like), wiring, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material forming the components. Other possible steps might include sand blasting, polishing, powder coating, zinc plating, anodizing, hard anodizing, and/or painting the components for example.
[0054] While this disclosure has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the present disclosure as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure, as required by the following claims. The claims provide the scope of the coverage of the present disclosure and should not be limited to the specific examples provided herein. | An adjustable writing device is provided. The adjustable writing device has a digit engaging member that has an adjustable diameter for functionally engaging a portion of a user's digit without substantially impeding articulation of the digit. The writing device has a cartridge engaging member that includes a writing tip coupled to the cartridge engaging member and an ink cartridge adapted to communicate with the cartridge engaging member to allow ink within the ink cartridge to be dispensed from the writing tip. The writing tip can be oriented substantially orthogonal to an axis of the digit engaging member. A friction fit between the digit engaging member and the digit prevents the writing tip from rotating about the digit. | 1 |
FIELD OF THE INVENTION
The invention relates to a subpicture image signal vertical compression circuit for vertically compressing sub pictures operating at respective synchronous timings different from that of the main picture when a plurality of image signals, having respective different synchronizations, are displayed on an image display device. Specifically, the invention relates to a subpicture image signal vertical compression circuit for a compressed interlace display of one or more subpictures having respective synchronous timings different from that of a main picture displayed on an image display device together with the main picture.
BACKGROUND OF THE INVENTION
The need for simultaneously displaying a plurality of images and information has recently increased. In particular, demand for displays corresponding to multimedia requirements have increased. FIGS. 6(a) and 6(b) show examples of the display device. A subpicture 2 is displayed in the main picture 1 as shown in FIG. 6 (a), or subpictures 4, 5, 6 having the same size as the main picture 3 are simultaneously displayed as shown in FIG. 6 (b). The picture displayed as the main picture is the image signal used as the synchronization signal of the display screen.
When a plurality of image signals having respective synchronization signals are simultaneously displayed on an image display device, the synthesis of those images is important.
Since the main picture signal is synchronized with the image display device, the timing of its image signal processing, such as picture compression, is not a problem. On the other hand, because the subpicture signals are not synchronized with the image display device, the timing of those signals must be considered.
The invention relates to a subpicture image signal vertical compression circuit for compressing the subpicture image signal in the vertical direction by vertical interpolation. The main picture signal and the subpicture signal are assumed to be interlaced signals.
Hereafter, a conventional subpicture image signal vertical compression circuit will be illustrated referring to drawings. FIG. 4 is the block diagram of a conventional subpicture image signal vertical compression circuit. FIG. 5 is an operational waveform diagram for illustrating the operation of the conventional subpicture image signal vertical compression circuit. The signals shown in FIG. 4 and FIG. 5 correspond to each other.
In FIG. 4, 31 is a field discrimination circuit for determining, from the vertical pulse and the horizontal pulse, the polarity of the field, that is, for determining from which of a first field (odd number field) or a second field (even number field) the scan starts. 32 is an offset generation circuit for generating offsets corresponding to the compression rates in the first and second fields. 33 is an interpolation circuit for interpolating and compressing the input image signal by the compression rate.
The operation of the subpicture image signal vertical compression circuit structured as above is described below.
The field discrimination circuit 31 determines whether the polarity is the first field or the second field from the vertical pulse and the horizontal pulse and outputs the result. The offset circuit 32 makes the offset of the first field 0, and determines the offset of the second field according to the compression rate of the subpicture. In FIG. 5, a five line signal of an input subpicture image signal is compressed to a four line signal in the subpicture. The compression rate is 4/5, and 1/2 of the interlace is subtracted from 1/2 of the reciprocal of the compression rate and the offset becomes ##EQU1##
Interpolation circuit 33 sets pixel values between the scanning lines by interpolation and outputs the compressed image signal by thinning out the scanning lines. At this time, pixel values are interpolated at the position time-delaying by the offset at the second field.
As to the conventional constitution illustrated above, when the main picture and the subpicture, each having a different field polarity, are displayed at the same time, since the phase of the second field signal of the subpicture after the compression is not 1/2 that of the first field, the scanning order in the vertical direction of subpicture signal may be reversed at the first field and the second field and this causes distortion of the image in the vertical direction.
SUMMARY OF THE INVENTION
In consideration of the above problems, the present invention provides a subpicture image signal vertical compression circuit for providing a subpicture without distortion in the vertical direction through the steps of:
judging if the field polarity of the subpicture is the same as that of the main picture;
generating offsets of the first field and the second field according to above judgment;
correcting the phase of pixel value interpolation according to the offsets and performing the interpolation and the compression.
To solve above problems, the subpicture image signal vertical compression circuits comprise:
a main picture field discrimination circuit for generating a field discrimination signal for discriminating the polarity indicating if the field scan of the main picture starts, from the first field or second field from the vertical pulse and the horizontal pulse of the main picture;
a subpicture field discrimination circuit for generating a field discrimination signal for discriminating the field scan start polarity of the subpicture displaying a compressed input subpicture image signal compressed by a predetermined rate, from the vertical pulse and the horizontal pulse of the subpicture;
an offset generation circuit for generating offsets corresponding to the compression rate at the first field and the second field of the subpicture by imputing the main picture field discrimination signal, the subpicture field discrimination signal, and the compression rate;
an output circuit for inputting said offsets, said compression rate, and said input subpicture image signal; shifting the field scan start timing of the subpicture by the equivalent of the offset; vertically compressing said input subpicture image signal; and outputting the compressed signal.
The subpicture image signal vertical compression circuit of claim 5 of the invention comprises:
a main picture field discrimination circuit for generating a main picture field discrimination signal from the vertical pulse and the horizontal pulse of the main picture;
a subpicture field discrimination circuit for generating a subpicture field discrimination signal from the vertical pulse and the horizontal pulse of the subpicture;
the offset generation circuit generates offsets corresponding to said compression rate at the first field and the second field of the subpicture by imputing the main picture field discrimination signal, the subpicture field discrimination signal, and the compression rate;
the offset generation circuit generates offsets corresponding to said compression rate at the first field and the second field of the subpicture by imputing the main picture field discrimination signal, the subpicture field discrimination signal, and the compression rate;
a frequency difference detection circuit: inputting the output signal of the offset generation circuits, the main picture field frequency, and the subpicture field frequency; detecting the difference between the main picture field frequency and the subpicture field frequency; selecting the output signal of the offset generation circuit; and outputting the selected signal;
an interpolation circuit: inputting the output signal of said frequency difference detection circuit, the compression rate, and the input subpicture image signal; interpolating the input subpicture image signal; and outputting interpolated signal.
By this structure of the invention, suitable offsets are generated at the first field and the second field according to whether the polarities of main picture and subpicture are the same or not. The compression is performed, the inversion of the scan order in the vertical direction of the subpicture signal at the first field and the second field after the synthesis with main picture can be prevented, so a subpicture image, without unnatural movement in the vertical direction can be obtained.
Further, more preferable offsets can be generated by switching the two offset circuits by using the main picture field frequency and the subpicture field frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a subpicture image signal vertical compression circuit showing an embodiment of the invention.
FIG. 2 is a block diagram of a subpicture image signal vertical compression circuit showing another embodiment of the invention.
FIGS. 3(a) and 3(b) are operational waveform diagrams illustrating the operation of the circuit.
FIG. 4 is a block diagram of a conventional subpicture image signal vertical compression circuit.
FIG. 5 is an operational waveform diagram for illustrating the operation of the circuit.
FIG. 6 (a) is a first example of a plurality of image signals having respective different timings of the synchronization signal displayed on an image display device.
FIG. 6 (b) is a second example of a plurality of image signals having respective different timings of the synchronization signal displayed on an image display device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A subpicture image signal vertical compression circuit of an embodiment of the invention will be illustrated referring to the drawings. FIG. 1 is a block diagram of a subpicture image signal vertical compression circuit showing an embodiment of the invention. FIG. 2 is a block diagram of a subpicture image signal vertical compression circuit showing another embodiment of the invention. FIGS. 3(a) and 3(b) are operational waveform diagrams for illustrating the operation of the subpicture image signal vertical compression circuit showing an embodiment of the invention. Signals shown in FIGS. 1 through 3 correspond to each other.
In FIG. 1, 11 is a main picture field discrimination circuit for determining the field polarity of the main picture from the vertical pulse and the horizontal pulse of the image signal having the image information of the main picture. 12 is a subpicture field discrimination circuit for discriminating the field polarity of the subpicture from the vertical pulse and the horizontal pulse of the input subpicture image signal.
13 is an offset generation circuit for generating offsets corresponding to the compression rate at the first field and the second field of the subpicture. 14 is an interpolation circuit for interpolating the input subpicture image signal based on the offsets and the compression rate.
The operation of the subpicture image signal vertical compression circuit structured as above is described hereafter.
The main picture field discrimination circuit 11 determines whether the polarity is the first field or the second field from the vertical pulse and horizontal pulse of the main picture and outputs the result.
The subpicture field discrimination circuit 12 determines whether the polarity is the first field or the second field from the vertical pulse and horizontal pulse of the subpicture and outputs the result.
The offset circuit 13 determines offsets by the following steps.
When the field polarities of main picture and subpicture are the same, the offset of the first field is 0, and the offset of the second field is determined according to the compression rate. In FIGS. 3(a) and 3(b) a five line signal of an input subpicture image signal is compressed into a four line signal subpicture. The compression rate is 4/5, and 1/2 is subtracted from 1/2 of the reciprocal of the compression rate to result in an offset of 1/8.
When the field polarities of main picture and subpicture are different, the offset of the first field is obtained by subtracting 1/2 from 1/2 of the reciprocal of the compression rate and the offset of the second field is determined as -1.
Next, since interpolation circuit 14 sometimes has to arrange pixels at the portion where a scan line doesn't exist because of thinning out the compression and the like, pixels are arranged between the scan lines by interpolation, the input subpicture image signal is then compressed and output. In this way, the interpolation phases of the first field and the second field are delayed by each of the offsets.
Some thinning methods allow compression using pixels on a scan line, accordingly, interpolation is not performed in this case, and compression thinning of the same lines can be performed simply.
Using the offset circuit is shown in FIG. 3(a), when the field polarities of the main picture and subpicture are the same, since the offset of the first field is 0, the input subpicture image signal and the output subpicture image signal have the same interpolation phase (when main and sub fields have the same polarity), and since the offset of the second field is 1/8, the output subpicture image signal (when main and sub fields have the same polarity) is delayed by 1/8 with respect to the input subpicture image signal of the second field.
When the main and sub fields have different polarities, the offset is 1/8 in the first field, the output subpicture image signal (when main and sub fields have different polarities) is delayed by 1/8 of the phase with respect to the input subpicture image signal and since the offset of the second field is -1, the output subpicture image signal (when main and sub fields have different polarities) advances by 1 with respect to the input subpicture image signal of the second field.
As above, according to whether the main and sub field polarities are the same or not, the offsets generated at the first and second fields are switched to prevent the inversion of the scan order in the vertical direction at the first field and the second field of the subpicture signal after synthesis with the main picture to obtain the subpicture having natural movement in the vertical direction. Since the offset of the first field and the offset of the second field are only interchanged according to whether the polarities of main and sub pictures are the same or not, there is an advantage that picture quality of subpicture after interpolation and compression in the vertical direction can be maintained.
However, there is a disadvantage that the phase of the subpicture after interpolation and compression in the vertical direction moves by 0.5 line depending on whether the polarities of main and sub pictures are the same.
When the field polarities of main and sub pictures are the same the offset of the first field is determined as 0. The offset of the second field is obtained by subtracting 1/2 from 1/2 of the reciprocal of the compression rate. When the field polarities of main and sub pictures are different, however, the offset of the first field is 1/2 of the reciprocal of the compression rate, the offset of the second field is determined as -1/2 to make the phase of the subpicture after interpolation and compression in the vertical direction the same whether the field polarities of main and the sub pictures are the same or not.
As shown in FIG. 3(b), when the field polarities of the main picture and the subpicture are the same, since the offset of the first field is 0 the input subpicture image signal and the output subpicture image signal have the same interpolation phase (when main and sub fields have the same polarity), and since the offset of the second field is 1/8, the output subpicture image signal (when main and sub fields have the same polarity) is delayed by 1/8 of the phase with respect to the input subpicture image signal of the second field.
When main and sub fields have different field polarities, since the offset is 5/8 in the first field, the interpolation phase of the output subpicture image signal (when main and sub fields have different polarities) is delayed by 5/8 with respect to the input subpicture image signal. Since the offset in the second field is -1/2, the phase of the output subpicture image signal (when main and sub fields have different polarities) advances by 1/2 with respect to that of the input subpicture image signal of the second field.
However, since the offsets given are changed according to whether the main and sub field polarities are the same or not, the qualities of the subpicture after interpolation and compression in the vertical direction are different.
The offset generation circuits are switched based on whether the difference between the main picture frequency and the subpicture frequency is large or small.
When the frequency difference is small, since switching of the main and sub field polarities does not occur very often, the phase moves by 0.5 line of the subpicture after interpolation and compression in the vertical direction between the cases where the main and sub field polarities are the same or different is allowable. Priority being on the picture quality, the offset generation circuit 13a is selected, and the interpolation and compression is performed by using the output from the offset circuit 13a as the offsets. When the frequency difference is large, since switching of the same or different of main and sub field polarities occurs very often, so that the phase slide by 0.5 line is not allowable, the offset generation circuit 13b is selected to make the phase of subpicture after interpolation and compression in the vertical direction the same phase.
In the invention illustrated above, the offsets of the first field and the second field are switched according to whether the field polarities of main and sub pictures are the same or not, further, performing interpolation and compression by selecting one suitable offset generation circuit from the two offset circuits by the relation between the field frequencies of the main picture and the subpicture, a subpicture image with natural movement in vertical direction can be obtained. | A subpicture image signal vertical compression circuit for vertically compressing subpictures operating at respective synchronous timings different from that of the main picture when a plurality of image signals having respectively different synchronizations are displayed on an image display device. Depending on whether the field polarities of main and sub pictures are the same or not, the subpicture image signal vertical compression circuit generates suitable offsets for the first and the second fields to adjust the phases and prevent the inversion of the scan order in the vertical direction, at the first field and the second field of subpicture signal, after the phase adjustment to obtain a subpicture image with natural motion in the vertical direction. | 7 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a device for controlling displacement of a variable displacement hydraulic pump adapted to be driven with a fixed displacement hydraulic pump by a common prime mover.
(2) Description of the Prior Art
In the prior art device for controlling displacement of a variable displacement hydraulic pump as driven by a prime mover, pressure in a discharge pipe of the variable displacement hydraulic pump is detected, and displacement is controlled to be increased or decreased in response to the pressure to render a drive torque of the variable displacement hydraulic pump constant and thereby to maintain an output of the prime mover at a constant level.
In the case that both the variable displacement hydraulic pump and a fixed hydraulic pump are driven by a common prime mover, as the output of the prime mover is fluctuated in association with fluctuation in load of the fixed displacement hydraulic pump, reduction in a rotational speed of the prime mover is detected as excess of load of the prime mover (overload of the fixed hydraulic pump) as well as displacement control of the variable displacement hydraulic pump, and according to such detection, the displacement of the variable displacement hydraulic pump is reduced to maintain the output of the prime mover at a constant level.
However, since such a control device as above is designed to detect reduction in engine rotational speed and input a detection signal to a displacement control system of the variable displacement hydraulic pump to control the displacement, there will be created delay of reponse time, and stable displacement control may not be provided.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a device for controlling displacement of a variable displacement hydraulic pump which may control the displacement stably by inputting load fluctuations of the variable displacement hydraulic pump and the fixed displacement hydraulic pump to the displacement control system without delay of response time, and maintain an input torque of the prime mover at a constant level.
According to the present invention, the device for controlling displacement of at least a variable displacement hydraulic pump comprises a displacement control system for receiving a discharge pressure of the variable displacement hydraulic pump and a discharge pressure of a fixed displacement hydraulic pump to control the displacement of the variable displacement hydraulic pump. The displacement control system comprises a servopiston including a helical compression spring for maintaining the variable displacement hydraulic pump at a maximum swash angle in a neutral position of associated operating value, a servovalve including a spool for selectively controlling communication of hydraulic pressure between a control pump and a pair of fluid chambers defined in the servopiston, a control piston connected through a control lever pivotably supported by pivot pin to the spool and the servopiston, at least two helical compression springs for biasing the control piston and controlling torque and flow so as to approximate same to a constant torque curve, a floating spring seat interposed between the helical compression springs, and a guide rod for guiding the floating spring seat and accommodated in a bore formed in the housing at a base portion thereof to define a pressure chamber pressurized by a biasing spring, the pressure chamber being communicated through a conduit to a discharge passage of the fixed displacement hydraulic pump.
Other objects and advantages of the invention will become apparent from the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation, in section, of the displacement control device according to the present invention; and
FIGS. 2, 3 and 4 are graphs showing a relation between the discharge pressure and the displacement of first and second variable displacement hydraulic pumps.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, reference numerals 1, 2, 3 and 4 designate first and second variable displacement hydraulic pumps, a fixed displacement hydraulic pump and a control pump, respectively, which are driven by a common prime mover E. Discharge conduits 1a, 2a and 3a of the first and second variable hydraulic pumps 1 and 2 and the fixed hydraulic pump 3 are connected through operating valves 5, 6 and 7 to hydraulic equipments 8, 9 and 10. A discharge conduit 4a of the control pump 4 is connected to a displacement control system A.
The displacement control system A comprises a servopiston 30 accommodated in a housing 31 and connected through a rod or actuator arm 32 to swash plates 1b and 2b of the first and second variable hydraulic pumps 1 and 2, a helical compression spring 33 for maintaining the swash plates 1b and 2b of the first and second variable displacement hydraulic pumps 1 and 2 at a maximum angle in a neutral position of the operating valves 5 and 6, end covers 34 and 35 fixed by bolts and the like to the housing 31 and seal members 78 and 79.
Symbols B and C designate an input signal section of the displacement control system and a guide valve section of the displacement control system, respectively.
In the input signal section B, a control piston 36 is connected through a control lever 37 to a spool 38 and the servopiston 30. The control lever 37 is connected through a pivot pin 39 to the control piston 36. The control lever 37 is connected to the spool 38 and the servopiston 30 in such a manner that respective spherical portions 37' and 37" are engaged with respective recesses 30' and 30".
First and second helical compression springs 40 and 41 for controlling torque and flow, respectively, are used for purpose of approximation to a constant torque curve by two-step straight lines. In case of approximation by three-step straight lines, three similar compression springs may be used.
Reference numerals 42 and 44 designate a spring seat of the first spring 40 and a guide rod for a floating spring seat 43 of the first and second springs 40 and 41, respectively. The guide rod 44 serves to adjust an intermediate point of a broken line approximate to the constant torque curve. A spring seat 45 of the second spring 41 serving as an end cover for guiding the guide rod 44 is formed with a bore 46 engaging with a large diametrical portion of the guide rod 44 to define a first pressure chamber 47. The guide rod 44 is biased rightwardly by a spring 80, and a biasing force of the spring 80 may be adjusted by an adjusting screw 81. The first pressure chamber 47 is connected through a conduit 16-a to the discharge conduit 3a of the fixed displacement hydraulic pump 3. Reference numeral 57 designates a drain passage.
A biasing piston 48 receives at its shoulder portion a discharge pressure (self pressure) of the first variable displacement hydraulic pump 1 as transmitted through a conduit 17-a. The piston 48 is inserted in a guide sleeve 50. Similarly, a biasing piston 49 receives at its shoulder portion a discharge pressure of the second variable hydraulic pump 2 as transmitted through a conduit 18-a, and is inserted in a guide sleeve 51. Further, a piston 52 receives at its shoulder portion a discharge pressure of the fixed displacement hydraulic pump 3 as transmitted through a conduit 19-a, and is inserted in an end cover 53.
A passage 54 is formed in the housing 31 for communicating the conduit 17-a with the shoulder portion of the piston 48. Similarly, a passage 55 is formed in the housing 31 for communicating the conduit 18-a with the shoulder portion of the piston 49. A drain passage 56 is also formed in the housing 31.
In the valve guide section C, reference numeral 58 designates a guide sleeve in which the spool 38 is inserted. A hydraulic oil is fed from the control pump 4 through a conduit 14 to a passage 59. An outlet port 60 is communicated through a passage 62 to a first fluid chamber 64 of the servopiston 30, while an outlet port 61 is communicated through a passage 63 to a second fluid chamber 65 of the servopiston 30.
A spring 66 serves to prevent rattle among the control lever 37, spool 38 and servopiston 30, which spring 66 is seated on a spring seat 67. Reference numerals 68 and 69 designate drain passages.
Plugs or adjust screws 70 and 71 serve to change a position of the guide sleeve 58 to adjust a neutral position or an operating position of the displacement control system. The plugs 70 and 71 are threadedly engaged with end covers 72 and 73 and adapted to be moved in right and left directions so as to change the position of the sleeve 58.
The end covers 72 and 73 are fixed by bolts and the like to the housing 31. Reference numerals 72 and 75 designate seal members, and 76 and 77 designate lock nuts for the plugs 70 and 71.
(1) In operation, provided that a discharge pressure of the fixed displacement hydraulic pump 3 is zero, when the operating valves 5 and 6 are in a neutral position, that is, a discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 is under no load, the discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 as an input signal pressure to the displacement control system is zero, and accordingly there is created no force as leftwardly applied to the shoulder portions of the pistons 48 and 49.
A rightward biasing force of the first and second springs 40 and 41 is strong, and accordingly, the pistons 36, 48, 49 and 52 are rightwardly biased. At this time, a right-hand end of the piston 52 is in abutment against the end cover 53.
Under such a condition as above, a control hydraulic pressure transmitted through the conduit 14 is introduced through the passage 59, the outlet port 60 and the passage 62 to the first fluid chamber 64 of the servopiston 30. The second fluid chamber 65 of the servopiston 30 is communicated through the passage 63 and the outlet port 61 to the drain passage 69, and a discharge amount of the variable displacement pump 1 is maintained at a maximum displacement Qmax.
(2) Then, when both of the operating valves 5 and 6 are operated or either is operated to increase a discharge pressure of the first and second hydraulic pumps 1 and 2, pressure loaded on the shoulder portions of the pistons 48 and 49 is increased in the same manner as with the first and second hydraulic pumps 1 and 2, and therefore a leftward force is increased to compress the second spring 41.
If the discharge pressures of the first and second variable displacement hydraulic pumps 1 and 2 are defined as Pa1 and Pa2, respectively, the leftward force created by the pressure applied on the shoulder portions of the pistons 48 and 49 and the discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 acts to compress the second spring 41 and leftwardly move the piston 36 until (Pa1+Pa2)/2={(Pa1+Pa2)/2}L is reached. As a result, the spool 38 is also leftwardly moved, and an opening area between the control hydraulic passage 59 and the outlet port 60 is decreased.
When the condition of (Pa1+Pa2)/2={(Pa1+Pa2)/2}L is reached, the control hydraulic passage 59 is not communicated with both the outlet ports 60 and 61 by the movement of the spool 38.
(3) Next, when the discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 is further increased, the second spring 41 is further compressed to leftwardly move the piston 36. Accordingly, the spool 38 is also leftwardly moved to communicate the control hydraulic passage 59 with the outlet port 61, while communicating the outlet port 60 with the drain passage 69. As a result, the control hydraulic pressure is delivered through the conduit 14, the passage 59, the outlet port 61 and the passage 63 to the second fluid chamber 65, and the hydraulic oil in the first fluid chamber 64 is drained through the passage 62, the outlet port 60 and the drain passage 69, thereby leftwardly moving the piston 30 and decreasing the discharge amount of the variable pump 1.
The control lever 37 is rotated about the pivot pin 39 by the movement of the piston 30 to rightwardly return the spool 38. Further, when the servopiston 30 is positioned at (Pa1+Pa2)/2, the servo hydraulic passage 59 is not communicated with both the outlet ports 60 and 61 to retain a pump discharge amount Q corresponding to (Pa1+Pa2)/2.
Until the condition of (Pa1+Pa2)/2={(Pa1+Pa2)/2}M is reached, the second spring 41 is compressed as mentioned above, the pump discharge amount Q corresponding to the discharge pressures of the first and second variable displacement hydraulic pumps 1 and 2 is set.
(4) When the condition of (Pa1+Pa2)/2={(Pa1+Pa2)/2}M is reached, the first spring 40 is brought into abutment through the spring seat 43 against a shoulder 44b of the guide rod 44. When the discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 is further increased, the leftward force acting on the pistons 48 and 49 is increased to compress the first spring 40. In other words, a biasing force of the first spring 40 is set to be larger than that of the second spring 41. Thus, the piston 36 is leftwardly moved to move the spool 38 leftwardly.
As a result, the hydraulic oil in the servo hydraulic passage 59 as is blocked is introduced to the outlet port 61, and the hydraulic oil at the outlet port 60 is introduced to the drain passage 69. Accordingly, as is similar to the previous paragraph (3), the servopiston 30 is leftwardly moved to decrease the discharge amount of the first and second variable displacement hydraulic pumps 1 and 2. The control lever 37 is rotated about the pivot pin 39 by the leftward movement of the servopiston 30 to rightwardly return the spool 38.
When the servopiston 30 is positioned at (Pa1+Pa2)/2, the servo hydraulic passage 59 is brought into non-communication with both the outlet ports 60 and 61 to retain the pump discharge amount Q corresponding to (Pa1+Pa2)/2. Under the condition of (Pa1+Pa2)/2={(Pa1+Pa2)/2}M, a left-hand end of the piston 30 is in abutment against the end cover 34, and a minimum displacement Qmin of the first and second variable displacement hydraulic pumps 1 and 2.
In the case that the discharge pressure of the first and second variable displacement pumps 1 and 2 is decreased, operation is inverted with respected to the previous paragraphs (3) and (4).
As is above described, until the discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 reaches a given pressure, the first spring 40 is operated, and when the discharge pressure exceeds the given pressure, both the first and second springs 40 and 41 are operated. Consequently, as shown in FIG. 2, the relation between the displacement and the discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 is such that two-step straight lines D and E of different gradient as broken at a given pressure P* are given. Thus, the displacement is controlled under such two-step straight lines condition approximated to a number horse-power curve F.
Further, a discharge pressure of the fixed displacement hydraulic pump 3 is supplied to the first pressure chamber 47, and therefore when the discharge pressure is increased, the guide rod 44 is leftwardly moved against a biasing force of the spring 80. Accordingly, a stroke of the spring seat 43 to the abutment against the shoulder 44b is elongated, and a discharge pressure of the first and second variable displacement hydraulic pumps 1 and 2 upon starting of compression of the second spring 41 is raised, resulting in increase in the pressure P* in FIG. 2 to P1 as shown in FIG. 3 and change from the straight line D to D'.
As the discharge pressure of the fixed displacement hydraulic pump 3 is applied on the piston 52, the leftward force urging the piston 36 is increased, and resultantly the discharge pressure (Pa1+Pa2)/2 in FIG. 2 is raised, thereby permitting the straight lines D and E to be moved in parallel to the straight lines D" and E' as shown in FIG. 4, and rendering the displacement of the first and second variable displacement hydraulic pumps 1 and 2 smaller than the discharge pressure thereof.
In this connection, it is possible to maintain constant a torque for driving the first and second variable displacement hydraulic pumps 1 and 2 and the fixed displacement hydraulic pump 3, and maintain an input torque from the prime mover E at a constant level.
Further, since the discharge pressures of the first and second variable displacement pumps 1 and 2 and the fixed displacement hydraulic pump 3 are inputted to the displacement control system, load fluctuation of each pump may be inputted without delay, and therefore stable displacement control may be attained.
While the invention has been described with reference to the specific embodiment, the description is illustrative and is not to be construed as limiting the scope of the invention. Various modifications and changes may occur to those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims. | Disclosed herein is a device for controlling displacement of a variable displacement hydraulic pump comprising a displacement control system for receiving a discharge pressure of the variable displacement hydraulic pump and a discharge pressure of a fixed displacement hydraulic pump to control the displacement of the variable displacement hydraulic pump. The displacement control system comprises a servopiston including a helical compression spring for maintaining the variable displacement hydraulic pump at a maximum swash angle in a neutral position of associated operating valve, a servovalve including a spool for selectively controlling communication of hydraulic pressure between a control pump and a pair of fluid chambers defined in the servopiston, a control piston connected through a control lever pivotably supported by a pivot pin to the spool and the servopiston, at least two helical compression springs for biasing the control piston and controlling torque and flow so as to approximate same to a constant torque curve, a floating spring seat interposed between the helical compression springs, and a guide rod for guiding the floating spring seat and accommodated in a bore formed in the housing at a base portion thereof to define a pressure chamber pressurized by a biasing spring, the pressure chamber being communicated through a conduit to a discharge passage of the fixed displacement hydraulic pump. | 5 |
BACKGROUND OF THE INVENTION
This invention relates generally to storage racks and more particularly concerns storage racks for palletized articles.
Many articles of manufacture, and particularly relatively heavy articles produced on a production line basis, are palletized for shipment from the place of manufacture.
Storage of such palletized articles often result in waste of both space and labor. If the articles are left palletized the floor space required for storage, though used only temporarily, is considerable. This storage area requirement can be minimized by the use of permanent storage racks, resulting in a lesser, though permanent, use of space. Further space minimization may be possible by storage without using the pallets, but palletization and depalletization at each relocation of the articles requires a large expenditure of time and labor.
If, on the other hand, the pallets themselves can be converted into temporary storage racks, the storage area required will be both temporary and minimal and depalletization need occur only when the articles are to be used.
It is, therefore, an object of this invention to provide a device useful to convert such pallets into temporary storage racks.
SUMMARY OF THE INVENTION
In accordance with the invention a device for stacking pallets is provided. A pair of upright members are secured in spaced relationship with each other. At least one horizontal member is rigidly fixed to each of the upright members. The horizontal members are adapted to cantilever the pallet from the upright members. Means provided on the upright members will secure a similar pair of upright members, mounted in tandem thereon, against relative lateral motion with respect to each other. Means provided on at least one of the horizontal members permit detachable coupling of the horizontal member to the pallet.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which:
FIG. 1 is a perspective view of a pallet to be converted into a storage rack.
FIG. 2 is a perspective developmental view illustrating the use of several stacking devices to convert several pallets into a storage rack.
FIG. 3 is a perspective view of a stacking device for use with the pallet illustrated in FIG. 1.
While the invention will be described in connection with a preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
A typical pallet 10 on which articles of manufacture may be mounted for shipment is illustrated in FIG. 1. Such pallets are generally formed by a transverse arrangement of parallel members, such as the upper and lower arrays of I-bars 13 and 15 shown, in which the lower flanges 17 of the upper array I-bars 13 are fixed to the upper flanges 19 of the lower array I-bars 15.
Referring to FIG. 2, it can be seen that such a pallet can be converted into a storage rack by use of a pair of stacking devices 30. Each stacking device 30 consists essentially of a pallet spacing assembly 50, adapted so that similar assemblies 50 may be interlocked in a vertical tandem, and a pallet support assembly 70 rigidly secured to the spacing assembly 50 and adapted for detachable rigid connection with the pallet 10.
Turning to FIG. 3, the preferred embodiment of the stacking device 30 for use with the particular pallet 10 illustrated in FIG. 1 is shown.
The pallet spacing assembly 50 consists of a pair of upright members 51 secured in spaced relationship by cross-members 53. In the illustrated form, the upright members 51 are I-bars having their webs 55 disposed in parallel face-to-face relationship. The cross-members 53 are horizontally disposed channels having their ends fixed witin the pockets formed by the webs 55 and flanges 57 of the I-bars. The length of the upright members 51 is determined by the height of the articles to be stoved on the pallets 10, as can best be seen in reference to FIG. 2.
To insure a secure vertical tandem arrangement of several stacking devices 30, each upright member 51 is provided at its upper end with a seat 59 adapted to receive the lower end of the upright member which will be mounted above it. As shown, each seat 59 consists of a pair of rectangular plates 61. The lower ends of the plates 61 are secured to the opposite faces of the I-bar web 55 with the upper end of the plates 61 extending above the upper end of the I-bar. Thus, when the lower end of the next vertical tandem I-bar is rested on the upper end of its predecessor, its web 55 will be interposed in the seat 59. Ideally, the width of the plates 61 will be substantially equal to the width of the I-bar webs 55. The upper portion of the plates 61 then cooperates with the web and flanges of the added I-bar to secure the I-bars against relative lateral motion. As shown, the upper ends of each pair of plates 61 may be outwardly tapered or diverge from the respective webs to facilitate interposition of the webs of a similar pair of I-bars during the stacking process.
The pallet support assembly 70 consists of an arrangement of horizontal members 71 rigidly secured near the lower end of the pallet spacing assembly 50 and extending transversely therefrom. The support assembly 70 illustrated in FIG. 3 is adapted for use with the pallets 10 shown in FIG. 1. Two pairs of elongated members 71 having a rectangular cross-section are employed. Each pair is parallelly disposed and spaced so that the web 21 of an upper pallet I-bar 13 is insertable therebetween. The downward faces of the top flanges of the upper pallet I-bar 13 will therefore rest on the top faces of a pair of elongated members 71. The pallet I-bar web 21 cooperates with the inside faces of the elongated members 71 to prevent relative transverse motion of the pallet 10 with respect to the horizontal members.
In addition, one or more of the elongated members 71 may be provided with a locking means to secure the pallet 10 against forward or rearward motion with respect thereto. For example, in the case of the I-bar pallets 10 above described a rotating catch 73 may be mounted on the outer side face of one of the elongated members 71. The catch 73 may consist of a radial arm 75 extending beneath the bottom face of the elongated member 71 from which a lug 77 integrally extends toward the spacing assembly 50. Also provided on the bottom face of the elongated member 71 and more proximate the spacing assembly 50 than the catch 73 is a stop member 79. As the elongated member 71 is inserted in the slot formed by the web and flanges of the upper pallet I-bar 13, the leading edge of the catch 73 strikes the leading portion of the top flange 19 of the lower pallet I-bar 15. This impact rotates the catch 73 approximately 360°, causing the arm 75 and the lug 77 to engage the trailing portion of the top flange 19 of the lower pallet I-bar 15. Simultaneously, the leading face of the stop member 79 moves into abutment with the leading portion of the top flange 19 of the lower pallet I-bar 15. The stop member 79 and the catch 73 then cooperate with the flange to secure the pallet 10 against forward or rearward motion with respect to the elongated member 71.
It should be noted that the use of I-bars as upright members 51 facilitates securing the elongated members 71 to the spacing assembly 50. Notches 63 may be provided in the I-bar flanges from which the elongated members 71 may be cantilevered at one end. The web 55 of the upright member 51 will thus serve as a spacer between a pair of elongated members 71, providing the gap necessary to insert the pallet I-bar web 21 therebetween.
Additionally, the leading edges 81 of the elongated member 71 may be bevelled to facilitate insertion into the pallet I-bar 13.
Finally, it should be noted that both the spacing assembly 50 and the support assembly 70 may be made of a relatively light weight, rigid material such as aluminum or magnesium. Therefore the stacking device 30 can be easily manually handled.
In operation, several pairs of stacking devices 30 are secured to opposite sides of several pallets 10 by sliding the elongated members 71 into the upper pallet I-bars 13 until the stop member 79 and the catch 73 engage a lower pallet I-bar 15. Each such cantilevered arrangement may now be stacked above a preceding one by raising it above the preceding one and setting the lower ends of its upright members 71 into the seats 59 on the upper ends of the corresponding upright members 71 of the preceding arrangement.
Raising and lowering of the cantilevered arrangements can easily be accomplished by use of fork lift truck, and it should be obvious that articles may be conveniently stored without ever removing them from the pallets 10 on which they are transported.
To disassemble a stack the catch 73 may be manually released and the process reversed. The stacking devices 30 may then be stored in an area relatively small in comparison to the area that would have been taken by a permanent stacking arrangement serving the same purpose.
Thus it is apparent that a pallet stacking device has been provided that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with a specific embodiment thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in the light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims. | A device for use in stacking pallets in which a pallet spacing assembly adapted for vertical tandem mounting of a similar spacing assembly thereon has secured thereto a pallet support assembly, the support assembly being detachably connectable to the pallet to cantilever the pallet from the spacing assembly, thereby converting the pallet into a storage rack. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from a Provisional Application entitled Method For Designing and Analyzing Turbine Engine Disks by Peter jürgen Röhl, serial No. 60/230,194 filed Sep. 5, 2000.
BACKGROUND OF INVENTION
[0002] This invention relates generally to engineering computer design and analysis tools, and more particularly to a process, a digital computer, and a medium readable by a digital computer for the engineering design and analysis of turbine engine disks.
[0003] Typically, a turbine engine disk design engineer uses a computer-aided design (CAD) system and one or more engineering analysis programs to design rotating turbine engine hardware. One typical engineering analysis program is a finite element analysis (FEA) package. The analysis process typically includes a simplified representation of the geometric shape. For every design iteration, the simplified representation of the geometry has to be regenerated. Typically, the design engineer gives the initial design to an analyst. The analyst converts the CAD model into a neutral geometric representation, for example, IGES (International Geometry Exchange Standard), which is then loaded into an engineering analysis package and is then manually simplified (e.g. trimming unwanted pieces to simplify the geometry) to the level of detail necessary for the analysis. However, if the simplified geometry of the design remains so extensive that it cannot be handled by the engineering analysis package, the analyst may choose to build the simplified geometry from scratch.
[0004] If the analyst finds that the part does not meet its requirements, for example, because stresses, displacements, or temperatures are too high, the designer will modify the geometry and complete another iteration of the process, which process is time consuming and vulnerable to errors introduced by operators restructuring the models.
[0005] Therefore, there is a need for a process that automates the generation of analysis models from CAD geometry models and provides a level of association between topological features of the CAD geometry and the corresponding regions of the analysis model.
SUMMARY OF INVENTION
[0006] The present invention provides, in one embodiment, a method for automatically designing an article of manufacture comprising the steps of a) providing a master model and a context model specification; b) creating a context model from the master model and the context model specification; c) translating the context model into an engineering analysis model compatible with an engineering analysis program; d) executing the engineering analysis program to generate a performance estimate form the engineering analysis model; and e)optionally modifying the master model to improve the performance estimate.
BRIEF DESCRIPTION OF DRAWINGS
[0007] [0007]FIG. 1 shows a schematic block diagram (e.g., flow chart) of an implementation of the method of the invention for the analysis of an article of manufacture;
[0008] [0008]FIG. 2 is a flow chart expanding individual block 100 of FIG. 1; and
[0009] [0009]FIG. 3 is a flow chart expanding individual block 120 of FIG. 1.
DETAILED DESCRIPTION
[0010] The present invention, by way of example and not limitation, is an automated process implemented on a digital computer for the design and engineering analysis of mechanical device parts, in particular complex rotating parts such as disks found in turbine engines.
[0011] A flow chart representing one embodiment of the present invention is shown in the block diagram of FIG. 1. The input to the process is typically done in a digital computer using a computer aided design program (herein CAD). The CAD model (herein the master model) is obtained from a computer medium, for example a hard disk, in a form readable by a CAD program. The master model is defined as a parametric representation of a part usable within CAD software (e.g., commercially available examples of which are Unigraphics sold by Unigraphics Solutions, ProE sold by Parametric Technologies, CATIA sold by IBM/Dassault Systemes, I-DEAS sold by SDRC, etc.) in which part geometry is described in terms of features and dimensional parameters associated with these features. It will be appreciated that the geometric representation of the master model can be parametric or non-parametric.
[0012] In the first step of the process, the master model is read from an initial storage medium into the CAD program as represented by block 90 in FIG. 1. In the next step 100 of the invention, a user determines a specified portion of master model (called the context model specification) to be copied into an associative model (called the context model) and prepared for engineering analysis. Associative, as used herein, means that there exists a master-slave relationship between the master model and the context model. In other words, the master model is abstracted to a level of detail necessary to perform a specified engineering analysis (e.g., the necessary detail may comprise only one specific part of a larger design assembly). For example, when modeling a turbine disk, if a specific portion of the disk (e.g., the disk rim or any other highly stressed region) is needed for analysis, it is abstracted from the master model into the context model (i.e., the context model is a subset of the master model).
[0013] In the next step of the invention as represented by block 120 , the context model is translated into an engineering analysis compatible with an engineering analysis program. Typical engineering analysis programs, for example, provide algorithms for the solution of mechanical stress, heat transfer, modal analysis, buckling, and computational fluid dynamics problems. For example, an algorithm for the solution of mechanical stress in an engineering analysis program is used for analyzing a turbine disk rim exposed to high levels of stress. Such engineering analysis programs providing these type of algorithms may include, but are not limited to, ANSYS, ABAQUS and Star-CD™. Typical preparation of the context model 100 for engineering analysis includes, but is not limited to, de-featuring, simplification, trimming, 3d to 2d conversion, tagging and chunking (discussed below). The engineering analysis model, for example, is typically a finite element model comprising a finite element mesh having material information parameters and loads and boundary conditions.
[0014] In the next step of the invention as represented by block 140 , analysis of the engineering analysis model to generate a performance estimate is performed by applying a finite element or alternatively a finite difference method, for example. The result of the analysis is typically, and without limitation, a binary data file. In one embodiment, as represented by block 160 , the binary data file is processed to generate the performance estimate in a graphical or textual form, using at least one macro, so that an operator can analyze the results. In another embodiment, the binary data file is processed to generate the performance estimate in a form readable by a computer program, using at least one macro, so that the computer program, for example iSIGHT™, automatically analyzes the results. It will be appreciated that different types of analysis forms (e.g., graphs, charts, tables, worksheets, etc.), singly or in combination, may be used to display the data file in graphical or textual form. Typical data file output may include, but is not limited to, stresses, displacements, pressures, temperatures, velocities and the like. It will also be appreciated that at least one macro may be used in all design applications. Macro, as used herein, means a symbol, name, or key that represents a list of commands, actions, or keystrokes.
[0015] In the next step of the invention as represented by block 180 , an automated computer program or alternatively an operator, for example, evaluates the processed results and determines whether the design is satisfactory. If the results of the evaluation are found to be satisfactory, the process of the present invention ends. However, if the results of the evaluation are not satisfactory, the automated computer program (e.g., iSIGHT™ by Engineous Software or ModelCenter™ by Phoenix Integration) or alternatively the operator, for example, selects a new set of geometry parameters which results in updating the master model (represented by block 220 ), updating the context model (represented by block 230 ), re-generating the analysis model (represented by block 240 ), and re-running the analysis of the new engineering analysis model (represented by block 140 ). It will be appreciated that updating the context model, as represented by block 230 , occurs because the geometry and topology is controlled by the master model. In addition, it will be appreciated that re-generating that analysis model represented by block 240 involves the execution of existing macros created in the steps represented by blocks 600 and 610 (discussed below) and which macros do not need to be created again in subsequent iterations because the macros are dependent on the tagged geometry initially developed in the creation of the context model 100 .
[0016] In one embodiment, the loop represented by blocks 140 through 240 continues in iteration until a satisfactory design meeting required criteria is reached. Satisfactory design criteria for a turbine engine disk rim, for example, is a design that meets all imposed stress and displacement constraints. In an alternative embodiment, a pre-determined number of iterations (which can be the predetermined design criteria) of a design may be executed, as a result of time constraints for example, and the best design may be chosen from that number of iterations. It will be appreciated by those of ordinary skill in the art that the pre-determined number of iterations of a design may be one or more depending on the implementation. The process steps relating to the functions represented by block 100 are shown in more detail in FIG. 2. In the first step represented by block 500 , the master model 90 is loaded into the CAD program. Next, the “Set-up” step, represented by block 510 , generates an associative copy of the master model. One of ordinary skill in the art will appreciate that the context model may or may not be stored in the same physical file on the computer medium as the master model depending on the CAD system used. In addition, the step represented by block 100 may include one, all or a combination of the steps comprising Trim, Tag and Chunk, represented by blocks 520 , 530 and 540 , respectively. The step represented by block 520 includes trimming the associative copy of the geometry of the master model to a region of interest. “Trim”, as used herein, means to cut away parts of the associative copy of the geometry that are not needed for engineering analysis. The step represented by block 530 includes tagging the associative copy of the geometry after being trimmed. “Tagging”, as used herein, means applying unique identifiers to topological entities (e.g., solid bodies, faces, edges, etc.) which are later to be used by the engineering analysis program to perform the analysis (see block 140 ). Typically, the tags can be names or name-value pairs, where the names and values will have some meaning for the engineering analysis program. For example, a name titled Pressure_Face may be used for a face where the engineering analysis code needs to apply a pressure. A name-value pair, for example, may be temp123=1250.0 which applies to a region where the engineering analysis code needs to apply a temperature boundary condition with a value of 1250.0. “Chunking”, as used herein, means subdividing the associative copy of the geometry into a collection of simple shapes (e.g., for example six-sided volumes) where the boolean sum of the simple shapes make up the original shape and where each shape contains the full information of the parent geometry. It will be appreciated by one of ordinary skill in the art that the spatial relationship between the geometries of the master model and the simple shapes of the context model is retained by using a method of assembly functionality. “Assembly functionality”, as used herein, means the ability of a CAD system to handle spatial relationships between parts. A system that offers such functionality, for example, is Unigraphics™ sold by Unigraphics Solutions. One purpose of chunking, for example, is to simplify discretization for engineering analysis. “Discretization”, as used herein, means subdividing the parametric shape into pieces small enough to allow the field quantities of interest to be approximated by using polynomials, for example. Types of discretization, may include, but are not limited to, meshing used in finite element analysis (FEA) programs or gridding used in computational fluid dynamics (CFD) programs. In one embodiment, the steps represented by blocks 530 and 540 can be executed in any order after the step represented by block 520 . In an alternative embodiment, the step represented by block 530 can be executed in any order after the execution of the step represented by block 510 .
[0017] The process steps relating to the functions represented by block 120 are shown in more detail in FIG. 3. Macros are initially developed 600 to translate the context model. “Translating”, as used herein, is the use of the macro to load (translate) the context model, which includes the geometric shapes and tags from the CAD model developed in step 100 , and generate from the context model an engineering analysis model compatible with an engineering analysis program. As discussed above, typical engineering analysis programs may include, but are not limited to, ANSYS, ABAQUS and Star-CD™. In such programs, for example, the translating macros perform discretization (as described above), application of material information, application of boundary conditions and application of load conditions. Other forms of translating may include identifying standard shapes and loadings for which closed form engineering solutions are known. Next, the step represented by block 610 includes storing the macros in a computer medium. Typical languages for macros include, but are not limited to, parametric design language for ANSYS (APDL). In the step represented by block 620 , the macros are executed to generate the engineering analysis model which is subsequently reviewed by the operator (represented by block 630 ). If the engineering analysis model is found to be satisfactory, analysis 140 of the engineering analysis model is performed (see FIG. 1). However, if the engineering analysis model is not satisfactory 640 because of distorted elements in that model, for example, the operator modifies 650 one or more of the engineering analysis model generation macros (see FIG. 3). The process then loops back to block 620 . It will be appreciated by one of ordinary skill in the art that by using an automated computer, the loop involving executing the macros 620 to modifying the macros 650 is done automatically as compared to using an operator whose review is time consuming and vulnerable to errors in restructuring the model.
[0018] It will be apparent to those skilled in the art that, while the invention has been illustrated and described herein in accordance with the patent statutes, modification and changes may be made in the disclosed embodiments without departing from the true spirit and scope of the invention. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | The present invention provides, in one embodiment, a method for automatically analyzing an article of manufacture comprising the steps of a) providing a master model and a context model specification; b) creating a context model from the master model and the context model specification; c) translating the context model into an engineering analysis model compatible with an engineering analysis program; d) executing the engineering analysis program to generate a performance estimate form the engineering analysis model; and e) optionally modifying the master model to improve the performance estimate. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/725,925, filed Mar. 20, 2007. U.S. application Ser. No. 11/725,925 is hereby incorporated by reference as if set forth in its entirety herein. U.S. application Ser. No. 11/725,925 is pending as of the filing date of the present application.
BACKGROUND OF THE INVENTION
In many areas of technology, ceramic products are being used for their inert properties and heat resistance.
Many Rapid Prototyping processes have been developed in recent years and many more are currently being researched, but until recently, few of them have been used to fabricate ceramic objects.
One of the main challenges of the use of ceramic products with modern technologies is its reduction factor (shrinkage). Depending on the process used, drying, firing or hot pressing of a ceramic object can cause shrinkage as high as 20 percent. Such shrinkage can be a significant problem if the nature of the ceramic article requires precise dimensional control.
One of the first patents pertaining to the background of the present invention was obtained by Bredt et al. and is entitled “Method of three dimensional printing” (U.S. Pat. No. 5,902,441), May 11, 1999. This patent described the use of ink-jet print heads to deliver an aqueous solvent to a powder in cross-sections. This patent describes the basic technology of printers that may be used in accordance with the present invention, such as those commercially available from Z-corp of Burlington, Mass. A subsequent patent obtained by Bredt et al. and entitled “Method of three dimensional printing” (U.S. Pat. No. 7,087,109), Aug. 8, 2006 further describes the use of three-dimensional printer systems. Subsequent patents by Jialin Shen (U.S. Published Pat. Appl. 20020016387; 2002) and Kenneth Newell (U.S. Published Pat. Appl. 20040081573; 2004) describe means of producing more stable, stronger, and more durable RP objects through various combinations of binder and solvent. Newell's method produces a “green object,” an unfired ceramic negative for use as a mold for injected metal. Improvements in Newell's mold-making methods are found in subsequent patents by Bardes, Bruce Paul et al (U.S. Published Pat. Appls. 20040151935, 20040152581 and 20050252631; 2004 and 2005) and Lynch, Robert F. et al. (U.S. Published Pat. Appl. 20050281701; 2005).
An article entitled “Rapid Prototyping with Ceramics” by Elizabeth A. Judson & Thomas L. Starr of the Materials Science and Engineering of the Georgia Institute of Technology (found at http://www.pelcor.com/library/judson_starr/) explains the use of “Injection Molding and Stereolithography” for the creation of molds for casting purposes.
A publication entitled “The CAM-LEM Process” (found at http://dora.eeap.cwru.edu/camlem/camproc.html) explains how layers of ceramic material can be cut with the use of a computer assisted laser cutter and then stacked and fused in order to obtain a final ceramic article.
Notwithstanding these developments, there remains a need for methods of making shaped ceramics in an efficient manner while reducing the shrinkage attendant to prior art techniques. Some of the improvements sought to the prior art include apparatus, methods and compositions that are capable of producing ceramic precursors with high green strength and more accurate final ceramic shapes with a high degree of veracity to the desired shape, such as through the reduction in shrinkage and distortion. Ceramics produced in accordance with the present invention may also have relatively reduced porosity compared to ceramics from other methods.
SUMMARY OF THE INVENTION
The method of the present invention may be carried out using a version of the Massachusetts Institute of Technology's patented 3DP (Three-Dimensional Printing). The powder-based build system used in accordance with one embodiment of the invention preferably employs ink-jet technology to apply a specific ceramic binder to thin layers of ceramic precursor powder (typically clay powder), rapidly building objects from digital 3D drawing files.
It has been discovered that 3DP processes using certain organic ingredients such as cellulose in the ceramic powder used as a two part binder in preceding technologies (including those described in patents such as those described herein) causes a greater reduction in the final object than is normal in traditional ceramic object making. Due to the combustible nature of these organic binders, the object was left with a porous structure that sometimes caused it to collapse or suffer deformations when exposed to the high heat of the bisque. In order to decrease the reduction factor and increase the object's density, the present invention allows for the production of a ceramic-specific binder that does not require the addition of solid organic binding material to clay recipes. The final objects conform to the standards of traditional ceramics and thus can be used in a multitude of fashions similar to traditional ceramics.
The present invention includes a ceramic precursor article that may be fired into a finished ceramic article of a desired shape that may be predetermined, a method of making the precursor, a method of making the finished ceramic article, and the finished ceramic article made thereby.
Ceramic Precursor Article
In general terms, the present invention may be described as including a ceramic precursor article having a predetermined shape, the article comprising alternately deposited layers of (1) a ceramic precursor powder and (2) a binder comprising water and polyvinyl alcohol, in a pre-determined pattern, such that the ceramic precursor article is of the predetermined shape.
The ceramic precursor powder may comprise any combination of one or more clays and other ancillary material(s) (preferably so as to have plasticity; i.e., workability to be able to take and hold a shape through firing), such as feldspar, refractory cement and/or frit to produce a powder that may be handled and deposited using 3DP equipment, and capable of producing a ceramic precursor article in combination with one or more binder compositions. Preferably, the ceramic precursor powder additionally comprises clay and at least one silicate, most preferably sodium silicate. Also the ceramic precursor powder preferably has the plasticity associated with clays, that being the characteristic of being able to be formed into a shape and maintain that shape through the firing process. Such materials are also well adapted to accept and hold glaze.
A preferred formula of the ceramic precursor powder comprises:
(a) from about 50% to about 80% clay;
(b) from about 5% to about 20% feldspar;
(c) from about 2% to about 10% refractory cement;
(d) from about 2% to about 10% frit; and
(e) from about 0.5% to about 4% sodium silicate.
In a preferred embodiment the ceramic precursor article comprises alternately deposited layers of (1) a ceramic precursor powder and (2) a binder substantially free of cellulose, in a pre-determined pattern, such that the ceramic precursor article is of the predetermined shape.
It is preferred that the binder comprises polyvinyl alcohol (PVA). It is preferred that the polyvinyl alcohol have a molecular weight in the range of 7,000 to about 15,000, and most preferably in the range of from about 9,000 to about 10,000, so as not to be too viscous for use in a 3DP machine and process. It is also preferred that the polyvinyl alcohol having a degree of hydrolysis in the range of from about 65% to about 95%, and most preferably in the range of from about 75% to about 85%. Such polyvinyl alcohols are commercially available from Sigma-Aldrich of St. Louis, Mo.
The binder may also include one or more humectants, such as glycerol, and one or more flow agents, such as ethylene glycol.
It is preferred that the binder comprises, and preferably consists essentially of, polyvinyl alcohol from about 60 to about 80%, glycerol from about 15 to about 25% and ethylene glycol from about 5 to about 15% by weight of the binder absent water. Most preferably, the binder comprises polyvinyl alcohol from about 70 to about 75%, glycerol from about 15 to about 25% and ethylene glycol from about 5 to about 15% by weight of the binder absent water.
Most preferably, the binder is substantially free of cellulose. The binder may also be in the form of aqueous clay slurry.
The ceramic article made from the ceramic precursor article shrinks less than 15%, and most preferably less than 10%, as compared to its actual size upon being subjected to sufficient heat to form a ceramic article therefrom.
Method of Preparing a Ceramic Article
The method of the present invention may be described as preparing a ceramic article of a desired final shape comprising: (a) alternately depositing layers of (1) a ceramic precursor powder as described herein and (2) a binder comprising water and polyvinyl alcohol as described herein, in a pre-determined pattern so as to form a ceramic precursor article of a precursor shape from a plurality of the layers, and (b) subjecting the ceramic precursor article to heat for sufficient time to form a ceramic article of the desired final shape.
The method of the present invention is capable of producing a ceramic article made from the ceramic precursor article that shrinks less than 15%, and most preferably less than 10%, as compared to its actual size, upon being subjected to sufficient heat to form a ceramic article therefrom.
The method of the present invention also includes a method of preparing a ceramic article of a desired final shape using a computer-driven prototyping device having a microprocessor adapted to guide its action, the method comprising: (a) obtaining digital data reflecting the desired shape; (b) applying the digital data to a microprocessor so as to guide the action of the computer-driven three-dimensional prototyping device to alternately deposit layers of (1) a ceramic precursor powder as described herein and (2) a binder comprising water and polyvinyl alcohol as described herein, in a pre-determined pattern so as to form a ceramic precursor article of the desired final shape from a plurality of the layers, and (c) subjecting the ceramic precursor article to heat for sufficient time to form a ceramic article of the desired final shape.
The method of the present invention also includes preparing a ceramic article of a desired final shape using a computer-driven prototyping device having a microprocessor adapted to guide its action, the method comprising: (a) obtaining digital data reflecting a first portion of the desired shape; (b) obtaining digital data reflecting a second portion of the desired shape; (c) applying the digital data to a microprocessor so as to guide the action of the computer-driven prototyping device to alternately depositing layers of (1) a ceramic precursor powder as described herein and (2) a binder comprising water and polyvinyl alcohol as described herein, in a pre-determined pattern so as to form ceramic precursor articles of the first and second portion of the desired shape from a plurality of the layers, and (d) subjecting the ceramic precursor article to heat for sufficient time to form a ceramic articles of the first and second portion of the desired shape; and (e) assembling the ceramic articles of the first and second portion of the desired shape into ceramic article of the desired shape.
The present invention also includes a ceramic article of manufacture made in accordance with the method of the present invention as described herein.
With respect to the ceramic precursor powder, the present invention may employ any ceramic powder that may be deposited using a 3DP layering techniques and devices. For example, the ceramic precursor powder preferably comprises: (a) from about 50% to about 80% clay; (b) from about 5% to about 20% feldspar; (c) from about 2% to about 10% refractory cement; and (d) from about 2% to about 10% frit.
A preferred ceramic recipe is: (a) from about 20% to about 30% OM4; (b) from about 20% to about 30% Cedar Height; (c) from about 20% to about 30% Fire Clay; (d) from about 10% to about 20% Neph Sy; (e) from about 2% to about 7% Sar Bond; and (f) from about 2% to about 7% 3134 Frit. The most preferred amount of these components is (a) about 25% OM4; (b) about 25% Cedar Height; (c) about 25% Fire Clay; (d) about 15% Neph Sy; (e) about 5% Sar Bond; and (f) about 5% 3134 Frit.
The ceramic precursor powder of the present invention may also include at least one silicate, such as sodium silicate in an amount in the range of from about 0.5% to about 4% by weight of the total powder.
The binder of the present invention is principally formed using an aqueous solution/suspension comprising polyvinyl alcohol, with the optional inclusion of other components such as one or more humectants as are known in the art for the binder to help prevent too much evaporation of the solution (such as glycerol) and a flow agent or viscosity modifier, as are known in the art, that helps with the flow rate of the binder, to make it possible to increase the binding action (such as ethylene glycol).
The preferred binder composition includes polyvinyl alcohol, glycerol and ethylene glycol, in addition to the solvent, such as water.
The preferred ratio ranges for each of these components is polyvinyl alcohol to glycerol to ethylene glycol are from about 5:1:1 to about 3:2:1. The preferred ranges for each of these components where they are the only components other than water is polyvinyl alcohol from about 60 to about 80%, glycerol from about 15 to about 25% and ethylene glycol from about 5 to about 15% by weight of the binder not including the liquid water portion. The preferred amount of these components is polyvinyl alcohol 70%, glycerol 20% and ethylene glycol 10% by weight of the binder not including the liquid water portion. It is preferred that the binder composition consist essentially of polyvinyl alcohol and water. It is also preferred that the binder composition consist essentially of polyvinyl alcohol and water, and at least one humectant, such as glycerol. It is most preferred that the binder composition consist essentially of polyvinyl alcohol and water, at least one humectant, such as glycerol, and at least one flow agent, such as ethylene glycol.
Another variation of the present invention is the use of a binder that may include one or more a sugars in an amount in the range of from about 100 g to about 500 g per liter of water of the binder solution, and preferably in an amount in the range of from about 250 g to about 350 g per liter of water. The preferred sugar is sucrose, although other sugars may be used. This binder variation may include other optional components such as sodium polymethacrylate such as in an aqueous solution such as Darvan (74-76 percent by weight water and 24-26 percent by weight sodium polymethacrylate). The preferred amount of Darvan liquid is in the range of from about 15 to about 26 ml per 1000 ml of water, and most preferably about 20 ml per 1000 ml of water. Other optional components include calgon liquid detergent, and sodium silicate or colloidal silica. The binder may also include relatively small amounts of carboxymethylcellulose (CMC). These optional ingredients may serve as wetting agents or provide additional binding strength. Examples of binder formulations of this variation include: (a) water 1500 ml (b) Darvan 30 ml; (c) sucrose 400 g and (d) a few drops of dye to identify the product. Another variation on the same recipe with different ingredients and proportions for instance may be: (a) water 1500 ml (b) CMC 50 ml; (c) sucrose 500 g and (d) a few drops of dye to identify the product.
The present invention also includes a ceramic precursor article having a predetermined shape, the article comprising alternately deposited layers of (1) a ceramic precursor powder and (2) a binder comprising water sugar, in a pre-determined pattern, such that the ceramic precursor article is of the predetermined shape. It is preferred that the binder be substantially free of cellulose. The present invention may also include a ceramic precursor article having a predetermined shape, the article comprising alternately deposited layers of (1) a ceramic precursor powder and (2) a binder substantially free of cellulose, in a pre-determined pattern, such that the ceramic precursor article is of the predetermined shape.
It is preferred that the binder composition consist essentially of sugar and water. It is also preferred that the binder composition consist essentially of sugar and water at least one humectant as are known in the art, such as glycerol. It is most preferred that the binder composition consist essentially of polyvinyl alcohol, at least one humectant, such as glycerol, and at least one flow agent as are known in the art, such as ethylene glycol.
The binder thus preferably comprises an aqueous solution or slurry of the components as described above.
It is preferred that the ceramic precursor article shrinks less than 15% as compared to its actual size upon being subjected to sufficient heat to form a ceramic article therefrom, and most preferably less than 10%.
The present invention also includes a method of preparing a ceramic article of a desired final shape comprising: (a) alternately depositing layers of (1) a ceramic precursor powder as described herein and (2) a binder comprising water, sugar and sodium silicate as described herein, in a pre-determined pattern so as to form a ceramic precursor article of a precursor shape from a plurality of the layers, and (b) subjecting the ceramic precursor article to heat for sufficient time to form a ceramic article of the desired final shape.
It is preferred that the ceramic precursor article shrinks less than 15% as compared to its actual size upon being subjected to sufficient heat to form a ceramic article therefrom, and most preferably less than 10%. It is likewise preferred that the desired final shape differs from the precursor shape by less than 15%, preferably less than 10%, and that most preferably the desired final shape differs is substantially the same as the precursor shape.
The present invention also includes a method of preparing a ceramic article of a desired final shape using a computer-driven prototyping device having a microprocessor adapted to guide its action, the method comprising: (a) obtaining digital data reflecting the desired shape; (b) applying the digital data to a microprocessor so as to guide the action of the computer-driven prototyping device to alternately depositing layers of (1) a ceramic precursor powder and (2) a binder substantially free of organic material, in a pre-determined pattern so as to form a ceramic precursor article of the desired final shape from a plurality of the layers, and (c) subjecting the ceramic precursor article to heat for sufficient time to form a ceramic article of the desired final shape.
The method of the present invention also includes a method of preparing a ceramic article of a desired final shape using a computer-driven prototyping device having a microprocessor adapted to guide its action, the method comprising: (a) obtaining digital data reflecting a first portion of the desired shape; (b) obtaining digital data reflecting a second portion of the desired shape; (c) applying the digital data to a microprocessor so as to guide the action of the computer-driven prototyping device to alternately depositing layers of (1) a ceramic precursor powder as described herein and (2) a binder as described herein, in a pre-determined pattern so as to form ceramic precursor articles of the first and second portion of the desired shape from a plurality of the layers, and (d) subjecting the ceramic precursor article to heat for sufficient time to form a ceramic articles of the first and second portion of the desired shape; and (e) assembling the ceramic articles of the first and second portion of the desired shape into ceramic article of the desired shape.
Method of Preparing a Ceramic Article Precursor within Compression Step
The present invention also includes a method of preparing a ceramic article precursor by the sequential alternative application of layers of material as follows: (a) a layer of a ceramic precursor powder; and (b) a layer of an aqueous liquid binder solution having at least one water-soluble binder dissolved in water; so as to form a sequential material layer having an original thickness; and (c) compressing each sequential material layer so as to reduce the original thickness thereof, prior to the deposition of a subsequent sequential material layer; so as to form a ceramic precursor article.
Method of Preparing a Ceramic Article within Compression Step
The present invention further includes a method of preparing a ceramic article of a desired final shape comprising: (a) alternately depositing layers of (1) a ceramic precursor powder and (2) a binder, such as one comprising water and polyvinyl alcohol, each the alternate layers (1) and (2) having an original thickness, in a pre-determined pattern so as to form a ceramic precursor article of a precursor shape from a plurality of the layers, (b) following each deposition of layers (1) and (2), compressing each the alternate layer so as to reduce its original thickness; and (b) subjecting the ceramic precursor article to heat for sufficient time to form a ceramic article of the desired final shape.
This method has the effect of compacting the layers as they are formed, so as to place the constituent materials in more intimate contact. This leads to a stronger ceramic precursor article and ultimately to a finished ceramic that has reduced shrinkage and porosity.
The compression step may be performed by an apparatus as described herein, as well as by any other apparatus that is capable of providing controllable compression force to the object being formed without disrupting its intended shape.
Compression Apparatus—Apparatus for Preparing a Ceramic Article Precursor within Compression Step
Also part of the present invention is an apparatus for preparing a ceramic article precursor by the sequential alternative application of layers of material as follows: (a) a supply bed adapted to contain a supply of a ceramic precursor powder and a powder supply head adapted to transport and deposit layers of the ceramic precursor powder; (b) a binder depositor adapted to produce a patterned layers of a liquid an aqueous liquid binder solution having at least one water-soluble binder dissolved in water; (c) a build table positioned and adapted to accept alternating layers of the ceramic precursor powder from the powder supply head, and the aqueous liquid binder solution from the binder depositor; and to be lowered following each layer deposition; and (d) a tamper member adapted to compress successive alternating layers of the ceramic precursor powder and the aqueous liquid binder solution, so as to reduce the original thickness thereof.
It is preferred that the tamper member be actuated by a motor controlled by microprocessor or other control apparatus that applies an algorithm adapted to calculate the required dimensions of a given binder layer by determining the change in the original thickness of a binder/powder layer, and adjusting the dimensions of subsequent binder layers according to the reduction in overall height of the ceramic precursor as it is being built. That is, the algorithm determines the binder layer pattern next required in sequence based upon the regression in the build-up brought about by the know reduction in overall height of the object (based upon the controlled tamping compression of each layer) after each compression step.
This method may be used to prepare arrangements of more than one ceramic piece, such as may be required in ceramic constructions of any kind, such as anything from artistic forms, installations and murals, or multi-piece industrial constructions and arrangements where such multi-piece constructions are required or desirable. Examples may include filter arrangements, protective ceramic tiles, bricks, etc., and ceramic pieces having more than one piece that fit together, such as containers. Accordingly, the present invention allows for the creation of clay body formulas and binder recipes for use in a rapid prototyping process, consistent with industry standards for other types of ceramic fabrication, and processes including pottery, tile and brick.
The present invention also includes a ceramic article of manufacture made in accordance with the method of the present invention as described herein.
In accordance with the present invention, ceramic precursor articles may be successfully rendered and then fired at high temperature (i.e., using traditional kilns at temperatures of 1500-2000 degrees C.) to obtain ceramic positives. The ceramic article may be treated with any glazing as is known and applied in the art.
The objects produced in accordance with the present invention may be used to demonstrate the possible applications of this process. The ceramic objects obtained by this process have evidenced an average reduction of 15% and some have been subject to different types of glazing and surface treatments, as are known and applied in this field.
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
FIG. 1 is a perspective view of an apparatus in accordance with one embodiment of the present invention.
FIG. 2 is a perspective view of an apparatus in accordance with one embodiment of the present invention.
FIG. 3 is a perspective view of an apparatus in accordance with one embodiment of the present invention.
FIG. 4 is a detailed perspective view of an apparatus in accordance with one embodiment of the present invention.
FIG. 5 is a detailed perspective view of an apparatus in accordance with one embodiment of the present invention.
FIG. 6 is a detailed perspective view of an apparatus in accordance with one embodiment of the present invention.
FIG. 7 is a detailed perspective view of an apparatus in accordance with one embodiment of the present invention.
FIG. 8 is a perspective view of an original article that may be reproduced in accordance with one embodiment of the present invention.
FIG. 9 is a perspective view of a ceramic article prepared as a copy of the original article of FIG. 8 , in accordance with one embodiment of the present invention.
FIG. 10 is a perspective comparative view of the original article of FIG. 8 and the ceramic article shown in FIG. 9 .
FIG. 11 is a perspective view of an article made in accordance with one embodiment of the present invention.
FIG. 12 is a perspective view of another article made in accordance with one embodiment of the present invention.
FIG. 13 is a perspective view of test bars in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the foregoing summary, the following present a detailed description of the present invention, which is presently considered to be the best mode thereof.
As an example of the present invention, a digital representation of Martin
Newell's teapot was prepared obtained. This is a shape commonly used in computer graphics, 3D modeling, and 3D animation. A teapot is a challenging object to experiment with for its shape and form within the context of 3D software development. That same teapot serves as an excellent subject model to demonstrate the present invention.
The present invention allows for the fabrication of an article, such as a teapot, accurate in dimensions to the desired shape, and thus the production of sculptural objects and other object applications are possible. In accordance with the present invention, it is feasible to create a virtual 3D design that can become a functional object made of durable ceramic materials without the need to first prepare a prototype from which a mold is made. Rather, the present invention allows for the direct formation of a finished ceramic piece without the need for prototyping and mold making.
The use of binders and clay formulas of the present invention allow for the 3DP rapid prototyping processes and apparatus to be used to efficiently prepare final shaped ceramic pieces.
One of the aspects of the present invention is the creation of clay body formulae and binder recipes for use in a rapid prototyping process, consistent with industry standards for other types of ceramic fabrication and treatment processes, including those used to make pottery, tile and brick.
The testing standards can be organized around three main components: (1) shrinkage—important during each phase of fabrication; and (2) absorption and density through vitrification (absorption); and (3) strength—green, bisque and fired.
In order to prepare a ceramic article in accordance with the present invention, an example of the object may be imaged using either 2D or 3D imaging techniques in order to obtain a computer files or data representative of the object and adapted to be used to guide the 3DP machine. This may be done for instance using a scanner such as the ZScanner 700 commercially available from Z-Corp. One may extrapolate from 2D imaging for this purpose.
A 3DP machine, such as the ZPrinter 310 Plus, commercially available from Z-Corp is loaded with the ceramic powder and the binder in accordance with the present invention. The computer file(s) to guide the layered deposition are transferred to the machine and the machine deposits alternately layers of the binder and ceramic power such that a ceramic precursor of the desired shape is formed though the computer guidance obtained from the scanner. Computer instructions may also be converted from CAD files of the desired shape, such as by use of the ZPrint Software, commercially available from Z-Corp.
Typically and preferably, this is done with one-to-one ratio of the binder and ceramic powder, alternating one atop the other, although other layering arrangements may be found effective to create a precursor shape.
After the ceramic precursor of the desired shape is formed, it may be fired and/or glazed in accordance with methods and apparatus known and used in the art.
In the case of a teapot, the pot and cover may be scanned and deposited as individual pieces.
The present invention may be also demonstrated by the use of a basic standard test bar that may be used to measure the properties of the precursor through each stage of the process. Examples are seen in FIG. 13 . A virtual model of a test bar may be rendered in multiples each time material is run through the machine. Given that many test bars can be made during each run of the printer, it will be possible for instance to create a fine art object and five test bars in one printing session. Below is a description of each component.
Shrinkage
Each bar will have a 10 cm demarcation rendered directly into the bar. The bars may be measured after each process of air-drying, bisque firing, and final firing. The difference of the various measurements provides crucial data for shrinkage in a manner consistent with industry standards for all ceramic applications. The data for each formula modification may then be logged into a database and then compared to other known industry formulas. This will allow for one to control for shrinkage by preparing ceramic precursor articles with the amount of shrinkage to be allowed for, such that the desired accurate shape and size of the finished ceramic piece may be achieved. This may be done either in cases where the shrinkage of the unfinished (unfired) article places the article still within desired manufacturing tolerances, or in cases where the shrinkage of a given precursor binder-powder formulation is known such that it may be considered so as to arrive at the desired size of the finished article.
Absorption and Density
In order to determine the absorption and density of the precursor article made in accordance with the present invention, each bar will may be weighed immediately as it is removed from the printer. This base weight contains the total wet weight of the object. The bar may then be weighed after it has completely air-dried. (A small dryer may be used to eliminate variations in ambient air humidity, if desired). The difference between the dry weight and the wet weight will indicate the amount of liquid (in the binder) used to bind the powder, which is needed to determine the effects of different binder recipes and to measure consistency in the printing process. To determine the absorption of the sample, each bar may be weighed after it has been fired to a specific temperature, soaked for twenty-four hours in water, and weighed again. The tests may then be boiled for about two hours and weighed again; this will measure the coefficient of expansion, which is important information for clays that will be placed outdoors and in other harsh environments. The parameters of this test are known and used in industry.
Strength Testing
It typically will be important to monitor is green strength; i.e., is the object rendered durable enough to be handled after it is removed from the printer and placed in the kiln? It is preferred that the ceramic precursor objects in the green state be strong enough to be handled to be safely placed in the kiln. This strength is directly related to the effectiveness of the binder and can easily be measured by the following simple test. The bar may suspended on both ends and weight is incrementally applied to the center of the bar until it fails. The same test may be applied to the bar after firing to determine basic fired strength data. Bars of the same size and shape may be made with traditional fabrication methods and a known formula to establish a base-line measurement for comparison in further experiments. Eventually the best of the formulas may be sent to a ceramic lab to find the specific “Modulus of Rupture”. These data may then be compared with industry parameters for the object to be produced, if desired. This testing may confirm what is already observed in ceramic precursors produced in accordance with the present invention, and may be able to quantify it with industry standards.
Variations may be made from the preferred ceramic powder and binder formulation as desired for various applications. It is preferred that all tests be controlled and logged with all information needed for replication and confirmation. It is preferred that one not make changes both to the binder and the formula for each run as it is preferred to maintain one variable constant. That is, if one changes a material or its ratio in the clay formula, preferably one must measure it using the same binder. Likewise, if one changes the binder, one should compare those results on the same formula. While this complicates the testing procedures, it is possible to do given that effective binders and ceramic powder formulas are disclosed herein. It is important to note that all of the clay formulas may consist of materials that have been tested and chemically analyzed using a computer program that contains this information and can instantly calculate the molecular formula of any combination of the possible ingredients. Such computer programs are typically used in glaze and clay body calculations.
This testing provides crucial information as to the viability of specific formulas and binders. In addition to the tests described above, other tests may be done related to various ceramic processes including glazing and pyroplasticity (warping during firing). Some test bars may be glazed using various techniques and process and measured for “glaze fit” and other important phenomena related to potential applications of the present invention.
FIG. 13 is a perspective view of a series of test bars produced in accordance with the method of the present invention. Table 1 contains data from several test runs using the method of the present invention. Some of the significant aspects of the results reported in Table 1 are the reduced amount of shrinkage achieved through the method of the present invention, even without using the layer compression method of the present invention. The significant aspects of the results include the reduction in distortion and friction cracks.
The present invention also includes a three-dimensional printing apparatus and printing method.
Referring to the Figures, FIG. 1 shows three-dimensional printing device 1 having supply bed 2 and build table 3 .
Powder transport unit 4 is also bears reciprocating binder print head 5 .
On the trailing portion of powder transport unit 4 is compressor plate mechanism 6 which includes compressor plate 7 and actuator arms 8 .
In operation, powder transport unit 4 reciprocates between the position A as shown in FIG. 1 and position B as shown in FIG. 2 . As the powder transport unit 4 moves from position A to position B, it takes ceramic powder from supply bed 2 and deposits a layer of ceramic powder across build table 3 .
Powder transport unit 4 then reverses direction across build table 3 whereby reciprocating binder print head 5 deposits a layer of binder such as described herein.
This process is repeated as the build table is lowered to build a three-dimensional ceramic precursor article.
Following each successive deposit of a layer of powder (where powder transport unit 4 reaches position B), compressor plate 7 borne by actuator arms 8 provides a compressing downward tamping to each successive binder/powder layer as it is formed. This may be seen by reference to the position of compressor plate 7 and actuator arms 8 in FIGS. 2 and 3 . The compressor plate 7 in its lowered position may also be seen in FIGS. 4-6 . This has the effect of making the composite green article so formed better able to maintain its green strength, while ultimately leading to the production of a stronger ceramic piece as the constituent materials are placed in more intimate contact between the binder and powder layers before firing.
The action of the compressor plate 7 and actuator arms 8 may be controlled by an electronic actuator subject to algorithmic control. As each layer is placed and reduced in thickness by compression, the algorithmic controller adjusts the subsequent layer to be deposited in order to accommodate for the vertical displacement of each layer in the cross-sectional series of deposition. That is, as each binder/powder layer is compressed, the height of the article thus far produced is reduced from where is otherwise would be prior to compression. Accordingly, the programming algorithm controls the deposition to accommodate the resultant height of the post-compression article in determining the pattern to be laid in the next sequential deposit. This may be accomplished by amendments to the computer programming used in current three-dimensional printing devices to make mathematic changes to accommodate the regression in the cross-sectional series brought about through the known amount of thickness reduction brought about by compression.
FIGS. 4-6 show detailed views of the compressor plate 7 and actuator arms 8 in more detail, with the compressor plate 7 in its lowered position, as seen in FIG. 3 . FIG. 4 shows the tamping mechanism with cover 9 , while FIGS. 5 and 6 show views with cover 9 removed. These Figures also show gears 11 and 12 (which may also be friction wheels as an alternative), as well as electric motor 13 which turns shaft 14 so as to provide light tamping displacement against the sequential layers of the ceramic precursor as it is being built in sequential layers in build table 3 .
FIG. 7 shows the compressor plate 7 and actuator arms 8 in a raised position after the protective cover 10 of three-dimensional printing device 1 has been raised. This allows for the removal of the finished ceramic precursor piece for clean-up and firing.
The present invention may be used in a wide variety of artistic and industrial applications. One such application is in the area of ceramic filters. Ceramic articles of the present invention have been found to have relatively uniform porosity, such that they may find advantageous use as ceramic filters in a wide variety of industrial applications.
Still another application of the present invention is to provide replacement parts for ceramic constructions, industrial or artistic, where a piece has become broken or lost altogether. For instance, in preparing filler pieces to display archeological ceramics to be able to support and secure such items, the missing portion(s) may be obtained through digital scanning, and the missing piece prepared using the method of the present invention. Likewise, broken or missing industrial ceramic articles may be repaired or replaced, for instance by scanning a broken insulative tile to obtain a 3D digital image of the missing portion of the tile, in order to provide a replacement piece sized to fit precisely the space requiring repair.
Because the present invention allows for the direct and true-to-size creation of finished ceramic articles, one may create customized ceramic articles to fit or retrofit industrial, artistic or archeological articles, arrangements and installations efficiently.
An example of a ceramic object (i.e., a hand rendered ceramic) that may be reproduced in accordance with the present invention is shown in FIG. 8 . FIG. 9 shows a perspective view of a fired ceramic object made from the three dimensional digital rendering and printing process of the present invention as applied to the ceramic object of FIG. 8 . FIG. 10 shows a comparative perspective view of the original ceramic object shown in FIG. 8 and the finished ceramic object produced in accordance with one embodiment of the present invention shown in FIG. 9 .
Other examples of finished ceramic articles made in accordance with the method of the present invention and that would otherwise be impossible to make through standard molding techniques, owing to the presence of undercut in the piece, are shown in FIGS. 11 and 12 .
All of the patents and other publications referred to herein are hereby incorporated herein by reference.
TABLE 1
Bar
Date
Weight
Weight (g) after
Weight (g) after
First
Bisk
Number
Date Render:
Measured:
(g) @ machine
60 min @ 200 F.
Air clean
Bisk #
Cone
01-01-01
Aug. 24, 2006
Aug. 28, 2006
74
71
69
1
8
01-01-02
Aug. 24, 2006
Aug. 28, 2006
74
70
68
1
8
01-01-03
Aug. 24, 2006
Aug. 28, 2006
72
69
67
1
8
01-01-04
Aug. 24, 2006
Aug. 28, 2006
72
69
67
1
8
01-02-01
Aug. 28, 2006
Aug. 29, 2006
84
79
74
1
8
01-02-02
Aug. 28, 2006
Aug. 29, 2006
83
78
73
1
8
01-02-03
Aug. 28, 2006
Aug. 29, 2006
81
77
72
1
8
01-02-04
Aug. 28, 2006
Aug. 29, 2006
80
76
72
1
8
01-02-05
Aug. 28, 2006
Aug. 29, 2006
77
73
69
1
8
01-03-01
Aug. 31, 2006
Sep. 1, 2006
74
69
65
3
8
01-03-02
Aug. 31, 2006
Sep. 1, 2006
72
67
65
3
8
01-03-03
Aug. 31, 2006
Sep. 1, 2006
72
67
65
3
8
01-03-04
Aug. 31, 2006
Sep. 1, 2006
72
67
65
3
8
01-03-05
Aug. 31, 2006
Sep. 1, 2006
70
66
64
3
8
01-04-01
Sep. 5, 2006
Sep. 6, 2006
79
73
70
2
8
01-04-02
Sep. 5, 2006
Sep. 6, 2006
77
71
68
2
8
01-04-03
Sep. 5, 2006
Sep. 6, 2006
77
70
69
2
8
01-04-04
Sep. 5, 2006
Sep. 6, 2006
78
72
69
2
8
01-04-05
Sep. 5, 2006
Sep. 6, 2006
76
70
67
2
8
01-05-01
Sep. 7, 2006
Sep. 8, 2006
78
74
72
2
8
01-05-02
Sep. 7, 2006
Sep. 8, 2006
78
73
71
2
8
01-05-03
Sep. 7, 2006
Sep. 8, 2006
77
72
70
2
8
01-05-04
Sep. 7, 2006
Sep. 8, 2006
77
73
70
2
8
01-05-05
Sep. 7, 2006
Sep. 8, 2006
78
74
71
2
8
01-06-01
Sep. 13, 2006
Sep. 14, 2006
77
74
72
3
8
01-06-02
Sep. 13, 2006
Sep. 14, 2006
77
74
72
3
8
01-06-03
Sep. 13, 2006
Sep. 14, 2006
77
74
71
3
8
01-06-04
Sep. 13, 2006
Sep. 14, 2006
77
74
71
3
8
01-06-05
Sep. 13, 2006
Sep. 14, 2006
77
74
71
3
8
01-07-01
Sep. 30, 2006
Oct. 1, 2006
82
78
75
01-07-02
Sep. 30, 2006
Oct. 1, 2006
80
76
74
01-07-03
Sep. 30, 2006
Oct. 1, 2006
81
76
74
6
04
01-07-04
Sep. 30, 2006
Oct. 1, 2006
80
76
74
6
04
01-07-05
Sep. 30, 2006
Oct. 1, 2006
80
77
74
6
04
01-08-01
Oct. 1, 2006
Oct. 2, 2006
85
77
75
01-08-02
Oct. 1, 2006
Oct. 2, 2006
85
77
74
01-08-03
Oct. 1, 2006
Oct. 2, 2006
86
78
73
6
04
01-08-04
Oct. 1, 2006
Oct. 2, 2006
88
80
77
6
04
01-08-05
Oct. 1, 2006
Oct. 2, 2006
90
82
78
6
04
01-09-01
Oct. 1, 2006
Oct. 2, 2006
81
74
72
01-09-02
Oct. 1, 2006
Oct. 2, 2006
80
73
71
01-09-03
Oct. 1, 2006
Oct. 2, 2006
82
75
73
6
04
01-09-04
Oct. 1, 2006
Oct. 2, 2006
82
75
73
6
04
01-09-05
Oct. 1, 2006
Oct. 2, 2006
83
77
74
6
04
01-10-01
Oct. 16, 2006
Oct. 17, 2006
83
76
73
7
04
01-10-02
Oct. 16, 2006
Oct. 17, 2006
82
75
72
7
04
01-10-03
Oct. 16, 2006
Oct. 17, 2006
85
77
74
7
04
01-10-04
Oct. 16, 2006
Oct. 17, 2006
83
77
74
01-10-05
Oct. 16, 2006
Oct. 17, 2006
85
78
75
01-11-01
Oct. 17, 2006
Oct. 18, 2006
83
77
74
7
04
01-11-02
Oct. 17, 2006
Oct. 18, 2006
82
75
72
7
04
01-11-03
Oct. 17, 2006
Oct. 18, 2006
82
75
72
7
04
01-11-04
Oct. 17, 2006
Oct. 18, 2006
81
75
72
01-11-05
Oct. 17, 2006
Oct. 18, 2006
82
75
73
01-12-01
Oct. 19, 2006
Oct. 20, 2006
82
78
74
7
04
01-12-02
Oct. 19, 2006
Oct. 20, 2006
80
75
72
7
04
01-12-03
Oct. 19, 2006
Oct. 20, 2006
78
75
72
7
04
01-12-04
Oct. 19, 2006
Oct. 20, 2006
80
75
72
01-12-05
Oct. 19, 2006
Oct. 20, 2006
77
74
70
01-13-01
Oct. 25, 2006
Nov. 4, 2006
69
67
64
7
04
01-13-02
Oct. 25, 2006
Nov. 4, 2006
70
67
64
7
04
01-13-03
Oct. 25, 2006
Nov. 4, 2006
71
69
64
7
04
01-13-04
Oct. 25, 2006
Nov. 4, 2006
73
71
66
01-13-05
Oct. 25, 2006
Nov. 4, 2006
81
79
69
01-14-01
Nov. 4, 2006
Nov. 7, 2006
66
65
BROKE
01-14-02
Nov. 4, 2006
Nov. 7, 2006
70
69
65
4
04
01-14-03
Nov. 4, 2006
Nov. 7, 2006
72
71
66
4
04
01-14-04
Nov. 4, 2006
Nov. 7, 2006
72
70
67
01-14-05
Nov. 4, 2006
Nov. 7, 2006
73
71
67
02-15-01
Nov. 10, 2006
Nov. 11, 2006
63
58
57
02-15-02
Nov. 10, 2006
Nov. 11, 2006
62
56
54
4
04
02-15-03
Nov. 10, 2006
Nov. 11, 2006
62
56
54
4
04
02-15-04
Nov. 10, 2006
Nov. 11, 2006
62
56
55
02-15-05
Nov. 10, 2006
Nov. 11, 2006
61
56
54
03-16-01
Nov. 11, 2006
Nov. 13, 2006
79
76
74
03-16-02
Nov. 11, 2006
Nov. 13, 2006
78
74
72
4
04
03-16-03
Nov. 11, 2006
Nov. 13, 2006
77
74
71
4
04
03-16-04
Nov. 11, 2006
Nov. 13, 2006
76
72
71
03-16-05
Nov. 11, 2006
Nov. 13, 2006
74
71
69
04-17-01
Nov. 14, 2006
Nov. 15, 2006
93
87
85
04-17-02
Nov. 14, 2006
Nov. 15, 2006
94
89
86
4
04
04-17-03
Nov. 14, 2006
Nov. 15, 2006
98
91
88
4
04
04-17-04
Nov. 14, 2006
Nov. 15, 2006
98
91
86
04-17-05
Nov. 14, 2006
Nov. 15, 2006
98
92
89
Weight
Length
Length
Scnd
Weight
10 ml @
(g) after
Weight
(mm) @
(mm) @
Length
Bisk
Bisk
(g) after
Weight
SECOND
Length
Bisk
reduction
render
Bisk
reduction
#
Cone2
Second Bisk
reduction2
Bisk
reduction2
59
14.49%
97.9
88.4
9.70%
100.00%
100.00%
59
13.24%
97.9
88.2
9.91%
100.00%
100.00%
57
14.93%
97.9
88
10.11%
100.00%
100.00%
57
14.93%
97.9
88.1
10.01%
100.00%
100.00%
60
18.92%
98.3
88.4
10.07%
100.00%
100.00%
59
19.18%
98.3
88.1
10.38%
100.00%
100.00%
59
18.06%
98.3
88.5
9.97%
100.00%
100.00%
58
19.44%
98.3
88.1
10.38%
100.00%
100.00%
56
18.84%
98.3
88.1
10.38%
100.00%
100.00%
57
12.31%
99.5
87.8
11.76%
100.00%
100.00%
56
13.85%
99.5
87.8
11.76%
100.00%
100.00%
56
13.85%
99.5
87.8
11.76%
100.00%
100.00%
56
13.85%
99.5
87.8
11.76%
100.00%
100.00%
56
12.50%
99.5
87.8
11.76%
100.00%
100.00%
48
31.43%
97.6
89
8.81%
100.00%
100.00%
45
33.82%
97.6
89
8.81%
100.00%
100.00%
47
31.88%
97.6
88.8
9.02%
100.00%
100.00%
48
30.43%
97.6
88.8
9.02%
100.00%
100.00%
BROKE
#VALUE!
97.6
100.00%
100.00%
100.00%
48
33.33%
98.8
88.8
10.12%
05
10
61
15.28%
88.8
10.12%
48
32.39%
98.8
88.4
10.53%
05
10
61
14.08%
88.1
10.83%
47
32.86%
98.8
88.4
10.53%
05
10
60
14.29%
88.2
10.73%
44
37.14%
98.8
88.4
10.53%
05
10
60
14.29%
88.2
10.73%
45
36.62%
98.8
88.3
10.63%
05
10
61
14.08%
88.3
10.63%
62
13.89%
98.6
88.5
10.24%
100.00%
100.00%
62
13.89%
98.6
88.5
10.24%
100.00%
100.00%
61
14.08%
98.6
88.5
10.24%
100.00%
100.00%
61
14.08%
98.6
88.5
10.24%
100.00%
100.00%
61
14.08%
98.6
88.5
10.24%
This bar
100.00%
100.00%
broke right
before bisk
100.00%
98.6
100.00%
100.00%
100.00%
100.00%
98.6
100.00%
100.00%
100.00%
62
16.22%
98.6
93.3
5.38%
100.00%
100.00%
62
16.22%
98.6
93.6
5.07%
100.00%
100.00%
62
16.22%
98.6
93.4
5.27%
100.00%
100.00%
100.00%
99.5
100.00%
100.00%
100.00%
100.00%
99.5
100.00%
100.00%
100.00%
64
12.33%
99.5
93.6
5.93%
100.00%
100.00%
65
15.58%
99.5
93.4
6.13%
100.00%
100.00%
67
14.10%
99.5
93.8
5.73%
100.00%
100.00%
100.00%
98.5
100.00%
100.00%
100.00%
100.00%
98.5
100.00%
100.00%
100.00%
62
15.07%
98.5
93
5.58%
100.00%
100.00%
62
15.07%
98.5
92.8
5.79%
100.00%
100.00%
62
16.22%
98.5
93.1
5.48%
100.00%
100.00%
64
12.33%
97.5
93.4
4.21%
8
10
69
5.48%
88.6
9.13%
62
13.89%
97.5
93.1
4.51%
100.00%
100.00%
64
13.51%
97.5
93.3
4.31%
100.00%
100.00%
100.00%
97.5
100.00%
100.00%
100.00%
100.00%
97.5
100.00%
100.00%
100.00%
64
13.51%
98.4
93.6
4.88%
100.00%
100.00%
62
13.89%
98.4
93
5.49%
100.00%
100.00%
62
13.89%
98.4
93.2
5.28%
8
10
65
9.72%
88.4
10.16%
100.00%
98.4
100.00%
100.00%
100.00%
100.00%
98.4
100.00%
100.00%
100.00%
64
13.51%
98.9
93.1
5.86%
100.00%
100.00%
62
13.89%
98.9
92.9
6.07%
100.00%
100.00%
61
15.28%
98.9
93.3
5.66%
100.00%
100.00%
100.00%
98.9
100.00%
100.00%
100.00%
100.00%
98.9
100.00%
100.00%
100.00%
56
12.50%
98.8
94
4.86%
100.00%
100.00%
56
12.50%
98.8
93.9
4.96%
100.00%
100.00%
56
12.50%
98.8
93.3.
#VALUE!
100.00%
100.00%
100.00%
98.8
100.00%
100.00%
100.00%
100.00%
98.8
100.00%
100.00%
100.00%
#VALUE!
#DIV/0!
#VALUE!
88.2
#DIV/0!
57
12.31%
98.5
94.3
4.26%
5
10
57
12.31%
10.46%
59
10.61%
98.5
93.9
4.67%
5
10
58
12.12%
88.6
10.05%
100.00%
98.5
100.00%
100.00%
100.00%
100.00%
98.5
100.00%
100.00%
100.00%
100.00%
97.5
100.00%
100.00%
100.00%
48
11.11%
97.5
91.9
5.74%
5
10
48
11.11%
86
11.79%
48
11.11%
97.5
92.2
5.44%
5
10
48
11.11%
85.9
11.90%
100.00%
97.5
100.00%
100.00%
100.00%
100.00%
97.5
100.00%
100.00%
100.00%
100.00%
98.5
100.00%
100.00%
100.00%
64
11.11%
98.5
93.6
4.97%
5
10
63
12.50%
90
8.63%
64
9.86%
98.5
93.8
4.77%
5
10
63
11.27%
89.8
8.83%
100.00%
98.5
100.00%
100.00%
100.00%
100.00%
98.5
100.00%
100.00%
100.00%
100.00%
99
100.00%
100.00%
100.00%
75
12.79%
99
94.4
4.65%
5
10
75
12.79%
88.9
10.20%
77
12.50%
99
94.4
4.65%
5
10
76
13.64%
89.2
9.90%
100.00%
99
100.00%
100.00%
100.00%
100.00%
99
100.00%
100.00%
100.00% | The present invention includes a method of preparing a ceramic precursor article, the ceramic precursor made thereby, a method of making a ceramic article and an article made by that method. It also includes a method of replicating a ceramic shape.
Also included is a method of making a ceramic precursor, and the finished ceramic article therefrom, involving a compression step, and a compression-capable printer apparatus. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to Provisional U.S. Patent Application Ser. No. 60/759,681, filed Jan. 17, 2006, to David Raisner, et al. entitled SOUVENIR DISPLAY DEVICE and Provisional Patent Application Ser. No. 60/873,216 filed, Dec. 6, 2006 to David Raisner, et al. entitled SOUVENIR DISPLAY DEVICE, the entire contents of each of which are specifically incorporated by reference herein.
BACKGROUND
[0002] This application relates generally to souvenir display devices. More particularly, this application relates to display devices, which are generally transparent or translucent and which receive therein souvenirs such as casino chips for easy display thereafter.
[0003] It is typical for consumers to purchase or receive souvenirs from vacations, holidays, trips and certain activities such as visits to casinos. Particularly, with respect to casinos, it is quite common to give as a gift or to take home one or more casino chips as a memento of the trip to the casino. In fact, many people routinely collect casino chips from various casinos as a memento or souvenir of their trip. Such casino chips and other souvenirs typically are placed on a table or in a drawer and are easily forgotten (as such souvenirs may be difficult to properly display).
SUMMARY
[0004] The above-described and other problems and disadvantages of the art are overcome and alleviated by the present display device, which easily and efficiently stores a souvenir such as a casino chip for later display. An exemplary souvenir display device comprises a transparent or translucent plastic housing having a surface which includes an opening therein. The opening is sized and configured to allow the souvenir to be easily press fit (i.e., friction fit) therein. The housing also includes at least one flattened area so as to permit positioning of the housing on a flat surface such as a shelf or table. Because the housing is transparent or translucent, the souvenir is readably viewed from any side of the display device. Moreover, in the event that a different souvenir is desired to be placed in the display device, the friction fit will allow ease of removal of the souvenir with replacement of a different souvenir therein.
[0005] Another exemplary display device comprises a keychain type configuration.
[0006] The above-described display device is relatively inexpensive to manufacture and provides an easy cost-effective way of displaying a memento or other souvenir such as a casino chip.
[0007] The above-discussed and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Referring now to the exemplary drawings wherein like elements are numbered alike in the several FIGURES:
[0009] FIG. 1 is a front elevation view of an exemplary souvenir display device having a casino chip inserted therein in accordance with the present invention;
[0010] FIG. 2 is side elevation view of the display device of FIG. 1 ;
[0011] FIG. 3 is a bottom view of the display device of FIG. 1 ;
[0012] FIG. 4 is a perspective, exploded view of the display device of FIG. 1 showing the casino chip being inserted therein;
[0013] FIG. 5 is a front elevation view of another exemplary souvenir display device;
[0014] FIG. 6 is a side cross sectional view of the display device of FIG. 5 ;
[0015] FIG. 7 is a front perspective view of the display device of FIG. 5 ;
[0016] FIG. 8 is a rear perspective view of the display device of FIG. 5 ;
[0017] FIG. 9 is a perspective view of an exemplary display device;
[0018] FIG. 10 is a front schematic view of the exemplary display device of FIG. 9 ;
[0019] FIG. 11 is a side schematic view of the exemplary display device of FIG. 9 ;
[0020] FIG. 12 is a front perspective view of an exemplary display device;
[0021] FIG. 13 is a side schematic view of the exemplary display device of FIG. 12 ;
[0022] FIG. 14 is a front perspective view of an exemplary display device;
[0023] FIG. 15 is an exploded view of the exemplary display device of FIG. 14 ;
[0024] FIG. 16 is a front perspective view of an exemplary display device;
[0025] FIG. 17 is an exploded view of the exemplary display device of FIG. 16 ;
[0026] FIG. 18 is a front perspective view of an exemplary display device;
[0027] FIG. 19 is an exploded view of the exemplary display device of FIG. 18 ;
[0028] FIG. 20 is a front perspective view of an exemplary display device; and
[0029] FIG. 21 is a side schematic view of the exemplary display device of FIG. 20 .
DETAILED DESCRIPTION
[0030] Referring to FIGS. 1-4 , an exemplary display device for displaying a souvenir such as a casino chip is shown generally at 10 . In this embodiment, the display device is shown having a cylindrical shape with a relatively circular front surface 12 , a similarly shaped back surface 14 and a substantially cylindrical side surface 16 between front and back surfaces 12 and 14 . A flattened support surface 18 is formed along a portion of cylindrical side surface 16 . It will be appreciated that flattened support surface 18 provides a surface for display device 10 to be positioned on a table, shelf or other flattened surface for display of a souvenir.
[0031] Front surface 12 includes a cylindrical opening 20 therein. In this embodiment, opening 20 is comprised of a circular base surface 22 and a cylindrical sidewall 24 . Opening 20 is sized and configured to receive and frictionally engage with a souvenir such as a casino chip 26 shown in FIGS. 1 and 4 . In other words, the diameter and circumference of opening 24 is sized and configured such that casino chip 26 may be received into the opening but because the opening is slightly smaller than casino chip 26 , the chip will frictionally engage with and be retained by the sidewalls 24 of opening 20 . An exemplary dimension for opening 22 is a diameter of about 1.5 inch and a depth of about 0.1406 ( 9/16) inch.
[0032] Display device 10 is of one-piece construction and preferably molded although the device could be machined from a single block of material. Display device 10 is made from a suitable polymeric material, which exhibits transparency and/or translucency, examples of which include acrylics or polycarbonates.
[0033] Referring now the FIGS. 5 and 6 , another exemplary display device is illustrated generally at 30 . In this embodiment, the display device is shown having a cylindrical shape with a relatively circular front surface 12 , a similarly shaped back surface 14 and a substantially cylindrical side surface 16 between front and back surfaces 12 and 14 . A flattened support surface 18 is formed along a portion of cylindrical side surface 16 . It will be appreciated that flattened support surface 18 provides a surface for display device 10 to be positioned on a table, shelf or other flattened surface for display of a souvenir. FIGS. 7 and 8 show front and rear perspective views of the exemplary device of FIGS. 5 and 6 .
[0034] Front surface 12 includes a cylindrical opening 20 therein. In this embodiment, opening 20 is comprised of a circular base surface 22 and a cylindrical sidewall 24 . Opening 20 is sized and configured with one or more ribs 32 to receive and frictionally engage with a souvenir such as a casino chip 26 shown in FIGS. 1 and 4 . In other words, the diameter and circumference of opening 24 is sized and configured, and the at least one rib is formed therein, such that casino chip 26 may be received into the opening but because the inner circumference of the opening 20 with rib(s) 32 is slightly smaller than casino chip 26 , the chip will frictionally engage with and be retained by the rib(s) 32 of opening 20 . An exemplary dimension for opening 22 is a diameter of about 1.58 inch and a depth of about 0.1406 ( 9/16) inch. An exemplary dimension for each of three exemplary crush ribs on the sidewall 24 of the opening is about 0.03 inches protrusion from the sidewall 24 .
[0035] Display device 10 is of one-piece construction and preferably molded although the device could be machined from a single block of material. Display device 10 is made from a suitable polymeric material, which exhibits transparency and/or translucency, examples of which include acrylics or polycarbonates. Referring to FIG. 6 , to save materials and weight (and thus cost), the front side 12 of the display device 10 may be beveled from the outer circumference to the opening 20 . Also, a void 34 may be formed in the backside 16 of the display device, either or both of behind the opening 20 and behind the device 20 but outside the circumference of the opening 20 . Also, as illustrated, the relative volume of void space may differ across the display device, with the exemplary display device of FIG. 6 having more volume removed in the outer periphery of the device back 16 , and less removed behind the opening 20 . The void may be formed by a molding process when making the device, machined after making the device, or the equivalent. In the illustrated exemplary embodiment, the void space creates a peripheral sidewall having about 0.15 inches of thickness on a display device that measures about 2.76 inches from top to bottom. Again, these dimensions are merely exemplary and not limiting.
[0036] While the embodiments shown in FIGS. 1-8 have an overall generally cylindrical configuration, it will be appreciated that this is an example only. In fact, display device 10 may have any suitable overall configuration such as a square, rectangle or any other geometric shape including symmetric or asymmetric geometries. Further, it will be appreciated that while the embodiment shown in FIGS. 1-4 is sized to receive a coin-type souvenir (such as a casino chip) the opening 20 may be similarly configured to receive any other suitable souvenir such as a souvenir having a square, rectangular or other geometric shape, whether symmetrical or asymmetrical. It will also be appreciated that flattened surface 18 may have a variety of configurations and may include additional layers adhesively or otherwise applied thereto, such as a felt or fabric covering.
[0037] Referring now to FIGS. 9-11 , another exemplary display device is illustrated generally at 40 . This embodiment is of a key chain or FOB type, wherein the souvenir (not shown) will insert between front and rear faces 42 , 44 through a top portion, shown generally at 46 . When inserted, the souvenir will be supported by at least one supporting interior contour (i.e., either conforming to the shape of the souvenir or having multiple points of contact ( 48 , 50 , 52 in FIG. 10 ) to allow space around the souvenir, e.g., to at least some of the sides of the souvenir for viewing (see openings 54 , 56 , 58 in FIGS. 9 - 11 )). An opening 60 is provided through one or both of the front and rear 42 , 44 of the device to accommodate a key chain or the like. In the presently illustrated exemplary embodiment, it is noted that something inserted through one of the openings 60 would effectively prevent the souvenir from sliding out of the device. In an exemplary embodiment, the display device is not more than twice the diameter of the souvenir. In another exemplary embodiment, the device is not more than 1.5 times the diameter of the souvenir. In another exemplary embodiment, the device is not more than 1.1 times the diameter of the souvenir.
[0038] Of course, any portion of the device may have tackiness or be configured to frictionally engage the souvenir to resist movement of the souvenir in an installed configuration.
[0039] Referring now to FIGS. 12 and 13 , another exemplary embodiment allows for deformation of a part of the display device (in the illustrated case, at least a portion of the back surface 44 ) to accommodate the souvenir. Referring now to FIGS. 20 and 21 , another exemplary embodiment allows for deformation of a part of the display device (in the illustrated case, spreading of an upper region 70 of the device) to accommodate the souvenir.
[0040] Referring now to FIGS. 14 and 15 , another exemplary embodiment allows for disassembly and reassembly of a part of the display device (in the illustrated case, disassembly of the front surface 42 from the back surface 44 ) to accommodate the souvenir. This embodiment may include any of various mechanisms to resist detaching of the pieces when assembled, including snap fits or other mechanical locks (see snap fit portions 62 configured to mate with recesses 64 ), among others. FIGS. 16 and 17 illustrate another such embodiment, wherein two portions 66 , 68 are hingedly attached. FIGS. 18 and 19 illustrate another exemplary embodiment that allows for disassembly and reassembly of a part of the display device (in the illustrated case, a different kind of hinged relationship, where front and back surfaces 42 , 44 include a hinge 72 therebetween) to accommodate the souvenir.
[0041] While exemplary embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A souvenir display design is described comprising a transparent or translucent housing, the housing having at least one flattened surface for supporting the housing on a planar surface and a recess in a surface of the housing for frictionally receiving and engaging a souvenir. In another embodiment, the souvenir display comprises a keychain type configuration. | 0 |
This application is a continuation-in-part of application no. 08/599,985 filed Feb. 14, 1996, now abandoned entitled "Bicycle Shift Levers Which Surround a Handlebar."
BACKGROUND OF THE INVENTION
The present invention is directed to a bicycle shifting device which operates a shifting mechanism via a shifter cable, and specifically concerns a device in which a take-up body that takes up the shifter cable is caused to rotate in the take-up direction by means of a first shift lever which freely returns to a home position, and is caused to rotate in the pay-out direction by means of a second shift lever which freely returns to a separate home position.
A bicycle shifter operating device equipped with first and second shift levers such as those described above is known (for example) from Japanese Patent Application Kokai No. 4-183696. In this shifter operating device, the first shift lever and the second shift lever can pivot about a common pivoting axis wherein the operating direction of the first shift lever is clockwise and the operating direction of the second shift lever is counterclockwise. The first shift lever is arranged so that it can be operated by the thumb of the hand gripping the handlebar, and the second shift lever is arranged so that it can be operated by the index finger of the hand gripping the handlebar. In such shifting devices the first and second levers typically pivot about an axis that is perpendicular to the handlebar.
During high performance riding on rough terrain it is often desirable to keep the hands as firmly positioned on the handlebars as possible. However, when using the above shifting devices it is necessary to remove the index finger from the handlebar in order to operate the second shift lever. Some cyclists find the movement of the index finger in such cases undesirable.
Some shifting devices are constructed as shown in U.S. Pat. No. 4,900,291 wherein the shifting operation is performed by rotating a sleeve mounted coaxially with the handlebar. Unfortunately, if the hand is maintained in position around the sleeve while riding there is a risk of unintended shifting when encountering rough terrain. If the hand is ordinarily kept in position on the rigid portion of the handlebar, then the entire hand must be removed from the handlebar to grasp the sleeve during shifting, which is even more undesirable. Thus, there is a need for a shifting device which allows the hand to be firmly positioned on the handlebar at all times with a minimum of movement during shifting.
Another ergonomic consideration of shifting devices is the sensory feedback provided by the shifting device. Some cyclists prefer a shifting device which provide very different sensory feedback between the upshifting and downshifting operations. For those cyclists a shifting device with two pivoting levers does not provide sufficient sensory difference between the upshifting and downshifting operation, since both levers pivot. The same is true with shifting devices constructed with a rotating sleeve, since both upshifting and downshifting is performed by rotating the sleeve.
A bicycle shifter operating device in which the first shift lever is operated by pivoting and the second shift lever is operated by means of a button in order to achieve a clear sensory difference between the shifter cable take-up operation and the shifter cable pay-out operation is known from British Patent Disclosure No. 2,169,065 (corresponding to Japanese Patent Application Kokai No. 61-222889). In this shifter operating device, a pivoting lever is used when the take-up body is to be rotated in the direction which takes up the shifter cable. When the take-up body is to be rotated in the direction which pays out the shifter cable (using the driving force of a return spring), the cable is returned one speed at a time by means of a button-operated sliding pawl. Here, the shifter cable take-up operation is accomplished by a pivoting action, while the shifter cable pay-out operation is accomplished by a sliding action. Accordingly, there is a clear sensory difference between the two operations. Unfortunately, because of structural limitations, the pivoting lever and the button-operated part must be installed in completely different locations. Accordingly, it is difficult to perform both shifting operations using the fingers of the hand gripping the handlebar without undesirable movement of the hand.
Yet another ergonomic consideration is the placement of the finger contacting portions of the shift levers. When a shift lever is to be operated by the thumb, the shift lever should be placed in a position that does not require awkward movement of the thumb. This is especially true when separate shift levers are provided for upshifting and downshifting. Some riders prefer thumb operated shift levers to be located at the approximate plane of the palm. Unfortunately, the approximate plane of the palm usually corresponds to the location of the handlebar, and it is not feasible to mount conventional shift levers in front of the handlebar. That is because conventional shift levers require a relatively large swing angle to operate, and it would be necessary to mount the lever a great distance forward of the handlebar to prevent the lever from striking the handlebar during operation. This, in turn, would destroy the ergonomic positioning of the lever.
SUMMARY OF THE INVENTION
The present invention is directed to a bicycle shifting device which allows the shifting operation to be performed without undesirable movement of the hand and which also can be constructed to provide very different sensory feedback between the upshifting and downshifting operations. In one embodiment of a bicycle shifter operating device according to the present invention for operating a shifting mechanism via a transmission element, a control body is provided for mounting to a bicycle in close proximity to a handlebar for controlling a pulling and releasing of the transmission element. A first lever is mounted to the control body for movement which causes the control body to effect pulling of the transmission element, and a second lever is mounted to the control body for movement which causes the control body to effect releasing of the transmission element. Both levers may be operated by the cyclist's thumb without movement of any other fingers or the palm from the handlebar. The control body may be mounted to a bracket used for mounting a brake lever to the bicycle, thus allowing the shifting levers to be placed very close to the brake lever to facilitate shifting while braking.
In a more specific embodiment, one lever may be pivotally coupled to the control body, and the other lever may be coupled for linear movement relative to the control body. This embodiment maximizes the difference in sensory feedback between upshifting and downshifting (i.e., sliding vs. pivoting) while still allowing the shifting operation to be accomplished without excessively moving the fingers and palm from the handlebar. The lever structured for linear movement may be coupled to a transmission mechanism for operating the control body in such a way that very little linear movement is needed to operate the control body. The transmission mechanism may include a plurality of ratchet teeth disposed in a common plane, where the path of movement of the linear operating body is parallel to the plane of the ratchet teeth. With such a structure, the finger contacting part associated with the linearly moving lever may be placed in front of the handlebar (by curving the body of the lever, if necessary) so that the finger contacting part moves toward the handlebar in operation without striking the handlebar. As a result, both levers may be placed near the plane of the rider's palm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a particular embodiment of a shifter operating device according to the present invention attached to a brake bracket;
FIG. 2 is a sectional view of the shifter operating device taken along line II--II in FIG. 3;
FIG. 3 is a sectional view of the shifter operating device taken along line III--III in FIG. 2;
FIG. 4 is a sectional view of the shifter operating device taken along line IV--IV in FIG. 2;
FIG. 5 is a side view of a particular embodiment of a rotating plate of the sliding operating body shown in FIG. 3;
FIG. 6 is a side view of a particular embodiment of the pivoting operating body shown in FIG. 3;
FIG. 7 is an exploded perspective view of a particular embodiment of a positioning mechanism according to the present invention;
FIG. 8 is a perspective view of an alternative embodiment of a shifter operating device according to the present invention;
FIG. 9 is a front view of the shifter operating device shown in FIG. 8;
FIG. 10 is a view taken along line X--X in FIG. 9;
FIG. 11 is a cross sectional view of the main portions of the shifter operating device shown in FIG. 8;
FIG. 12 is an exploded view of the shifter operating device shown in FIG. 12;
FIG. 13 is a detailed view of the transmission mechanisms disposed between the operating levers and the control body;
FIGS. 14A-14B are detailed views illustrating the operation of the pivoting lever shown in FIG. 13;
FIGS. 15A-15C are detailed views showing the operation of the position retaining pawl during operation of the pivoting lever shown in FIG. 13; and
FIGS. 16A-16C are detailed views illustrating the operation of the sliding lever shown in FIG. 13.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 is a perspective view showing a particular embodiment of a shifter operating mechanism according to the present invention. As shown in FIG. 1, a brake bracket 3 which pivotally supports a brake lever 2 is fastened in place adjacent to a grip 1a formed on the handlebar 1 of a bicycle. A shifter operating device 5 which pulls and releases a shifter cable 4 is attached to the side surface of this brake bracket 3. The arm-shaped sliding operating body 20 of the shifter operating device 5 extends above the handlebar 1, and the pivoting operating body 30 of the shifter operating device 5 extends beneath the handlebar 1, so that operation of both levers is possible with the thumb of the hand gripping the handlebar grip 1a.
As is shown in FIGS. 2 and 3, the shifter operating device 5 includes a supporting shaft 8 which is rigidly fastened by means of an attachment bolt 7 to a bracket 6 which, in turn, may be formed as an integral part of the brake bracket 3. A take-up body 70 is attached to the base end of supporting shaft 8, and a positioning mechanism 80 is built into a recessed area 71 formed in take-up body 70. A first ratchet mechanism 50, used as a first transmission means, transmits the displacement of a sliding operating body 20 to the take-up body 70 to cause the rotation of the take-up body 70 in one direction, and a second ratchet mechanism 60, used as a second transmission means, transmits the displacement of a pivoting operating body 30 to the take-up body 70 to cause the rotation of the take-up body 70 in the other direction.
As shown in FIGS. 2, 3 and 4, the sliding operating body 20 is equipped with a first arm part 21 which forms the main part of the sliding operating body, a first finger contact part 22 which is formed on the tip of the first arm part 21 in order to allow finger operation, a rotating plate 23 (constituting a root part) which is supported on the supporting shaft 8 so that the plate 23 can rotate about the supporting shaft 8, and a pair of link members 26 which link the first arm part 21 with a projecting part 23a of the rotating plate 23 via pivot pins 24 and 25. The pivoting operating body (30) is equipped with a second arm part 31 which forms the main part of the pivoting operating body, a second finger contact part 32 which is formed on the tip of the second arm part 31 in order to allow finger operation, and a rotating plate 33 (constituting a root part) which is supported on the supporting shaft 8 so that the plate 33 can rotate about the supporting shaft 8.
The first ratchet mechanism 50 is equipped with a first feeding pawl 51 which is rotatably attached to the pivot pin 24, a first ratchet part 72 which is formed on the outer circumferential surface of the take-up body 70 so that the ratchet part 72 can engage with the feeding pawl 51, and a spring 52 which drives the first feeding pawl 51 in the direction of engagement. In this embodiment, first ratchet part 72 includes a plurality of ratchet teeth disposed in a common plane (T) as shown in FIGS. 2 and 3. The second ratchet mechanism 60 is equipped with a second feeding pawl 61 which is rotatably attached to a pivot pin 34 installed on the transitional part 33a between the rotating plate 33 and second arm part 31, a second ratchet part 73 which is formed on the outer circumferential surface of the take-up body 70 so that the ratchet part 73 can engage with the feeding pawl 61, and a spring 62 which drives the second feeding pawl 61 in the direction of engagement.
The take-up body 70 is equipped with a drum part which is constructed so that the inner wire 4a of the shifter cable 4 from a shifting mechanism (not shown) on the front or rear of the bicycle is taken up along a wire groove 74. By rotating in the forward direction or reverse direction with respect to the supporting shaft 8, the take-up body 70 takes up or pays out the inner wire 4a.
As is shown in FIG. 4, the first arm part 21 of the sliding operating body 20 is linked with the rotating plate 23 by means of the link members 26 and pivot pin 24. Both ends of the pivot pin 24 are extended, and the extended end portions are inserted into grooves 6a formed in the bracket 6. Accordingly, the first arm part 21 is guided by the grooves 6a, and performs a linear sliding motion. As a result of this sliding motion, the rotating member 23, which is pivotably fit over the supporting shaft 8 via a bush 9a, is caused to pivot about the axial center X of the supporting shaft 8.
As shown in FIG. 5, the rotating plate 23 has a projection 23b which projects radially outward. This projection 23b is designed so that it will contact one side surface of a stopper 10a formed by bending a circumferential projecting part 10a of a cam member 10 which is attached to the supporting shaft 8 in the pivoting track of the projection 23b. Rotating plate 23 is driven by a return spring 11a which engages a stationary plate 12 in the direction which causes contact between the projection 23 and the stopper 10a. The position in which the projection 23b and stopper 10a are in contact with each other constitutes the home position HP1 of the rotating plate 23 and the sliding operating body 20. The sliding operating body 20 is operated with this home position as a starting point.
In the case of the pivoting operating body 30, as is shown in FIG. 6, the second arm part 31, second finger contact part 32 and rotating plate 33 (which constitutes the second root part) are formed as an integral unit, and the rotating plate 33 is pivotably fit over the supporting shaft 8 via a bush 9b. Accordingly, when the second finger contact part 32 is pressed, the rotating plate 33 pivots about the axial center X of the supporting shaft 8. The transitional part between the second arm part 31 and the rotating plate 33, i.e., the root of the second arm part 31, is designed so that it contacts the other side surface of the stopper 10a formed by a portion of the cam member 10 in the pivoting track of the root of the second arm part 31. Furthermore, the second arm part 31 is driven by a return spring 11b in the direction which causes contact between the second arm part 31 and the stopper 10a. The position in which the second arm part 31 and stopper 10a are in contact with each other constitutes the home position HP2 of the rotating plate 33 and operating body 30. The pivoting operating body 30 is operated with this home position as a starting point.
Regardless of any restrictions on the attachment position of the take-up body (70), the first and second finger contact parts (22,32) can easily be set in positions which are convenient for the fingers of the hand gripping the handlebar grip, since the finger contact parts (22,32) are located in positions distant from the take-up body. Furthermore, if the system is constructed so that the first finger contact part (22) is displaced in substantially the same plane as the plane of the pivoting track of the second finger contact part (32), i.e., if the first finger contact part (22) is positioned on a line constituting a direct extension of the pivoting range of the second finger contact part (32), then the two operating bodies can be operated by a bending motion and a pivoting motion of the thumb of the hand gripping the handlebar grip. Here, the above expression to the effect that "the first finger contact part (22) is displaced in substantially the same plane as the plane of the pivoting track of the second finger contact part (32)" is to be interpreted merely as indicating that there is no great expansion in the direction of width of the first finger contact part (22) and second finger contact part (32) regardless of how said finger contact parts are displaced. In other words, this expression is not to be interpreted in a strict mathematical sense. As a result of such an arrangement, two motions of the thumb which are desirable from the standpoint of human engineering can be utilized for shifting operations.
When the sliding operating body 20 is positioned in the home position HP1, the tip of the first feeding pawl 51 rides up on a first cam part 10b formed on the circumference of the cam member 10. Accordingly, as a result of being pushed upward by the first cam part 10b of the cam member 10, the first feeding pawl 51 is released from the first ratchet part 72, so that rotation of the take-up body 70 by the pivoting operating body 30 is made possible. When the sliding operating body 20 slides in the direction indicated by the arrow from the home position HP1, the first feeding pawl 51 is released from the first cam part 10b and is caused to pivot toward the first ratchet part 72 by the driving force of the first pawl spring 52. Thereafter, the feeding pawl 51 engages with one of the plurality of ratchet teeth of the first ratchet part 72, thus coupling the sliding operating body 20 and the take-up body 70 so that the bodies rotate as a unit. When the sliding operating body 20 moves from a prescribed shift operating position to the home position HP1, the first feeding pawl 51 is pushed upward by the shape of the ratchet teeth of the first ratchet part 72, so that the engagement of the first feeding pawl 51 with the first ratchet part 72 is automatically released. Accordingly, when the sliding operating body 20 moves from the home position HP1 to the shift operating position, the first ratchet mechanism 50 transmits the sliding displacement of the sliding operating body 20 to the take-up body 70 to cause a take-up rotational operation of the take-up body 70. Thereafter, when the sliding operating body 20 slides from the shift operating position to the home position HP1, the engagement between the first feeding pawl 51 and the first ratchet part 72 is released, thus making it possible for the sliding operating body 20 to return to the home position HP1 while the take-up body 70 remains in a prescribed shift position.
When the pivoting operating body 30 is positioned in the home position HP2, the tip of the second feeding pawl 61 rides up on a second cam part 10c formed on the circumference of the cam member 10. Accordingly, as a result of being pushed upward by the second cam part 10c of the cam member 10, the second feeding pawl 61 is released from the second ratchet part 73, so that rotation of the take-up body 70 by the sliding operating body 20 is made possible. When the pivoting operating body 30 pivots in the direction indicated by the arrow from the home position HP2, the second feeding pawl 61 is released from the second cam part 10c and is caused to pivot toward the second ratchet part 73 by the driving force of the second pawl spring 62. Thereafter the feeding pawl 61 engages with one of the plurality of ratchet teeth of the second ratchet part 73, thus coupling the pivoting operating body 30 and the take-up body 70 so that the bodies rotate as a unit. When the pivoting operating body 30 pivots from a prescribed shift operating position to the home position HP2, the second feeding pawl 61 is pushed upward by the shape of the ratchet teeth of the second ratchet part 73, so that the engagement of the second feeding pawl 61 with the ratchet part 72 is automatically released. Accordingly, when the pivoting operating body 30 pivots from the home position HP2 to the shift operating position, the second ratchet mechanism 60 transmits the pivoting displacement of the pivoting operating body 30 to the take-up body 70 to cause a pay out rotational operation of the take-up body 70. Thereafter, when the pivoting operating body 30 pivots from the shift operating position to the home position HP2, the engagement between the second feeding pawl 61 and the second ratchet part 73 is released, thus making it possible for the pivoting operating body 30 to return to the home position HP2 while the take-up body 70 remains in a prescribed shift position. In this embodiment, the first finger contact part 22 is displaced in the same plane P as the plane of the path of movement of the second finger contact part 32 as shown in FIG. 3.
The positioning mechanism 80 is constructed from a first positioning plate 81 and second positioning plate 82 which are fit over the supporting shaft 8 inside the take-up body 70, and a pair of coned disk springs 83 which are fit over the supporting shaft 8 between the first positioning plate 81 and the bottom surface of a recessed part 71. As shown in FIG. 7, a circular through-hole 81a is formed in the central portion of the first positioning plate 81, and spline projections 81b are formed on the circumference of the first positioning plate 81. This through-hole 81a is used to fit the first positioning plate 81 over the supporting shaft 8, and the spline projections 81b are inserted into the spaces between a plurality of radially oriented projecting parts formed on the inside circumferential surface of a tube-form part 75 which forms the recessed part 71 of the take-up body 70. Thus, the first positioning plate 81 can slide along the supporting shaft 8 and rotates as a unit with the take-up body 70. The second positioning plate 82 is spline-engaged with the supporting shaft 8 by means of a spline hole 82a, and the second positioning plate 82 is positioned with respect to its upper limit by means of a tightening nut 84 via a spacer 85.
Coned disk springs 83 drive the first positioning plate 81 toward the second positioning plate 82 so that a plurality of projecting strips 81c formed on the first positioning plate 81 respectively enter a plurality of recessed grooves 82b formed in the second positioning plate 82. When the positioning mechanism 80 is in this engaged state, the second positioning plate 82 fastened to the supporting shaft 8 stops the rotation of the take-up body 70 via the first positioning plate 81. However, when the take-up body 70 is caused to pivot by an operating force which exceeds a set force determined by the spring force of the coned disk springs 83, the first positioning plate 81 slides away from the second positioning plate 82 against the force of the coned disk springs 83, so that the engaged state is switched to a disengaged state in which the projecting strips 81c slip out of the recessed grooves 82b formed in the second positioning plate 82, thus allowing rotation of the take-up body 70. In other words, when an operating force exceeding the set force is applied, the positioning mechanism 80 assumes a disengaged state so that the take-up body 70 can rotate. Afterward, the positioning mechanism 80 positions the take-up body 70 in the prescribed shift position by again switching from a disengaged state to an engaged state.
The shifting operation of this shifter operating device 5 will be described below with reference to FIG. 3.
When the thumb of the hand gripping the handlebar grip is contacts the first finger contact part 22 and the sliding operating body 20 is caused to slide from the home position HP1 in the direction indicated by the arrow, i.e., toward the shift position, the first ratchet mechanism 50 transmits the sliding displacement of the sliding operating body 20 as a rotational displacement of the take-up body 70. As a result, the positioning mechanism 80 assumes a disengaged state, and the take-up body 70 rotates toward the take-up side so that the inner wire 4a is taken up. When the take-up body 70 reaches a prescribed shift position, the sliding operation of the sliding operating body 20 is stopped. At this point, the take-up body 70 is in a new shift position which is the target position of the shifting operation, so that the take-up of a prescribed length of the inner wire 4a is completed. At the same time, the positioning mechanism 80 switches from a disengaged state to an engaged state, so that the take-up body 70 is maintained in the new shift position. Meanwhile, the sliding operating body 20 is automatically returned to its home position HP1 by the return spring 11a. As a result, the first finger contact part 22 and second finger contact part 32 are again located adjacent to each other as shown in FIG. 3.
When the thumb of the hand gripping the handlebar grip contacts the second finger contact part 32 and the pivoting operating body 30 is caused to slide from the home position HP2 in the direction indicated by the arrow, the second ratchet mechanism 60 transmits the pivoting displacement of the pivoting operating body 30 as a rotational displacement of the take-up body 70. As a result, the positioning mechanism 80 assumes a disengaged state, and the take-up body 70 rotates toward the pay-out side so that the inner wire 4a is paid out. When the take-up body 70 reaches a prescribed shift position, the pivoting operation of the pivoting operating body 30 is stopped. At this point, the take-up body 70 is in a new shift position which is the target position of the shifting operation, so that the pay-out of a prescribed length of the inner wire 4a is completed. At the same time, the positioning mechanism 80 switches from a disengaged state to an engaged state, so that the take-up body 70 is maintained in the new shift position. Meanwhile, the pivoting operating body 30 is automatically returned to its home position HP1 by the return spring 11b. As a result, the first finger contact part 22 and second finger contact part 32 are again located adjacent to each other as shown in FIG. 3.
In regard to the positioning mechanism 80 which maintains the position of the take-up body 70, it would also be possible to use a means in which this positioning is accomplished by friction between a positioning member on the fixed side and a positioning member on the take-up body side, instead of using a construction in which the positioning is accomplished by engaging means as in the embodiment described above. Furthermore, it would also be possible to use a so-called "index shifting mechanism" in which shifting one speed at a time is realized by means of a pivoting anchoring pawl which acts to link the sliding operating body 20 and pivoting operating body 30. In other words, the term "positioning mechanism 80" use here may refer to any universally known mechanism for temporarily maintaining the position of the take-up body 70.
FIG. 8 is a perspective view of an alternative embodiment of a shifter operating device according to the present invention. As shown in FIG. 8, a brake bracket 103 which pivotally supports a brake lever 102 is fastened in place adjacent to a grip 101a formed on the handlebar 101 of a bicycle. A shifter operating device 105 which pulls and releases a shifter cable 104 is attached to the side surface of this brake bracket 103. Bracket 103 has an annular sleeve portion 103a which fits around handlebar 101 to fasten bracket 103 to handlebar 101 in a known manner. An arm-shaped linearly sliding operating body 120 (FIGS. 12 and 13) of the shifter operating device 105 extends from below the handlebar 101, curves with the sleeve portion 103a and terminates in front of handlebar 101. A finger contacting part 122 of operating body 120, in the form of a button, is disposed within sleeve portion 103a. Finger contacting part 122 moves toward handlebar 101 when operating body 120 is operated. As can be ascertained from FIG. 9, a portion 122a of finger contacting part 122 will move toward a central axis H of handlebar 101 when operating body 120 is operated.
A pivoting operating body 130 of the shifter operating device 105 also extends below the handlebar 101. A finger contacting part 132 of operating body 130, in the form of a button, is disposed beneath finger contacting part 122 of operating body 120. As a result, operation of both levers is possible with the thumb of the hand gripping the handlebar grip 101a.
As is shown in FIGS. 11 and 12, the shifter operating device 105 includes a supporting shaft 108 which is rigidly fastened by means of an attachment bolt 107 and washers 107a and 107b to a bracket 106 which, in turn, may be formed as an integral part of the brake bracket 103. A take-up body 170 is rotatably mounted around supporting shaft 108.
A first ratchet mechanism 150, used as a first transmission means, transmits the displacement of sliding operating body 120 to the take-up body 170 to cause the rotation of the take-up body 170 in one direction, and a second ratchet mechanism 160, used as a second transmission means, transmits the displacement of pivoting operating body 130 to the take-25 up body 170 to cause the rotation of the take-up body 170 in the other direction. In this embodiment, displacement of pivoting operating body 130 causes the take-up body 170 to pull on cable 104, and displacement of sliding operating body 120 causes the take-up body 170 to release cable 104.
The take-up body 170 is equipped with a drum part which is constructed so that the shifter cable 104 from a shifting mechanism (not shown) on the front or rear of the bicycle is taken up along a wire groove 174. By rotating in the forward direction or reverse direction with respect to the supporting shaft 108, the take-up body 170 takes up or pays out the shifter cable 104. Take-up body 170 is coupled to a drive plate 171 for integral rotation therewith. As shown in FIG. 13, drive plate 171 includes a plurality of drive teeth 173 and a plurality of position retaining teeth 172, all of which are disposed in a common plane T. The operation of drive plate 171 will be discussed in more detail below.
As shown in FIGS. 12 and 13, the sliding operating body 120 is equipped with a first arm part 121 which forms the main part of the sliding operating body, the first finger contact part 122 which is formed on the curved end of the first arm part 121 in order to allow finger operation, a pawl pushing part 123 extending from a side of the arm part 121, and a pawl stop part 126. Sliding operating body 121 is slidingly fitted within openings 127A and 127B of a bracket 127 attached to sleeve 103A. Bracket 127 also includes a bracket extension 127C that is fitted around support shaft 108 and a guide 128 containing opening 127B. A spring 111A is connected between bracket 127 and a spring retainer 124 projecting from a side of arm part 121 for biasing arm part 121, and hence finger contacting part 122, to the home position HP1 shown in FIG. 13.
The first ratchet mechanism 150 comprises a first pawl 151 which is rotatably attached to a pivot pin 152 mounted in bracket 103, the plurality of position retaining teeth 172 which are formed on the outer circumferential surface of the drive plate 171, and a spring 153 which drives the first pawl 151 counterclockwise in the direction of engagement with position retaining teeth 172. First pawl 151 includes pawl tips 151A and 151B, a pawl operating part 151C for engaging pawl pushing part 123 on arm 121, and a pawl limit part 151D for contacting limit part 126 on arm 121 to limit the counterclockwise rotation of pawl 151. The operation of first ratchet mechanism 150 will be discussed in more detail below.
The pivoting operating body 130 is equipped with a second arm part 131 which forms the main part of the pivoting operating body, the second finger contact part 132 which is formed on the tip of the second arm part 131 in order to allow finger operation, a pawl supporting part 133 and a splined bushing 130A for rotatably mounting pivoting operating body 130 to support shaft 108. A spring 111B is connected between washer 107A and second arm part 131 for biasing pivoting operating body 130, and hence finger contacting part 122, to the home position HP2 shown in FIG. 13. In this embodiment, as in the first embodiment, the path of motion of sliding operating body 120 is substantially parallel to the ratchet teeth plane T.
The second ratchet mechanism 160 comprises a second pawl 161 which is rotatably attached to a pivot pin 162, the plurality of drive teeth 173 formed on the outer circumferential surface of the drive plate 171, and a spring 163 which drives the second pawl 161 counterclockwise in the direction of engagement with drive teeth 173. When pivoting operating body 130 is in the home position shown in FIG. 13, a tip 161A of pawl 161 rests on a ledge 127D of bracket part 127C, shown more clearly in FIG. 14A and 14B, this uncoupling pawl 161 from drive plate 171b.
When the thumb of the hand gripping the handlebar grip contacts the second finger contact part 132 and the pivoting operating body 130 is caused to pivot from the home position in the direction indicated by the arrow in FIG. 13, pawl 161 moves counterclockwise as shown in FIGS. 14A and 14B, and tip 161A of pawl 161 moves off the ledge 127C into engagement with an adjacent drive tooth 173. Further pivoting of pivoting operating body 130 causes pawl tip 161A to rotate drive plate counterclockwise to wind shifter cable 104 around take-up part 170. At the same time, as shown in FIGS. 15A and 15B, a position retaining tooth 172B pushes against pawl tip 151A, thus causing pawl 151 to rotate clockwise against the biasing force of spring 153. As drive plate 171 rotates further, position retaining tooth 172B moves past pawl tip 151A, and pawl 151 moves counterclockwise with the biasing force of spring 153. When pivoting operating body 130 is returned to its home position, pawl tip 161A of pawl 161 climbs back up on ledge 127D, but pawl tip 151A of pawl 151 abuts against position retaining tooth 172B as shown in FIG. 15C to maintain drive plate 171, and hence take-up element 170, in the desired rotational position. The same sequence occurs for shifts to the remaining drive teeth 173.
To rotate take-up element 170 in the opposite direction from this position, the thumb of the hand gripping the handlebar grip contacts the first finger contact part 122, and the sliding operating body 120 is caused to slide linearly from the home position in the direction indicated by the arrow in FIG. 13, and pawl pushing part 123 presses against pawl operating part 151C, thus causing pawl 151 to rotate clockwise against the biasing force of spring 153 as shown in FIG. 16A. When pawl 151 rotates to the position where pawl tip 151A clears position retaining tooth 172B, drive plate 171 immediately rotates clockwise as a result of the biasing force of spring 180 until position retaining tooth 172C abuts against pawl tip 151B as shown in FIG. 16B. When sliding operating body 120 is allowed to move back to its home position, pawl 151 rotates counterclockwise as a result of the biasing force of spring 163. As soon as pawl tip 151B clears position retaining tooth 172C, drive plate 171 continues rotating clockwise as shown in FIG. 16C. However, pawl tip 151A then abuts against position retaining tooth 172B to prevent further rotation of drive plate 171. As a result, drive plate 171, and hence take-up element 170, is maintained in the desired position. The same sequence occurs for shifts among the remaining position retaining teeth 172.
Because sliding operating body 120 operates pawl 151 by pressing pawl pressing part 123 against pawl operating part 151 C, very little movement (e.g., 5 millimeters) is required to operate pawl 151. As a result, sliding operating body 120 may be curved to follow the contour of sleeve 103A so that finger contacting part 122 may be disposed in front of handlebar 101 at the approximate plane of the rider's palm. Because of the short operating stroke of sliding operating body 120, handlebar 101 does not interfere with the operation of sliding operating body 120.
While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. For example, operating body 20 or 120 may cause take-up body 70 or 170 to rotate in the cable pay out direction, and operating body 30 130 may cause take-up body 70 or 170 to rotate in the cable take-up direction. If desired, operating body 20 or 120 may be constructed for pivoting displacement, and operating body 30 or 130 may be constructed for sliding displacement. Both operating bodies 20, 120, 30 and 130 may be sliding operating bodies. While the path of movement of each sliding operating body 20 and 120 in the above embodiments is substantially parallel to the plane of the ratchet teeth T, the path may vary, for example, by plus or minus thirty degrees.
Thus, the scope of the invention should not be limited by the specific structures disclosed. Instead, the true scope of the invention should be determined by the following claims. Of course, although labeling symbols are used in the claims in order to facilitate reference to the figures, the present invention is not intended to be limited to the constructions in the appended figures by such labeling. | A bicycle shifter operating device for operating a shifting mechanism via a transmission element includes a control body for mounting to a bicycle in close proximity to a handlebar for controlling a pulling and releasing of the transmission element. A first lever is mounted to the control body for movement which causes the control body to effect pulling of the transmission element, and a second lever is mounted to the control body for movement which causes the control body to effect releasing of the transmission element. One lever may be pivotally coupled to the control body, and the other lever may be coupled for linear movement relative to the control body. The lever structured for linear movement may be coupled to a transmission mechanism for operating the control body in such a way that very little linear movement is needed to operate the control body. The transmission mechanism may include a plurality of ratchet teeth disposed in a common plane, where the path of movement of the linear operating body is parallel to the plane of the ratchet teeth. With such a structure, the finger contacting part associated with the linearly moving lever may be placed in front of the handlebar (by curving the body of the lever, if necessary) so that the finger contacting part moves toward the handlebar in operation without striking the handlebar. As a result, both levers may be operated by the cyclist's thumb without movement of any other fingers or the palm from the handlebar. | 8 |
PRIORITY
This application claims the benefit under 35 U.S.C. § 119(a) of Korean patent application nos. 2005-29630 and 2006-6504, filed Apr. 8, 2005, and Jan. 20, 2006, respectively, in the Korean Intellectual Property Office, the entire contents of both of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an array antenna system. More particularly, the present invention relates to an apparatus and method for optimal beam-forming for transmitting and receiving high-speed data at high performance based on a regular spatial interpolation.
2. Description of the Related Art
Reception quality of radio signals is affected by many natural phenomena. One of the natural phenomena is temporal dispersion caused by signals reflected on obstacles in different positions in a propagation path before the signals arrive at a receiver. With the introduction of digital coding in a wireless system, a temporal dispersion signal can be successfully recovered using a Rake receiver or equalizer.
Another phenomenon called fast fading or Rayleigh fading is spatial dispersion caused by signals dispersed in a propagation path by an object located a short distance from a transmitter or a receiver. If signals received through different spaces, that is, spatial signals, are combined in an inappropriate phase region, the sum of the received signals is very low in intensity, approaching zero. This becomes a cause of fading dips where received signals substantially disappear, and the fading dip occurs as frequently as a length corresponding to a wavelength.
A known method of removing fading is to provide an antenna diversity system to a receiver. The antenna diversity system is provided with two or more spatially separated receive antennas. Signals received by the respective antennas have a low relation in fading, reducing the possibility that the two antennas will simultaneously generate the fading dips.
Another phenomenon is interference that is severe at the time of radio transmission. Interference is defined as an undesired component received through a desired signal channel. In a cellular radio system, interference is directly related to a requirement of communication capacity. Because resources of radio spectra are limited, a radio frequency band given to a cellular operator should be efficiently used.
Due to increasing use of cellular systems and their deployment over increasing numbers of geographic locations, research is being conducted on an array antenna geometry connected to a Beam-former (BF) as a new scheme for increasing traffic capacity by removing any influences of interference and fading. Each antenna forms a set of antenna beams. A signal transmitted from a transmitter is received in each of the antenna beams, and spatial signals experiencing different spatial channels are maintained by individual angular information. The angular information is determined according to a phase difference between different signals. Direction estimation of a signal source is achieved by demodulating a received signal. A direction of a signal source is indicated by a Direction of Arrival (DoA).
FIG. 1 illustrates an example of a Node B with an array antenna, which communicates with a plurality of User Equipment (UE) (or Mobile Stations (MSs)). Referring to FIG. 1 , a Node B 10 has an array antenna 20 provided with four antenna elements. Five Users A, B, C, D and E are located in a service area of the Node B 10 . A receiver 15 selects signals from desired users of the five users through beam-forming. Because the array antenna 20 of FIG. 1 has only the four antenna elements, the receiver 15 recovers signals from a maximum of four users, for example, signals from Users A, B, D and E as illustrated in FIG. 1 through beam-forming.
FIG. 2 illustrates, as an example, spatial characteristics of beam-forming for selecting a signal from User A. As illustrated in FIG. 2 , a very high weight, or gain, is applied to a signal from User A, while a gain close to zero is applied in directions from the other users.
Estimation of a DoA is used to select an antenna beam for signal transmission in a desired direction or to steer an antenna beam in a direction where a desired signal is received. A beam-former estimates steering vectors and DoAs for simultaneously detected multiple spatial signals, and determines beam-forming weight vectors from a set of the steering vectors. The beam-forming weight vectors are used for recovering signals. Algorithms used for beam-forming are Multiple Signal Classification (MUSIC), Estimation of Signal Parameters via Rotational Invariance Techniques (ESPRIT), Weighted Subspace Fitting (WSF), and Method of Direction Estimation (MODE).
An adaptive beam-forming process depends on exact information about spatial channels. Therefore, adaptive beam-forming can generally only be accomplished after estimation of the spatial channels. This estimation should consider not only temporal dispersion of channels, but also DoAs of radio waves received at a receive antenna.
In an antenna diversity system using an array antenna, resolvable beams are associated with arrival directions of maximum incident waves. In order to achieve beam-forming, a receiver should acquire information about a DoA, and the information about the DoA can be obtained through DoA estimation. However, estimated DoAs are not regularly spaced apart from each other. Therefore, in a digital receiver, conventional beam-forming includes irregular spatial samplings. The ultimate goal of beam-forming is to separate an incident wave so as to fully use spatial diversity in order to suppress fading. However, its latent faculty is limited by the geometry of an array antenna having a finite spatial resolution.
Because a single-path channel is considered in a typical multipath and multiuser scenario, multi-path channels cannot be used in actual communication environments. Spatial selective channel estimation based on irregular spatial sampling proposed to solve this problem requires considerably complex implementation. Thus, a method based on regular spatial sampling has been proposed. The regular spatial sampling technique simplifies an Angle of Arrival (AoA) estimation and beam-forming process on the basis of the regular spatial sampling using a set of antenna elements uniformly distributed over the same circumference of a circle. This method estimates an AoA as a primary angle of an antenna element with the maximum received energy value.
FIG. 3 illustrates a structure of a receiver 300 of a conventional array antenna system, and FIG. 4 is a flowchart illustrating operations of an interference and noise estimator 340 , a channel estimator 350 , and a beam-former 360 in the receiver 300 . Next, the respective components will be described in more detail.
Referring to FIG. 3 , an antenna 310 is an array antenna with antenna elements of a predetermined combination structure, and receives a plurality of spatial signals that are incident thereupon through spaces. In an example of FIG. 3 , incident plane waves are received in one direction at the antenna elements with different phases. Multipliers 320 multiply outputs of their associated antenna elements by antenna element-by-antenna-element weights set by the operation of the beam-former 360 , respectively. A data detector 330 performs frequency down-conversion, demodulation, and channel selection on the weighted outputs of the antenna elements, thereby generating a digital data signal.
In step 410 of FIG. 4 , the interference and noise estimator 340 estimates the interference power and the spectral noise density N 0 of the thermal noise power using the data signal provided from the data detector 330 . A covariance matrix indicative of the noise power is computed from a combined noise vector obtained by using the estimated interference power and the estimated spectral noise density. Because a received data signal is absent if a beam is first formed, the interference power is initialized to an arbitrary value and therefore the noise power is computed.
In step 420 , the channel estimator 350 computes a phase matrix A s , including a phase factor Φ associated with User k and Antenna Element k a using N b predetermined DoA values, computes directional channel impulse response vectors ĥ d using Equation (1), and computes combined channel impulse response vectors h by multiplying the directional channel impulse response vectors by the phase matrix.
ĥ d =( A s H ( I k a {circumflex over (x)}G H ) R n −1 ( I k a {circumflex over (x)}G H ) −1 A s H ( I k a {circumflex over (x)}G H ) R n −1 e Equation (1)
In Equation (1), the matrix G is a midamble known between a transmitter and a receiver and e is a combined received signal vector. I k a is a (k a *k a ) identity matrix and R n is a covariance matrix indicative of the total noise power between antenna elements.
In step 430 , the channel estimator 350 evaluates channel estimates with antenna element-by-antenna-element energies with respect to the directional channel impulse response vectors, and ranks energies ∥ ĥ d (k,n a ) ∥ 2 of the directional channel impulse responses estimated in directions n a for all K users in order of magnitude.
In step 440 , the channel estimator 350 selects one direction with the maximum impulse response energy for each user, maintains only the channel impulse response energy in the selected direction, sets energies of all other channel impulse responses to zero, and forms modified directional channel impulse response ĥ d,mod . The modified directional channel impulse responses are used to compute the final combined channel impulse vectors ĥ along with the phase matrix A s using the fixed DoA values.
In step 450 , the beam-former 360 computes steering vectors for adaptive beam-forming in all directions on the antenna element-by-antenna-element basis using the computed combined channel impulse response vectors ĥ . In step 460 , the beam-former 360 performs beam-forming using the combined channel impulse response vectors and the steering vectors in estimated DoA of incident waves.
The beam-forming method based on the above-described regular spatial sampling can simply implement a system because it is simpler than an adaptive beam-forming method. In terms of implementation, the beam-forming method based on the above-described regular spatial sampling can obtain a significant gain. However, it is difficult for this method to correctly estimate the location of a target UE because a given space is regularly divided and a direction/angle of a signal arrived in a region of the divided space is indicated by one DoA value. Accordingly, the performance of the beam-forming system is degraded. The performance can be improved by increasing the number of antenna elements to solve the problem. When this occurs, the complexity and cost of the system increase.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been designed to address the above and other problems occurring in the prior art. Therefore, exemplary embodiments of the present invention provide an apparatus and method that estimate spatial channels and form beams without considering DoAs of maximum incident waves requiring irregular spatial sampling in an antenna diversity system.
Moreover, exemplary embodiments of the present invention provide an apparatus and method that compute in advance a linear system model based on regular spatial sampling using a regular spatial separation at beam angles, thereby reducing the complexity of channel estimation.
In accordance with an aspect of exemplary embodiments of the present invention, there is provided a beam-forming apparatus for an antenna diversity system with an array antenna configured by a plurality of antenna elements. The beam-forming apparatus comprises an interference and noise calculator for estimating an interference power and a spectral noise density of a radio channel with a signal received via the radio channel from a user, and computing a total noise power of the radio channel according to the interference power and the spectral noise density. The beam-forming apparatus further comprises a channel estimator for estimating directional channel impulse responses at beam-forming angles mapped to a antenna elements using the total noise power, an AoA determiner for generating candidate angles of arrival that are more than the number of antenna elements, applying a spatial interpolation to energy values at the beam-forming angles according to the estimated directional channel impulse responses, evaluating the energy values at the beam-forming angles, and selecting a primary angle of arrival among the candidate angles of arrival according to the evaluated energy values. The beam-forming apparatus further comprises a beam-former for computing beam-forming weights based on differences between the angles of arrival and the selected primary angle of arrival, and applying the weights to a signal to be transmitted or received through the array antenna.
In accordance with another aspect of exemplary embodiments of the present invention, there is provided a beam-forming method for an antenna diversity system with an array antenna configured by a plurality of antenna elements. The beam-forming method comprises estimating an interference power and a spectral noise density of a radio channel with a signal received via the radio channel from a user, and computing a total noise power of the radio channel according to the interference power and the spectral noise density. The beam-forming method further comprises estimating directional channel impulse responses at beam-forming angles mapped to the plurality of antenna elements using the total noise power, setting candidate angles of arrival that are more than the number of antenna elements, applying a spatial interpolation to energy values at the beam-forming angles according to the estimated directional channel impulse responses, evaluating the energy values at the beam-forming angles, and selecting a primary angle of arrival among the candidate angles of arrival according to the evaluated energy values. The beam-forming method further comprises computing beam-forming weights based on differences between the beam-forming angles and the selected primary angle of arrival, applying the beam-forming weights to the plurality of antenna elements of the array antenna, and performing beam-forming.
In accordance with another aspect of exemplary embodiments of the present invention, there is provided a beam-forming apparatus for an antenna diversity system with an array antenna configured by a plurality of antenna elements. The beam-forming apparatus comprises an interference and noise calculator for estimating an interference power and a spectral noise density of a radio channel with a signal received via the radio channel from a user, and computing a total noise power of the radio channel according to the interference power and the spectral noise density. The beam-forming apparatus further comprises a channel estimator for estimating directional channel impulse responses at beam-forming angles mapped to the plurality of antenna elements using the total noise power, an AoA determiner for generating candidate angles of arrival that are more than the number of antenna elements, applying a spatial interpolation to energy values at the beam-forming angles according to the estimated directional channel impulse responses, evaluating the energy values at the beam-forming angles, and selecting primary and secondary angles of arrival closest to a direction in which the user is located among the candidate angles of arrival according to the evaluated energy values The beam-forming apparatus further comprises a beam-former for computing beam-forming weights based on the beam-forming angles and the selected primary and secondary angles of arrival, and applying the beam-forming weights to the plurality of antenna elements of the array antenna, such that beams are uniformly distributed between the primary and secondary angles of arrival.
In accordance with another aspect of exemplary embodiments of the present invention, there is provided a beam-forming method for an antenna diversity system with an array antenna configured by a plurality of antenna elements. The beam-forming method comprises estimating an interference power and a spectral noise density of a radio channel with a signal received via the radio channel from a user, and computing a total noise power of the radio channel according to the interference power and the spectral noise density. The beam-forming method further comprises estimating directional channel impulse responses at beam-forming angles mapped to the plurality of antenna elements using the total noise power, setting candidate angles of arrival that are more than the number of antenna elements, applying a spatial interpolation to energy values at the beam-forming angles according to the estimated directional channel impulse responses, evaluating the energy values at the beam-forming angles, and selecting primary and secondary angles of arrival closest to a direction in which the user is located among the candidate angles of arrival according to the evaluated energy values The beam-forming method further comprises computing beam-forming weights based on the beam-forming angles and the selected primary and secondary angles of arrival, applying the beam-forming weights to the plurality of antenna elements of the array antenna, and performing beam-forming, such that beams are uniformly distributed between the primary and secondary angles of arrival.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other exemplary features and aspects of the present invention will be more clearly understood from the following detailed description of certain exemplary embodiments taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates an example of a Node B with an array antenna that communicates with a plurality of User Equipment (UE);
FIG. 2 is a polar plot illustrating spatial characteristics of beam-forming for selecting a signal from one user;
FIG. 3 is a schematic block diagram illustrating a conventional transceiver;
FIG. 4 is a flowchart illustrating a conventional beam-forming procedure;
FIG. 5 is a schematic block diagram illustrating a beam-forming transceiver using a spatial interpolation in accordance with a first exemplary embodiment of the present invention;
FIG. 6 is a schematic flowchart illustrating a beam-forming procedure using the spatial interpolation in accordance with the first exemplary embodiment of the present invention;
FIGS. 7A and 7B are flowcharts illustrating an energy evaluation process in accordance with an exemplary embodiment of the present invention;
FIG. 8 is a schematic block diagram illustrating a beam-forming transceiver using the spatial interpolation and a secondary angle of arrival in accordance with a second exemplary embodiment of the present invention; and
FIG. 9 is a schematic flowchart illustrating a beam-forming procedure using the spatial interpolation and the secondary angle of arrival in accordance with the second exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The matters exemplified in this description are provided to assist in a comprehensive understanding of various exemplary embodiments of the present invention disclosed with reference to the accompanying figures. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the exemplary embodiments described herein can be made without departing from the scope and spirit of the claimed invention. Descriptions of well-known functions and constructions are omitted for clarity and conciseness.
The present invention as described below does not consider arrival directions/angles of maximum incident waves requiring irregular spatial sampling when beam-forming is performed by estimating spatial channels in an antenna diversity system. The irregular spatial sampling requires accurate time measurement and time-varying reconstruction filtering, and is more complex to implement than a regular sampling strategy. In accordance with exemplary embodiments of the present invention, a linear system model beginning at regular spatial sampling which exploits a regular spatial separation at a beam angle is computed in advance, thereby significantly reducing the complexity of channel estimation.
For spatial channel estimation, a receiving side requires the deployment of an array antenna with K a antenna elements. This array antenna serves as a spatial low-pass filter with a finite spatial resolution. Spatial low-pass filtering indicates an operation of dividing incident waves of an array antenna into spatial signals that pass through different spatial regions. A receiver with the above-described array antenna combines finite N b number of spatial signals through beam-forming. As described above, the best possible beam-forming requires information about predetermined Direction of Arrival (DoA) and temporal dispersion channel impulse responses associated with the DoAs. An N b value cannot exceed a K a value, and is the number of resolvable spatial signals. The maximum N b value, that is, max (N b ), is fixed according to array antenna geometry.
In an example as described below, system antenna deployment is based on a Uniform Circular Array (UCA). That is, it assumed that antenna elements are uniformly distributed over the circumference of a circle and the total number of antenna elements is an even number. Furthermore, it is assumed that the total number of antenna elements at a Node B is K a . A signal transmitted from User k is incident upon the array antenna in N b different directions. Each direction is denoted by n b . A beam-forming angle for a spatial signal n b of User k is defined as shown in Equation (2).
β
(
k
,
n
b
)
=
2
π
N
b
(
n
b
-
1
)
k
=
1
…
K
,
n
b
=
1
…
N
b
Equation
(
2
)
In Equation (2), K represents the number of users and N b is the number of beams, which is assumed to be identical with the number of antenna elements.
First Exemplary Embodiment
FIG. 5 is a schematic block diagram illustrating a beam-forming transceiver using a spatial interpolation in accordance with a first exemplary embodiment of the present invention.
Referring to FIG. 5 , a signal received through an array antenna 510 , which can comprise incident plane waves received at the antenna elements with different phases, is demodulated to a data signal through a data detector 530 . The data signal is input to an interference and noise estimator 540 . The interference and noise estimator 540 estimates the interference power and the spectral noise density N 0 of the thermal noise power using the data signal provided from the data detector 530 . An output of the interference and noise estimator 540 is input to a channel estimator 550 . The channel estimator 550 computes channel impulse response information. At this time, channel impulse responses are computed on the basis of antenna elements and users for performing communication through the array antenna 510 . As a result, an output of the channel estimator 550 is an estimation matrix of the channel impulse responses.
The channel impulse responses estimated by the channel estimator 550 are input to an Angle of Arrival (AoA) determiner 560 for determining a primary AoA using a spatial interpolation and a Signal-to-Noise Ratio (SNR). Herein, the primary AoA indicates a direction in which a received signal is predicted to be present. Functions of the AoA determiner 560 are as follows:
1. Evaluate an energy value in every path of arrival;
2. Generate candidate angles of arrival that are more than the number of antenna elements;
3. Evaluate energy per candidate AoA using the spatial interpolation;
4. Evaluate energy at each candidate AoA using the spatial interpolation and a Directional Channel Impulse Response (DCIR); and
5. Determine a primary AoA.
The functions will be described in more detail with reference to FIG. 6 . When the primary AoA is determined, the AoA determiner 560 inputs the primary AoA to a beam-former 570 . Then, the beam-former 570 sets proper weights (W) on an antenna element-by-antenna-element basis according to the primary AoA and provides the weights to multipliers 520 , such that antenna elements form beams in a direction mapped to the primary AoA.
FIG. 6 is a schematic flowchart illustrating a beam-forming procedure using the spatial interpolation in accordance with the first exemplary embodiment of the present invention. An operation will be described step-by-step.
Referring to FIG. 6 , the channel estimator 550 estimates directional channel impulse responses h d between users and antenna elements of a Node B in step 600 . h d is a matrix with elements of ĥ d (k,n a ) according to User k and Antenna Element n b . Subscript d denotes the directivity and a hat ^ denotes an estimated value. The magnitude of the directional channel impulse response matrix depends on the number of beams, that is, the number of antenna elements and the number of users. The estimated directional channel impulse responses are transferred to step 610 for evaluating energy values at angles of arrival.
In accordance with an exemplary embodiment of the present invention, the AoA determiner 560 can perform step 610 to evaluate the energy values at the angles of arrival according to a procedure as illustrated in FIG. 7A or 7 B. The same results can be obtained when the procedures of FIGS. 7A and 7B evaluate the energy values in step 610 of FIG. 6 . Both the procedures of FIGS. 7A and 7B do not need to be performed.
First, the operation for evaluating the energy values in accordance with the first exemplary embodiment as illustrated in FIG. 7A is as follows. In step 700 , the energy values are estimated with the estimated directional channel impulse responses. An energy value between User k and Antenna Element n b is estimated according to the directional channel impulse responses as shown in Equation (3).
Ê d (k,n b ) =∥ ĥ d (k,n b ) Equation (3)
After the energy values are estimated in step 700 , candidate angles of arrival are generated in step 710 . Specifically, step 710 generates N c candidate angles of arrival that are more than the number of beams, N b , identical with the number of antenna elements. When a v-th candidate AoA is denoted by β v , it is expressed as shown in Equation (4).
β
v
=
2
π
N
c
(
v
-
1
)
v
=
1
…
N
c
N
c
>
N
b
Equation
(
4
)
A set of the generated candidate angles of arrival is used for energy evaluation at each candidate AoA in step 720 . In step 720 , an energy value at each candidate AoA is computed using a spatial interpolation. Step 720 comprises the following.
The AoA determiner 560 computes Equation (5) with the energy values computed in step 710 and the candidate AoAs generated in step 720 .
E
d
(
k
)
(
β
v
)
=
∑
n
b
=
1
N
b
E
^
d
(
k
,
n
b
)
t
pSLP
(
β
(
k
,
n
b
)
-
β
v
)
,
k
=
1
…
K
,
v
=
1
…
N
c
Equation
(
5
)
In Equation (5), E d (k) (β v ) is an energy value of User k evaluated at a candidate AoA β v , and β (k,n b ) is a beam-forming angle for a spatial signal n b of User k as shown in Equation (2). t pSLP of Equation (5) is a spatial interpolation coefficient for applying the spatial interpolation based on periodic spatial low pass filtering (pSLP), and is defined as shown in Equation (6).
t
pSLP
(
β
)
=
1
N
b
[
1
+
cos
{
N
b
β
/
2
}
+
2
∑
v
=
1
(
N
b
/
2
)
-
1
cos
{
v
β
}
]
Equation
(
6
)
In Equation (6), the spatial interpolation coefficient has a constant value at an antenna element's angle (β=β (k,n b ) ) among candidate AoAs according to regular spatial sampling, but has a median value between known interpolation coefficients at adjacent DoAs, as to coefficients at other angles. When the antenna elements have a UCA corresponding to a middle form between sector and adaptive-type arrays, angles of the deployed antenna elements are angles of direction (DoAs) according to the regular spatial sampling. As a result, a median value between energy values at the known adjacent DoAs is taken in relation to an angle at which an antenna element is not deployed. This is based on gradual variations rather than sudden variations in spatial characteristics according to angular variations. In other words, the spatial interpolation technique computes a median energy value according to angular variations.
When the energy values estimated in step 700 are denoted in the form of a vector, it is expressed as shown in Equation (7).
{circumflex over (ε)} d (k) =[Ê d (k,1) Ê d (k,2) . . . Ê d (k,n b ) . . . Ê d (k,N b ) ] T , k=1 . . . K Equation (7)
Spatial interpolation coefficients used in step 720 are expressed as a spatial interpolation matrix T pSLP (k) as shown in Equation (8).
T
pSLP
(
k
)
=
[
t
pSLP
(
β
(
k
,
1
)
-
β
1
)
t
pSLP
(
β
(
k
,
1
)
-
β
2
)
⋯
t
pSLP
(
β
(
k
,
1
)
-
β
N
c
)
t
pSLP
(
β
(
k
,
2
)
-
β
1
)
t
pSLP
(
β
(
k
,
2
)
-
β
2
)
t
pSLP
(
β
(
k
,
2
)
-
β
N
c
)
⋮
⋮
⋰
⋮
t
pSLP
(
β
(
k
,
N
b
)
-
β
1
)
t
pSLP
(
β
(
k
,
N
b
)
-
β
2
)
⋯
t
pSLP
(
β
(
k
,
N
b
)
-
β
N
c
)
]
,
k
=
1
…
K
Equation
(
8
)
A matrix of energy values at candidate angles of arrival computed by Equations (7) and (8) in step 720 is given as shown in Equation (9).
ε d,int. (k)T ={circumflex over (ε)} d (k)T T pSLP (k) =[E d (k) (β 1 c ) E d (k) (β 2 c ) . . . E d (k) (β N c )] T , k= 1 . . . K Equation (9)
As a result, the AoA determiner 560 obtains energy values at the candidate angles of arrival in step 720 .
The energy values computed at the candidate angles of arrival obtained according to the procedure of FIG. 7A are used to determine a primary AoA in step 620 . The AoA determiner 560 determines the primary AoA on the basis of the energy values computed at the candidate angles of arrival in step 620 . A basic determination criterion is to select one AoA with the maximum energy value among the energy values at the candidate angles of arrival. Step 620 is defined as shown in Equation (10).
β
(
k
)
=
arg
max
v
=
1
N
c
{
E
d
(
k
)
(
β
v
)
}
,
k
=
1
…
K
Equation
(
10
)
Equation (10) is used in a process for selecting a candidate AoA with the maximum energy value for each user as a primary AoA β (k) of User k.
In step 630 , the beam-former 570 sets pre-weights for beam-forming based on primary angles of arrival selected on a user-by-user basis in step 620 . Herein, the pre-weights are obtained by applying the spatial interpolation to general weights.
For a better understanding of a beam-forming operation, the conventional beam-forming method will be briefly described as follows.
A beam-forming direction in the regular spatial sampling scheme is fixed and is expressed as shown in Equation (11).
β
(
k
,
n
b
)
=
2
π
N
b
(
n
b
-
1
)
k
=
1
…
K
,
n
b
=
1
…
N
b
Equation
(
11
)
Equation (11) is equal to Equation (2) as described above. A phase of a spatial signal with an AoA of Equation (11) is expressed as shown in Equation (12).
ψ
(
k
,
k
a
,
n
b
)
=
2
π
l
(
k
a
)
λ
·
cos
(
β
(
k
,
n
b
)
-
α
(
k
a
)
)
k
=
1
…
K
,
k
a
=
1
…
K
a
,
n
b
=
1
…
N
b
Equation
(
12
)
In Equation (12), k(=1 . . . K) is a user index, k a (=1 . . . K a ) is an antenna element index, and n b (=1 . . . N b ) is a spatial signal index. An angle α is associated with the physical deployment of antenna elements. That is, α (k a ) is an angle between a virtual straight line and a reference line passing through a predetermined antenna array reference point, and is a value known in a receiver according to the array antenna geometry. The virtual straight line is connected between the predetermined antenna array reference point and antenna elements deployed at a predetermined distance from each other. An angle β (k,n b ) is an AoA of a radian unit indicating a direction of an n b -th spatial signal incoming from User k on the basis of the reference line. λ is a wavelength at a subcarrier frequency and l (k a ) is a distance between a k a -th antenna element and the antenna array reference point.
A steering vector according to the phase is expressed as shown in Equation (13).
b s (k,n b ) =( e jψ (k,1,n b ) . . . e jψ (k,k a, n b ) ) T , k= 1 . . . K, n b =1 . . . N b Equation (13)
Equation (14) is a matrix of steering vectors for all users and all antenna elements.
B
_
s
(
k
)
=
(
ⅇ
jψ
(
k
,
1
,
1
)
ⅇ
jψ
(
k
,
1
,
2
)
⋯
ⅇ
jψ
(
k
,
1
,
n
b
)
⋯
ⅇ
jψ
(
k
,
1
,
N
b
)
ⅇ
jψ
(
k
,
2
,
1
)
ⅇ
jψ
(
k
,
2
,
2
)
⋯
ⅇ
jψ
(
k
,
2
,
n
b
)
⋯
ⅇ
jψ
(
k
,
2
,
N
b
)
⋮
⋮
⋮
⋮
⋮
⋮
ⅇ
jψ
(
k
,
k
a
,
1
)
ⅇ
jψ
(
k
,
k
a
,
2
)
⋯
ⅇ
jψ
(
k
,
k
a
,
n
b
)
⋯
ⅇ
jψ
(
k
,
k
a
,
N
b
)
⋮
⋮
⋮
⋮
⋮
⋮
ⅇ
jψ
(
k
,
K
a
,
1
)
ⅇ
jψ
(
k
,
K
a
,
2
)
⋯
ⅇ
jψ
(
k
,
K
a
,
n
b
)
⋯
ⅇ
jψ
(
k
,
K
a
,
n
b
)
)
Equation
(
14
)
In the regular spatial sampling scheme, an optimal beam-forming weight matrix for the DoAs is expressed as shown in Equation (15).
W opt (k) =[ R DOA *+N 0 I K a ] −1 B s (k) *=[ w opt (k,1) w opt (k,2) . . . w opt (k,n b ) . . . w opt (k,N b ) ], k= 1 . . . K Equation (15)
In Equation (15), a matrix R DOA is a (K a *K a ) interference power matrix.
When the proposed spatial interpolation in accordance with an exemplary embodiment of the present invention is applied which is different from the conventional regular spatial sampling scheme, a beam-forming direction is mapped to one of the candidate angles of arrivals β v rather than one of the fixed N b DoAs. In this case, a beam-forming weight must also be changed and the spatial interpolation is applied in the beam-forming step.
When the spatial interpolation is applied, a beam-forming weight for beam-forming of User k is computed in advance, and is given as shown in Equation (16).
w pSLP (k,n b ) (β (k) )= t pSLP (β (k,n b ) −β (k) ), k= 1 . . . K, n b =1 . N b Equation (16)
A beam-forming weight applied to Equation (16) is computed using Equation (17). Equation (17) is equal to Equation (6) as described above.
t
p
SLP
(
β
)
=
1
N
b
[
1
+
cos
{
N
b
β
/
2
}
+
2
∑
v
=
1
(
N
b
/
2
)
-
1
cos
{
v
β
}
]
Equation
(
17
)
When Equation (16) is expressed in a matrix for all directions, Equation (18) is given.
w pSLP (k) (β (k) )=[ w pSLP (k,1) w pSLP (k,2) . . . w pSLP (k,n b ) ] T , k= 1 . . . K Equation (18)
After the pre-weights are set according to the spatial interpolation in step 630 , step 640 is performed to form beams for transmission and reception from the Node B. A description of Step 640 is as follows.
When Equations (18) and (15) are combined, a signal for User k output from the Node B is expressed as shown in Equation (19).
y
_
n
(
k
)
=
W
_
opt
(
k
)
w
_
pSLP
(
k
)
(
β
(
k
)
)
d
_
n
(
k
)
=
[
R
_
DOA
*
+
N
0
I
K
a
]
-
1
B
_
s
(
k
)
*
w
pSLP
(
k
)
(
β
(
k
)
)
d
_
n
(
k
)
Equation
(
19
)
In Equation (19), d n (k) is an n-th symbol to be transmitted to User k.
Next, a second exemplary embodiment for evaluating the energy values in step 610 will be described with reference to FIG. 7B . In accordance with the exemplary embodiment as illustrated in FIG. 7B , the DCIRs obtained in step 600 are used.
In step 730 , the AoA determiner 560 generates a plurality of candidate angles of arrival as described with reference to step 710 . The generated candidate angles of arrival are transferred to step 740 for evaluating energy values.
In step 740 , channel impulse responses H d,int. (k) spatially interpolated at the candidate angles of arrival are computed with the directional channel impulse response matrix h d as shown in Equations (20) and (21).
H d,int. (k) = Ĥ d (k) T pSLP (k) , k=1 . . . K Equation (20)
Ĥ d (k) =└ Ĥ d (k,1) Ĥ d (k,2) . . . Ĥ d (k,N b ) ┘, k=1 . . . K Equation (21)
The spatial interpolation matrix T pSLP (k) is computed by Equations (6) and (8) as described above.
When Equation (20) is expressed by a matrix, Equations (22) and (23) are given.
H d,int. (k) =[ h d,int. (k,1) h d,int. (k,2) . . . h d,int. (k,N x )], k= 1 . . . K h d,int. (k,v) =[[ h d,int. (k,v) ] 1 [ h d,int. (k,v) ] 2 . . . [ h d,int. (k,v) ] W ] T , k=1 . . . K, v=1 . . . N c Equation (22)
h d,int. (k,v) = ĥ d (k,n b ) t pSLP (β (k,n b ) −β v ), k= 1 . . . K,v= 1 . . . . N c Equation (23)
The channel impulse responses computed in the procedure of FIG. 7B are used to determine the primary AoA in step 620 . In accordance with this exemplary embodiment, the primary AoA is determined as shown in Equation (24).
β
(
k
)
=
arg
max
v
=
1
N
c
{
h
_
d
,
int
.
(
k
,
v
)
2
}
,
k
=
1
…
K
Equation
(
24
)
That is, the primary angles of arrival are determined as candidate angles of arrival at which energy values of the spatially interpolated channel impulse responses are maximal.
The process for selecting the candidate angles of arrival with the maximum energy values as the primary angles of arrival on a user-by-user basis has been described with reference to step 620 . In accordance with another exemplary embodiment of the present invention, a Carrier-to-Interference Ratio (CIR) can be used to determine the primary angles of arrival. A CIR at each candidate AoA is expressed as shown in Equation (25).
(
C
I
)
d
(
k
)
(
β
v
)
=
E
d
(
k
)
(
β
v
)
∑
k
i
=
1
K
i
E
d
(
k
i
)
(
β
v
)
,
k
=
1
…
K
,
v
=
1
…
N
c
Equation
(
25
)
When the CIR is used, the primary AoA is selected as shown in Equation (26).
β
(
k
)
=
arg
max
v
=
1
N
c
{
(
C
I
)
d
(
k
)
(
β
v
)
}
,
k
=
1
…
K
Equation
(
26
)
In the other exemplary embodiment of the present invention, the candidate AoA at which the CIR is maximal is selected as the primary AoA.
Similarly, the beam-former 570 computes beam-forming weights (W) based on the spatial interpolation at the angles of arrival computed in the other exemplary embodiment and provides the beam-forming weights (W) to the multipliers 520 .
Second Exemplary Embodiment
A second exemplary embodiment as described below determines two angles of arrival closest to the direction in which a user is located, that is, a primary AoA and a secondary AoA, using energy values evaluated at candidate angles of arrival, and computes beam-forming weights (W) at the primary AoA and the secondary AoA.
FIG. 8 is a schematic block diagram illustrating a beam-forming transceiver using the spatial interpolation and the secondary AoA in accordance with the second exemplary embodiment of the present invention.
Referring to FIG. 8 , a signal received through an array antenna 810 , which can comprise incident plane waves received at the antenna elements with different phases, is demodulated to a data signal through a data detector 830 . The data signal is input to an interference and noise estimator 840 . The interference and noise estimator 840 estimates the interference power and the spectral noise density N 0 of the thermal noise power using the provided data signal. An output of the interference and noise estimator 840 is input to a channel estimator 850 . The channel estimator 850 computes channel impulse response information. The channel impulse responses are computed on the basis of antenna elements and users for performing communication through the array antenna 810 . As a result, an output of the channel estimator 850 is an estimation matrix of the channel impulse responses.
The channel impulse responses estimated in the channel estimator 850 are input to an enhancer 860 for determining primary and secondary angles of arrival using a spatial interpolation and an SNR. Functions of the enhancer 860 are as follows:
1. Evaluate an energy value in every path of arrival;
2. Generate candidate angles of arrival that are more than the number of antenna elements;
3. Evaluate energy per candidate AoA using the spatial interpolation;
4. Evaluate energy at each candidate AoA using the spatial interpolation and a DCIR; and
5. Determine a primary AoA and a secondary AoA.
The functions will be described in more detail with reference to FIG. 9 . When the primary and secondary angles of arrival are determined, the enhancer 860 inputs the primary and secondary angles of arrival to a beam-former 870 . Then, the beam-former 870 sets proper weights (W) on an antenna element-by-antenna-element basis according to the primary and secondary angles of arrival and provides the weights (W) to multipliers 820 , such that antenna elements form beams in associated directions.
FIG. 9 is a schematic flowchart illustrating a beam-forming procedure using the spatial interpolation in accordance with the second exemplary embodiment of the present invention. An operation will be described step by step.
Referring to FIG. 9 , the channel estimator 850 estimates directional channel impulse responses h d between users and antenna elements of a Node B in step 900 . h d is a matrix with elements of ĥ (k,n a ) according to User k and Antenna Element n b . Subscript d denotes the directivity and a hat ^ denotes an estimated value. The magnitude of the directional channel impulse response matrix depends on the number of beams, that is, the number of antenna elements and the number of users. The estimated directional channel impulse responses are transferred to step 910 of evaluating energy values at angles of arrival.
In accordance with an exemplary embodiment of the present invention, the enhancer 860 can perform step 910 to evaluate the energy values at the angles of arrival according to a procedure as illustrated in FIG. 7A or 7 B. The same results can be obtained when the procedures of FIGS. 7A and 7B evaluate the energy values in step 910 of FIG. 9 . Both the procedures of FIGS. 7A and 7B do not need to be performed.
First, the operation for evaluating the energy values in accordance with the first exemplary embodiment as illustrated in FIG. 7A is as follows. In step 700 , the energy values are estimated with the estimated directional channel impulse responses. An energy value between User k and Antenna Element n b is estimated according to the directional channel impulse responses as shown in Equation (27).
Ê d (k,n b ) =∥ ĥ d (k,n b ) ∥ 2 Equation (27)
After the energy values are estimated in step 700 , candidate angles of arrival are generated in step 710 . Specifically, step 710 generates N c candidate angles of arrival that are more than the number of beams, N b , identical with the number of antenna elements. When a v-th candidate AoA is denoted by β v , it is expressed as shown in Equation (28).
β
v
=
2
π
N
c
(
v
-
1
)
v
=
1
…
N
c
N
c
>
N
b
Equation
(
28
)
A set of the generated candidate angles of arrival is used for energy evaluation at each candidate AoA in step 720 . In step 720 , an energy value at each candidate AoA is computed using a spatial interpolation. Step 720 is as follows.
That is, the enhancer 860 computes Equation (29) with the energy values computed in step 910 and the candidate angles of arrival generated in step 920 .
E
d
(
k
)
(
β
v
)
=
∑
n
b
=
1
N
b
E
^
d
(
k
,
n
b
)
t
pSLP
(
β
(
k
,
n
b
)
-
β
v
)
k
=
1
…
K
,
v
=
1
…
N
c
Equation
(
29
)
In Equation (29), E d (k) (β v ) is an energy value of User k evaluated at the candidate AoA β v , and β (k,n b ) is a beam-forming angle for a spatial signal n b of User k as shown in Equation (2). t pSLP of Equation (29) is a spatial interpolation coefficient for applying a spatial interpolation based on pSLP, and is defined as shown in Equation (30).
t
pSLP
(
β
)
=
1
N
b
[
1
+
cos
{
N
b
β
/
2
}
+
2
∑
v
=
1
(
N
b
/
2
)
-
1
cos
{
v
β
}
]
Equation
(
30
)
In Equation (30), the spatial interpolation coefficient has a constant value of 2/N b at an antenna element's angle (β=β (k,n b ) among candidate angles of arrival according to regular spatial sampling, but has a median value between known interpolation coefficients at adjacent DoAs, as to coefficients at other angles. As a result, a median value between energy values at the known adjacent DoAs is taken in relation to an angle at which an antenna element is not deployed. This is based on gradual variations rather than sudden variations in spatial characteristics according to angular variations. In other words, the spatial interpolation technique computes a median energy value according to angular variations.
When the energy values estimated in step 700 are denoted in the form of a vector, it is expressed as shown in Equation (31).
ε d (k) =[Ê d (k,1) Ê d (k,2) . . . Ê d (k,n b ) . . . Ê d (k,N b ) ] T , k=1 . . . K Equation (31)
Spatial interpolation coefficients used in step 720 are expressed as a spatial interpolation matrix T pSLP (k) as shown in Equation (32).
T
pSLP
(
k
)
=
[
t
pSLP
(
β
(
k
,
1
)
-
β
1
)
t
pSLP
(
β
(
k
,
1
)
-
β
2
)
⋯
t
pSLP
(
β
(
k
,
1
)
-
β
N
c
)
t
pSLP
(
β
(
k
,
2
)
-
β
1
)
t
pSLP
(
β
(
k
,
2
)
-
β
2
)
t
pSLP
(
β
(
k
,
2
)
-
β
N
c
)
⋮
⋮
⋰
⋮
t
pSLP
(
β
(
k
,
N
b
)
-
β
1
)
t
pSLP
(
β
(
k
,
N
b
)
-
β
2
)
⋯
t
pSLP
(
β
(
k
,
N
b
)
-
β
N
c
)
]
,
k
=
1
…
K
Equation
(
32
)
A matrix of energy values at candidate angles of arrival computed by Equations (31) and (32) in step 720 is given as shown in Equation (33).
ε d,int. (k)T ={circumflex over (ε)} d (k)T T pSLP (k) =[E d (k) (β 1 c ) E d (k) (β 2 c ) . . . E d (k) (β v ) . . . E d (k) (β N c )] T , k= 1 . . . K Equation (33)
As a result, the enhancer 860 obtains energy values at the candidate angles of arrival in step 720 .
The energy values computed at the candidate angles of arrival obtained according to the procedure of FIG. 7A are used to determine primary and secondary angles of arrival in step 920 . The enhancer 860 determines the primary and secondary angles of arrival on the basis of the energy values computed at the candidate angles of arrival in step 920 . A basic determination criterion is to select one AoA with the maximum energy value and the other AoA with the next maximum energy value by comparing the energy values at the candidate angles of arrival. Step 920 is defined as shown in Equations (34) and (35).
β
′
(
k
)
=
arg
max
v
=
1
N
c
{
E
d
(
k
)
(
β
v
)
}
,
k
=
1
…
K
Equation
(
34
)
β
′′
(
k
)
=
arg
max
v
=
1
,
v
≠
v
′
N
c
{
E
d
(
k
)
(
β
v
)
}
,
k
=
1
…
K
Equation
(
35
)
Equation (34) is used in a process for selecting a candidate AoA with the maximum energy value for each user as a primary AoA β ′(k) of User k. For convenience, an index of a candidate AoA determined as the primary AoA is denoted by v′.
In Equation (35), the secondary AoA β ″(k) is selected as a v″-th candidate AoA with the maximum energy value among the remaining candidate angles of arrival except the v′-th candidate AoA, that is, the primary AoA.
That is, in step 920 , the candidate angles of arrival are arranged in descending order of the energy values, and the candidate AoA with the maximum energy value and the candidate AoA with the next maximum energy value are selected as the primary AoA and the secondary AoA, respectively.
When the primary and secondary angles of arrival are determined in step 920 , the beam-former 870 sets beam-forming directions while considering a uniform distribution of the remaining beams in step 930 . The distribution process of the remaining beams uniformly distributes the remaining N b −2 beams, except the two beams allocated at the primary and secondary angles of arrival, between the primary AoA β ′(k) and the secondary AoA β ″(k) . An example of typical beam-forming is the same as described above. In results of the above-described process, new beam-forming directions and new beam-forming weights are determined by Equation (36).
β ′(k,n b ) , n b =1 . . . N b , k= 1 . . . K w pSLP (k,n b ) (β ′(k,n b ) ) =t pSLP (β ′(k,n ) ), k= 1 . . . K, n b =1 . . . N b Equation (36)
The new beam-forming directions are set as N b values with a uniform interval between the primary AoA and the secondary AoA. A spatial interpolation coefficient t pSLP applied to Equation (36) is defined as shown in Equation (17) as described above.
In step 940 , the beam-former 870 sets pre-weights for beam-forming on the basis of two angles of arrival selected for each user basis.
When the spatial interpolation proposed in the present invention is applied which is different from the conventional regular spatial sampling scheme as shown in Equations (11) to (15), a beam-forming direction is present between two angles selected from the candidate angles of arrival β v rather than the fixed N b DoAs. A new beam-forming direction is defined by Equation (36). In this case, a beam-forming weight is also changed as shown in Equation (36) and the spatial interpolation is applied in the beam-forming step.
After the pre-weights are set according to the spatial interpolation in step 940 , step 950 is performed to form beams for transmission and reception from the Node B. That is, a signal to be transmitted from the Node B to User k is defined as shown in Equation (19).
Next, a second exemplary embodiment for evaluating the energy values will be described with reference to FIG. 7B . In accordance with the exemplary embodiment as illustrated in FIG. 7B , the DCIRs obtained in step 900 are used.
In step 730 , the enhancer 860 generates a plurality of candidate angles of arrival as described with reference to step 710 . The generated candidate angles of arrival are transferred to step 740 of evaluating the energy values.
In step 740 , channel impulse responses H d,int. (k) spatially interpolated at the candidate angles of arrival are computed with the directional channel impulse response matrix hd as shown in Equations (20) and (21).
The spatially interpolated channel impulse responses computed in the procedure of FIG. 7B are used to determine the primary AoA and the secondary AoA in step 920 . In accordance with another exemplary embodiment of the present invention, the primary AoA is determined as shown in Equation (37).
β
′
(
k
)
=
arg
max
v
=
1
N
c
{
h
_
d
,
int
.
(
k
,
v
)
2
}
Equation
(
37
)
For convenience, an index of the primary AoA is denoted by v′. The secondary AoA is determined as shown in Equation (38).
β
″
(
k
)
=
arg
max
v
=
1
,
v
≠
v
′
N
c
{
h
_
d
,
int
.
(
k
,
v
)
2
}
Equation
(
38
)
In Equation (38), the secondary AoA β ″(k) is selected as a v″-th candidate AoA with the maximum channel impulse response energy value among the remaining candidate angles of arrival except the v′-th candidate AoA, in other words, the primary AoA. That is, in step 920 , the candidate angles of arrival are arranged in descending order of the channel impulse response energy values, and the candidate AoA with the maximum energy value and the candidate AoA with the next maximum energy value are selected as the primary AoA and the secondary AoA, respectively.
When the primary and secondary angles of arrival are determined, beam-forming is performed at the angles of arrival as described above.
As is apparent from the above description, exemplary embodiments of the present invention have the following effects.
Exemplary implementations of the present invention apply a spatial interpolation to a regular spatial sampling scheme capable of simplifying a structure of a beam-forming system, thereby improving system performance without an additional antenna element. Moreover, exemplary implementations of the present invention improve performance with a small increase in computation amount.
While the present invention has been particularly shown and described with reference to certain exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims and equivalents thereof. | A beam-forming apparatus and method for improving system performance using a spatial interpolation and at least one Angle of Arrival (AoA) in a system based on regular spatial sampling is provided. The AoA is estimated using a carrier-to-interference ratio. Beam-forming angles are distributed and steered in a predefined scheme such that an identical process is applied in all directions. According to this steering, a linear system model is computed based on regular spatial sampling using regular spatial separation at beam angles. Beam-forming performance is improved by compensating for a difference between adaptive and sector-type arrays. Only the steps of computing a spatial interpolation and determining an angle range for beam-forming using at least one AoA are added. The precision of estimating an AoA and the precision of beam-forming increase without an additional antenna. Because the system is simpler than that of an adaptive beam-forming system, significant gain is obtained. | 7 |
This application is a US National Stage of International Application No. PCT/CN2013/072632, filed on 14 Mar. 2013, designating the United States, and claiming priority from Chinese Patent Application No. 201210121152.8, filed with the Chinese Patent Office on Apr. 11, 2012 and entitled “Air interface security method and device”, which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to the field of network security among information security technologies, and particularly to an air interface security method and device.
BACKGROUND OF THE INVENTION
The ISO/IEC 14443 standard includes four parts, i.e., physical characteristics, radio frequency interface energy and signal interfaces, initialization and anti-collision, and transmission protocols, and also includes two patterns, i.e., Type A and Type B. This standard solves the technical problems in the communication field of passive (no power supply in a card) and non-contact, and has the feature of more rapid and convenient communication. At present the ISO/IEC 14443 Type A has been widely applied to mobile payment, channel control, charging in public transportation, checking work attendance, access control, etc., and the Type B has been primarily applied to the second generation of resident identity cards in P. R. China, both of which have very broad application prospects.
The ISO/IEC 14443 standard relates to communication via an air interface without any physical or visual contact, and this feature enables it to be widely applied but at the same time causes it to face a variety of security threats. For example, an attacker may listen to or illegally intercept information exchanged between a proximity card and a proximity coupling device; falsify the legal proximity card by duplicating or counterfeiting it; read remotely confidential information in the proximity card through the proximity coupling device at high radio-frequency power and then decipher the information in the proximity card by using a backend server for the purpose of obtaining illegally the information, etc., and various attacks have been emerging all the time. Due to the absence of a security protection mechanism for the air interface in the ISO/IEC 14443 standard, increasing applications of various products using this standard have come with a growing number of insecurity accidents of various applicable cards, including counterfeiting, information wiretapping, tampering, etc., thus endangering personal property and also causing social turbulence to thereby degrade public security.
SUMMARY OF THE INVENTION
In order to solve the numerous technical problems in the prior art, an embodiment of the invention provides an air interface security method including the following steps in the transmission protocol process:
1) a proximity coupling device transmitting a security parameter request message to a proximity card;
2) the proximity card feeding back security parameters to the proximity coupling device after receiving the security parameter request message; and
3) the proximity coupling device and the proximity card setting up a secure link between them according to the security parameters.
An embodiment of the invention further provides a proximity coupling device implementing the method described above, where the proximity coupling device is capable of performing the transmission protocol process and includes:
a transmission unit configured to transmit a security parameter request message to a proximity card; a reception unit configured to receive security parameters fed back from the proximity card; and a link setup unit configured to set up a secure link with the proximity card according to the security parameters.
An embodiment of the invention further provides a proximity card implementing the method described above, where the proximity card is capable of performing the transmission protocol process and includes:
a reception unit configured to receive a security parameter request message transmitted by a proximity coupling device; a transmission unit configured to feed back security parameters to the proximity coupling device; and a link setup unit configured to set up a secure link with the proximity coupling device according to the security parameters.
Through the introduction of the security mechanisms, the invention provides the security protection capability of the air interface to thereby provide the proximity coupling device and the proximity card with the identity authentication function so as to ensure the legality and authenticity of identities of both sides in communication without bring any additional hardware overhead of the proximity coupling device and the proximity card.
BRIEF DESCRIPTION OF THE DRAWINGS
No drawings.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In order to make the objects, technical solutions and advantages of the invention more apparent, the invention will be further described below in details with reference to particular embodiments and drawings. The exemplary embodiments of the invention and the description thereof herein are used to explain the invention but not intended to limit the invention.
With an air interface security method of the invention, security mechanisms of security parameter negotiation, identity authentication, confidential communication, etc., are introduced to the transmission protocol to thereby enhance the security protection capability of the air interface of the transmission protocol. The implementation process of the air interface security method of the invention includes:
Step 1, a proximity coupling device transmits a security parameter request message, for example, including message codes, to a proximity card;
Step 2, the proximity card feeds back security parameters to the proximity coupling device after receiving the security parameter request message; and
Step 3, the proximity coupling device and the proximity card set up a secure link between them according to the security parameters.
A particular embodiment of the step 1 described above can be as follows:
When the proximity coupling device and the proximity card perform the ISO/IEC 14443 transmission protocol process, the proximity coupling device transmits a Request for Answer To Select (RATS) including the security parameter request message to the proximity card to initiate the security parameter negotiation with the proximity card.
A particular embodiment of the step 2 described above can be as follows:
When the proximity coupling device and the proximity card perform the ISO/IEC 14443 transmission protocol process, the proximity card returns an Answer To Select (ATS) to the proximity coupling device after receiving the RATS of the proximity coupling device, where the ATS includes information on a support condition of the proximity card for an authentication mechanism, a cipher algorithm and other security parameters. The authentication mechanism includes but will not be limited to an authentication mechanism based on a pre-shared key or an authentication mechanism based on a certificate, and the cipher algorithm includes but will not be limited to a symmetric cipher algorithm or an asymmetric cipher algorithm.
A particular embodiment of the step 3 described above can be as follows:
After the proximity coupling device negotiates about the security parameters with the proximity card (that is, the security parameters are requested and fed back in the steps 1 and 2), both of them perform identity authentication in accordance with the authentication mechanism among the security parameters as a result of the negotiation, e.g., the authentication based on the pre-shared key or the authentication based on digital certificate. The secure link between the proximity coupling device and the proximity card is thus set up upon successful identity authentication.
In another implementation, the step 3 can further include:
The proximity coupling device can negotiate with the proximity card in the identity authentication to generate a session key so that the proximity coupling device and the proximity card can encrypt and transmit data by the session key for confidential communication. Alternatively the session key can be generated in another way such as a pre-distribution way, that is, the session key is distributed in advance to the proximity coupling device and the proximity card prior to the confidential communication.
Before the step 1, the method can further include step 0, in which the proximity card notifies the proximity coupling device of its security capability, particularly as follows:
Step 0, the proximity card notifies the proximity coupling device that the proximity card has the air interface security protection capability in communication initialization and anti-collision processes.
A particular embodiment of the step 0 is as follows:
Step 01, the proximity coupling device transmits a select command to the proximity card in ISO/IEC 14443 protocol initialization and anti-collision processes; and
Step 02, the proximity card returns a response including information indicating that it supports the air interface security protection capability after receiving the select command transmitted by the proximity coupling device.
A particular embodiment of the step 02 described above can be as follows:
In the ISO/IEC 14443 protocol initialization and anti-collision processes, the proximity card transmits a Select AcKnowledge (SAK) to the proximity coupling device after receiving the select command transmitted by the proximity coupling device, where the SAK includes the information indicating that the proximity card supports the air interface security protection capability, and the information can be carried by newly adding a value to the original values of the SAK to notify the proximity coupling device selecting the proximity card that the proximity card has the air interface security protection capability.
Particular embodiments of the step 1 and the step 2 described above can be as follows:
In a first example, in the step 1 described above, when the proximity coupling device and the proximity card perform the ISO/IEC 14443 transmission protocol process, the proximity coupling device transmits the RATS including the security parameter request message to the proximity card, where the message includes all of authentication mechanisms supported by the proximity coupling device and all of cipher algorithms supported by the proximity coupling device; and in the step 2 described above, after receiving the RATS, the proximity card firstly selects a combination of one of all the authentication mechanisms supported by the proximity coupling device and one of all the cipher algorithms supported by the proximity coupling device according to a local strategy, and then returns the ATS including the combination of the authentication mechanism and the cipher algorithm to the proximity coupling device.
In a second example, in the step 1 described above, when the proximity coupling device and the proximity card perform the ISO/IEC 14443 transmission protocol process, the proximity coupling device transmits the RATS including the security parameter request message to the proximity card; and in the step 2 described above, the proximity card returns the ATS to the proximity coupling device after receiving the RATS, where the ATS includes all of authentication mechanisms supported by the proximity card and all of cipher algorithms supported by the proximity card, so that the proximity coupling device can select a combination of one of all the authentication mechanisms supported by the proximity card and one of all the cipher algorithms supported by the proximity card as the security parameters as a result of negotiation with the proximity card according to its local strategy.
In a third example, in the step 1 described above, when the proximity coupling device and the proximity card perform the ISO/IEC 14443 transmission protocol process, the proximity coupling device transmits the RATS including the security parameter request message to the proximity card; and in the step 2 described above, after receiving the RATS, the proximity card selects a combination of one of all of its supported authentication mechanisms and one of all of its supported cipher algorithms as the security parameters as a result of negotiation with the proximity coupling device, and returns the ATS including the selected combination to the proximity coupling device.
In a fourth example, in the step 1 described above, when the proximity coupling device and the proximity card perform the ISO/IEC 14443 transmission protocol process, the proximity coupling device transmits the RATS including the security parameter request message to the proximity card, where the message includes a combination of one of all of authentication mechanisms and one of all of cipher algorithms supported by the proximity coupling device, both of which are selected by the proximity coupling device; and in the step 2 described above, after receiving the RATS, the proximity card judges whether it supports the combination of the authentication mechanism and the cipher algorithm in the RATS according to the local strategy and returns the judgment result to the proximity coupling device via the ATS.
The invention further provides a proximity coupling device for implementing the air interface security method described above. The proximity coupling device includes a first transmission unit, a first reception unit and a first link setup unit.
The first transmission unit of the proximity coupling device is configured to transmit a security parameter request message to a proximity card, the first reception unit is configured to receive security parameters fed back from the proximity card, and the first link setup unit is configured to set up a secure link with the proximity card according to the security parameters.
A particular embodiment of the proximity coupling device can be as follows:
In the transmission protocol process of the ISO/IEC 14443 protocol performed by the proximity coupling device, the first transmission unit of the proximity coupling device transmits an RATS including the security parameter request message to the proximity card to initiate the security parameter negotiation with the proximity card; the first reception unit receives an ATS transmitted by the proximity card, where the ATS includes information on a support condition of the proximity card for an authentication mechanism, a cipher algorithm and other security parameters; and the first link setup unit performs identity authentication on the proximity card in accordance with the authentication mechanism among the negotiated security parameters after negotiating with the proximity card about the security parameters. The secure link between the proximity coupling device and the proximity card is thus set up upon successful identity authentication.
In another embodiment, the first link setup unit of the proximity coupling device can further negotiate with the proximity card in the identity authentication to generate a session key so that the proximity coupling device and the proximity card can encrypt and transmit data by the session key for confidential communication. Alternatively the session key can be generated in another way such as a pre-distribution way, that is, the session key is distributed in advance to the first link setup unit of the proximity coupling device and the proximity card prior to the confidential communication.
Furthermore, in another embodiment, the proximity coupling device can further receive the security capability of which the proximity card notifies the proximity coupling device, that is, the proximity coupling device receives the information indicating that the proximity card has the air interface security protection capability, of which the proximity card notifies the proximity coupling device, in communication initialization and anti-collision processes. In a preferred embodiment, during the ISO/IEC 14443 protocol initialization and anti-collision processes, the first transmission unit of the proximity coupling device transmits a select command to the proximity card; and the first reception unit receives information indicating that the proximity card supports the air interface security protection capability, of which the proximity card notifies the proximity coupling device, where the information can be included in the SAK transmitted by the proximity card and can be carried by newly adding a value to the original values of the SAK.
Particular embodiments of the first transmission unit and the first reception unit of the proximity coupling device can be as follows:
In a first example, the first transmission unit transmits the RATS including the security parameter request message to the proximity card, where the message includes all of authentication mechanisms supported by the proximity coupling device and all of cipher algorithms supported by the proximity coupling device; and the first reception unit receives the ATS transmitted by the proximity card, where the ATS includes a combination of one of all the authentication mechanisms supported by the proximity coupling device and one of all the cipher algorithms supported by the proximity coupling device, both of which are selected by the proximity card according to its local strategy.
In a second example, the first transmission unit transmits the RATS including the security parameter request message to the proximity card; and the first reception unit receives the ATS transmitted by the proximity card, where the ATS includes all of authentication mechanisms supported by the proximity card and all of cipher algorithms supported by the proximity card, so that the first link setup unit of the proximity coupling device can select a combination of one of all the authentication mechanisms supported by the proximity card and one of all the cipher algorithms supported by the proximity card as the security parameters as a result of negotiation with the proximity card according to the local strategy of the proximity card.
In a third example, the first transmission unit transmits the RATS including the security parameter request message to the proximity card; and the first reception unit receives the ATS transmitted by the proximity card, where the ATS includes a combination of one of all of authentication mechanisms and one of all of cipher algorithms supported by the proximity card, both of which are selected by the proximity card, as the security parameters as a result of the negotiation of the proximity coupling device with the proximity card.
In a fourth example, the first transmission unit transmits the RATS including the security parameter request message to the proximity card, where the message includes a combination of one of all of authentication mechanisms and one of all of cipher algorithms supported by the proximity coupling device, both of which are selected by the first link setup unit; and the first reception unit receives the ATS transmitted by the proximity card, where the ATS includes a result of judging by the proximity card whether it supports the combination of the authentication mechanism and the cipher algorithm in the RATS according to its local strategy.
The invention further provides a proximity card for implementing the air interface security method described above. The proximity card includes a second reception unit, a second transmission unit and a second link setup unit.
The second reception unit of the proximity card is configured to receive a security parameter request message transmitted by a proximity coupling device, the second transmission unit is configured to feed back security parameters to the proximity coupling device, and the second link setup unit is configured to set up a secure link with the proximity coupling device according to the security parameters.
A particular embodiment of the proximity card can be as follows:
In the transmission protocol process of the ISO/IEC 14443 protocol performed by the proximity card, the second reception unit of the proximity card receives an RATS including the security parameter request message transmitted by the proximity coupling device to initiate the security parameter negotiation with the proximity card; the second transmission unit transmits an ATS to the proximity coupling device, where the ATS includes information on a support condition of the proximity card for an authentication mechanism, a cipher algorithm and other security parameters; and the second link setup unit performs identity authentication in accordance with the authentication mechanism among the negotiated security parameters after negotiating with the proximity coupling device about the security parameters. The secure link between the proximity coupling device and the proximity card is thus set up upon successful identity authentication.
In another embodiment, the second link setup unit of the proximity card can further negotiate with the proximity coupling device in the identity authentication to generate a session key so that the proximity card and the proximity coupling device can encrypt and transmit data by the session key for confidential communication. Alternatively the session key can be generated in another way such as a pre-distribution way, that is, the session key is distributed in advance to the second link setup unit of the proximity card and the proximity coupling device prior to the confidential communication.
Furthermore, in another embodiment, the proximity card can further notify the proximity coupling device of its security capability, that is, the proximity card notifies the proximity coupling device that it has the air interface security protection capability in communication initialization and anti-collision processes. In a preferred embodiment, in the ISO/IEC 14443 protocol initialization and anti-collision processes, the second reception unit of the proximity card receives a select command transmitted by the proximity coupling device; and the second transmission unit returns information indicating that the proximity card supports the air interface security protection capability to the proximity coupling device, where the information can be carried by newly adding a value to the original values of the SAK and transmitted to the proximity coupling device via the SAK to notify the proximity coupling device that the proximity card has the air interface security protection capability.
Particular embodiments of the second transmission unit and the second reception unit of the proximity card can be as follows:
In a first example, the second reception unit receives the RATS including the security parameter request message transmitted by the proximity coupling device, where the message includes all of authentication mechanisms supported by the proximity coupling device and all of cipher algorithms supported by the proximity coupling device; and the second transmission unit returns the ATS to the proximity coupling device, where the ATS includes a combination of one of all the authentication mechanisms supported by the proximity coupling device and one of all the cipher algorithms supported by the proximity coupling device, both of which are selected by the second link setup unit according to the local strategy of the proximity card.
In a second example, the second reception unit receives the RATS including the security parameter request message transmitted by the proximity coupling device; and the second transmission unit returns the ATS to the proximity coupling device, where the ATS includes all of authentication mechanisms supported by the proximity card and all of cipher algorithms supported by the proximity card, so that the proximity coupling device can select a combination of one of all the authentication mechanisms supported by the proximity card and one of all the cipher algorithms supported by the proximity card as the security parameters as a result of the negotiation with the proximity card according to its local policy.
In a third example, the second reception unit receives the RATS including the security parameter request message transmitted by the proximity coupling device; and the second transmission unit returns the ATS to the proximity coupling device, where the ATS includes a combination of one of all of authentication mechanisms supported by the proximity card and one of all of cipher algorithms supported by the proximity card, both of which are selected by the second link setup unit as the security parameters as a result of the negotiation with the proximity coupling device.
In a fourth example, the second reception unit receives the RATS including the security parameter request message transmitted by the proximity coupling device, where the message includes a combination of one of all of authentication mechanisms and one of all of cipher algorithms supported by the proximity coupling device, both of which are selected by the proximity coupling device; and the second transmission unit returns the ATS to the proximity coupling device, where the ATS includes a result of judging by the second link setup unit whether it supports the combination of the authentication mechanism and the cipher algorithm in the RATS according to the local strategy of the proximity card.
Through the introduction of security capability notification, security parameter negotiation, identity authentication, confidential communication and other security mechanisms, the invention can enhance the security protection capability of the ISO/IEC 14443 air interface, and provide the proximity coupling device and the proximity card with the identity authentication function so as to ensure the legality and authenticity of the identities of both sides in communication, and can further provide the proximity coupling device and the proximity card with the confidential communication function as needed to thereby prevent communication data from being stolen, tampered or the like. Also the invention can well solve the problem of compatibility so that the air interface security ISO/IEC 14443 protocol can be fully compatible with the original ISO/IEC 14443 protocol, and the secure communication can be performed in the method of the invention only if both the proximity coupling device and the proximity card support the ISO/IEC 14443 protocol enhancing the security protection capability of the air interface. In another situation where only the proximity coupling device supports the ISO/IEC 14443 protocol with the security protection capability of the air interface, or only the proximity card supports the ISO/IEC 14443 protocol with the security protection capability of the air interface or the like, the proximity coupling device and the proximity card still use the original ISO/IEC 14443 protocol for communication. Moreover the ISO/IEC 14443 protocol enhancing the security protection capability of the air interface improves the system security without bring any additional hardware overhead of the proximity coupling device and the proximity card.
The objects, technical solutions and advantageous effects of the invention have been further described in details in the particular embodiments described above. It should be appreciated that the foregoing disclosure is merely the particular embodiments of the invention but not intended to limit the scope of the invention, and any modifications, equivalent substitutions, adaptations, etc., made without departing from the sprit and the principle of the invention shall come into the scope of the invention. | Provided is an air interface security method. In the process of protocol transmission, the method executes: 1) a short-range coupling device sending a security parameter request message to a short-range card; 2) after receiving the security parameter request message, the short-range card conduct security parameter feedback on the short-range coupling device; and 3) the short-range coupling device and the short-range card establish a security link according to a security parameter. Provided are a short-range coupling device, a short-range card, etc. for achieving the method. By introducing a security mechanism, the present invention provides a security protection capability for an air interface, can provide identity authentication for a short-range coupling device and a short-range card to ensure the validity and authenticity of the identities of both sides in the communications, and at the same time, will not bring additional hardware overhead to the short-range coupling device and the short-range card. | 7 |
This application is a Divisional of application Ser. No. 08/386,187 filed Feb. 9, 1995, now abandoned; which itself is a Continuation of Ser. No. 07/987,160 filed Dec. 8, 1992 now abandoned, which is a Division of Ser. No. 07/885,643 filed May 19, 1992 now abandoned, which is a Division of Ser. No. 07/707,178 filed May 24, 1991 (now U.S. Pat. No. 5,142,344), which is a Continuation of Ser. No. 07/520,756 filed May 9, 1990 now abandoned, which is a Division of Ser. No. 07/153,477 filed Feb. 3, 1988 (now U.S. Pat. No. 4,959,700); which is a Continuation of Ser. No. 06/735,697 filed May 20, 1985 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an insulated gate field effect transistor (herein after refer to as an insulated gate FET or an FET) and its manufacturing method.
2. Description of the Prior Art
Heretofore there has been proposed an insulated gate FET of the type that it has a high resistivity semiconductor layer formed on a substrate having an insulating surface, a gate electrode formed on the semiconductor layer with a gate insulating layer sandwiched therebetween in a manner to divide the semiconductor into two as viewed from above, and N or P conductivity type source and drain regions formed in the semiconductor layer in a manner to leave a channel forming region between first and second regions on both sides of the gate electrode as viewed from above, the source and drain regions being lower in resistivity than the channel region.
The insulated gate FET of such a construction is called an N-channel type or P-channel type insulated gate FET depending upon whether the source and drain regions are the N or P conductivity type, and it operates in such a manner as follows:
When supplied with a control voltage across the source region and the gate electrode with a DC power source connected across the source and drain regions via a load, the insulated gate FET remains in the OFF state if the control voltage is lower than a certain threshold voltage when the FET is the N-channel type, or if the control voltage is higher than the threshold voltage when the FET is the P-channel type. In this case, substantially no current flow (drain current) is caused in the drain region, supplying no current to the load. In the case where the control voltage is higher than the threshold voltage when the FET is the N-channel type, or where the control voltage is lower than the threshold voltage when the FET is the P-channel type, however, a channel region of the same conductivity type as that of the source and drain regions is formed in the channel forming region to extend between the source and drain regions on the side of the gate insulating layer, and the FET is turned ON to cause the drain current to flow, feeding current to the load.
As a modification of the above insulated gate FET has been proposed such a structure that the entire region of the semiconductor layer is formed of a single-crystal semiconductor, and accordingly, the channel forming region, the first and second regions and the source and drain regions formed therein, respectively, are all formed of the single-crystal semiconductor.
With such an insulated gate FET, however, the semiconductor layer cannot be formed on the substrate unless the substrate is made of an insulating or semi-insulating single-crystal semiconductor.
When the semiconductor layer is formed of the single-crystal semiconductor layer, especially when the channel forming region is former of the single-crystal semiconductor, it has a smaller optical energy gap than does it when formed of a non-single-crystal semiconductor. For example, when the semiconductor layer is made of the single-crystal silicon, the optical energy gap of the channel forming region is 1.1 eV. On account of this, when the FET is in the OFF state, the train current is small but larger than in the case where the channel forming region is formed of the non-single-crystal semiconductor.
For this reason, the abovesaid insulated gate FET is poorer in the OFF characteristic than in the case where the channel forming region is made of the non-single-crystal semiconductor.
Another modified form of the above insulated gate FET heretofore proposed has such a structure that the entire region of the semiconductor layer is formed of a non-single-crystal semiconductor doped with a recombination center neutralizer.
In the case of such an insulated gate FET, even if the substrate is not made of the insulating or semi-insulating single-crystal semiconductor, and even if the substrate is a metallic substrate which has an insulated surface, or such as a glass, ceramic, organic synthetic resin or like insulating material substrate, the semiconductor layer can be formed on the substrate. Further, since the channel forming region is made of the non-single-crystal semiconductor doped with a recombination center neutralizer, it has a larger optical energy gap than in the case where it is formed of the single-crystal semiconductor, so long as it is sufficiently doped with the recombination center neutralizer. For instance, when the semiconductor layer is formed of non-single-crystal silicon well doped with the recombination center neutralizer, the channel forming region has an optical energy gap in the range of 1.7 to 1.8 eV. In consequence, when the insulated gate FET is in the OFF state, the drain current will be markedly small, negligible as compared with that when the channel forming region is formed of the single-crystal semiconductor. Accordingly, so long as the semiconductor layer is sufficiently doped with the recombination center neutralizer, the FET will exhibit a more excellent OFF characteristic than does it when the channel forming region is made of the single-crystal semiconductor.
In the case of such an insulate gate FET having the semiconductor layer formed of the non-single-crystal semiconductor, impurity-doped regions are formed in the first and second regions, for example, by ion implantation of an N- or P-type impurity, and then the source and drain regions are formed by heat treatment for the activation of the impurity doped in the impurity-doped regions. During the heat treatment, however, the recombination center neutralizer doped in the channel forming region is diffused therefrom to the outside by the heat. Therefore, the channel forming region contains no required and sufficient amount of recombination center neutralizer, and hence has a smaller optical energy gap than the predetermined.
Accordingly, the conventional insulated gate FET with the semiconductor layer formed of the non-single-crystal semiconductor possesses an excellent OFF characteristic as compared with the case where the channel forming region is made of the single-crystal semiconductor, but the OFF characteristic is not fully satisfactory.
Moreover, in the case of the above prior art insulated gate FET of the type having the semiconductor layer formed of the non-single-crystal semiconductor, since the source and drain regions are also obtained by heat treatment, the recombination center neutralizer doped therein is diffused to the outside during the heat treatment. Thus, since the source and drain regions have the same optical energy gap as that of the channel forming region, there is set up between each of the source and drain regions and the channel forming region substantially no or very small potential barrier against carriers flowing from the source or drain regions toward the channel forming region.
This is another cause of the unsatisfactory OFF characteristic of the conventional insulated gate FET which has the semiconductor layer formed of the non-single-crystal semiconductor.
Besides, when the semiconductor layer, and accordingly the source and drain regions are formed of the non-single-crystal semiconductor, they has the same degree of crystallization as that of the channel forming region and a far higher resistance than in the case where they are made of the single-crystal semiconductor. On account of this, in the conventional insulated gate FET of the type having the semiconductor layer formed of the non-single-crystal semiconductor, the speed of switching between the ON and the OFF state is lower than in the case where the source and drain regions are formed of the single-crystal semiconductor. Accordingly, this FET has the defect that its ON-OFF operation cannot be achieved at high speed.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a novel insulated gate FET which is free from the abovesaid defects of the prior art.
Another object of the present invention is to provide a novel method for the manufacture of such a novel insulated gate FET.
The insulated gate FET of the present invention has also the same structure as the above-described conventional insulated gate FET. That is, it has a high resistivity semiconductor layer formed on a substrate having an insulating surface, a gate electrode formed on the semiconductor layer with a gate insulating layer sandwiched therebetween so that it separates the semiconductor layer into two as viewed from above, and N or P conductivity type source and drain regions formed in the semiconductor layer so that they define a channel forming region between first and second regions on both sides of the gate electrode as viewed from above and extend vertically from the upper surface of the first and second regions toward the substrate, the source and drain regions having a lower resistivity than that of the channel forming region.
In the insulated gate FET of the present invention, however, the semiconductor layer is formed of a non-single-crystal semiconductor doped with a required and sufficient amount of recombination center neutralizer, and accordingly, the channel forming region is also formed of such a non-single-crystal semiconductor. In the first and second regions which constitute the source and drain regions in the semiconductor layer, there are provided on the sides of the source and drain regions, respectively, crystallized regions which have a higher degree of crystallization than the channel forming region and are doped with the recombination center neutralizer.
The insulated gate FET of the present invention is identical in construction with the aforesaid conventional insulated gage FET which has the semiconductor layer formed of the non-single-crystal semiconductor, except the inclusion of the abovesaid crystallized regions in the semiconductor layer.
Accordingly, the insulated gate FET of the present invention also operates in the same manner as the aforementioned conventional FET. That is, when supplied with a control voltage across the source region and the gate electrode with the power source connected across the source and drain regions via a load, it remains in the OFF state and causes no current flow to the load if the control voltage is lower (or higher) than a certain threshold voltage, and if the control voltage is higher (or lower) than the threshold voltage, it is turned ON to cause drain current to flow, supplying current to the load.
The insulated gate FET of the present invention has also the semiconductor layer formed of the non-single-crystal semiconductor, and hence it is free from the requirement that the substrate be an insulating or semi-insulating single-crystal semiconductor, as is the case with the conventional FET of this kind.
Further, since the semiconductor layer, and consequently the channel forming region is constituted of the non-single-crystal semiconductor doped with the recombination center neutralizer, the insulated gate FET of the present invention exhibits an excellent OFF characteristic over the FET in which the channel forming region is made of the single-crystal semiconductor.
In the insulated gate FET of the present invention, however, the channel forming region is doped with a required and sufficient amount of recombination center neutralizer, as will be evident from the manufacturing method of the present invention described later. Accordingly, the channel forming region has a predetermined optical energy gap, ensuring to provide an excellent OFF characteristic as compared with that of the conventional FET which has the semiconductor layer formed of the non-single-crystal semiconductor.
Moreover, in the insulated gate FET of the present invention, the crystallized regions, which have a higher degree of crystallization than the channel forming region and are doped with the recombination center neutralizer, are formed in the first and second regions which constitute the source and drain regions, respectively, and the crystallized regions form the effective regions of the source and drain regions. On the other hand, the crystallized regions have a smaller optical energy gap than does the channel forming region. Accordingly, there is established between each of the source and drain regions and the channel forming region a potential barrier against carriers which flow from the source or drain region toward the channel forming region.
This ensures that the FET of the present invention exhibits an excellent OFF characteristic over the conventional PET which has the semiconductor layer formed of the non-single-crystal semiconductor.
Besides, in the insulated gate FET of the present invention, the crystallized regions, which constitute the effective regions of the source and drain regions, are formed in the first and second regions, as mentioned above, and the crystallized regions are far lower in resistance than in the case where the first and second regions are not crystallized. On account of this, the speed at which the FET of the present invention is switched between the ON and OFF state is higher than in the case of the prior art FET which has the semiconductor layer formed of the non-single-crystal semiconductor. In other word, the ON-OFF operation of the FET of the present invention is higher in speed than the ON-OFF operation of the conventional FET.
The insulated gate FET manufacturing method of the present invention includes the following steps.
The manufacture starts with the formation of a non-single-crystal semiconductor layer doped with the recombination center neutralizer on a substrate having an insulating surface.
Next, a gate electrode is formed on the non-single-crystal semiconductor layer with a gate insulating layer sandwiched therebetween in such a manner that the non-single-crystal semiconductor layer is separated into two as viewed from above.
Next, source and drain regions doped with N- or P-type impurity and the recombination center neutralizer are formed in first and second regions of the non-single-crystal semiconductor layer on both sides of the gate electrode, as viewed from above, in such a manner to leave therebetween a channel forming region doped with the recombination center neutralizer.
Next, the first and second regions of the non-single-crystal semiconductor layer are exposed to irradiation by light for annealing at a temperature at which the recombination center neutralizer doped in the non-single-crystal semiconductor layer does not substantially diffuse to the outside. By this, the first and second regions of the non-single-crystal semiconductor layer are crystallized to form crystallized regions on the sides of the source and drain regions. And the N-type or P-type impurity in the source and drain regions is activated. The crystallized regions have a higher degree of crystallization than the channel forming region, are doped with the recombination center neutralizer and extend vertically from the upper surface of the first and second regions toward the substrate. In this instance, it is preferable that the gate insulating layer be formed on the semiconductor layer to cover the entire area of the surface of each of first and second regions before the exposure to the light irradiation for annealing so as to prevent that the recombination center neutralizer diffuse to the outside from the source and drain regions and the crystallized regions. Further, it is preferable that the light irradiation for annealing be performed intermittently so as to prevent that the high-temperature heating of the crystallized regions by the light irradiation will cause unnecessary diffusion from the source and drain regions and the crystallized regions of the recombination center neutralizer to the outside.
With such a manufacturing method of the present invention, it is possible to easily fabricate the insulated gate FET of the present invention which possesses the aforesaid advantages.
Other objects, features and advantages of the present invention will become more fully apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2 , 3 and 4 are sectional views schematically illustrating embodiments of the insulated gate FET of the present invention; and
FIGS. 5A to 5 G are sectional views schematically illustrating a sequence of steps involved in the manufacture of the insulated gate FET of FIG. 1 according to the manufacturing method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1, 2 , 3 and 4 illustrate first, second, third and fourth embodiments of the present invention, respectively, in which an island-shaped N − -, P − - or I-type non-single-crystal semiconductor layer 2 is formed, for example, 0.7 μm on, for example, a 1.1 mm thick insulating substrate 1 as of quartz glass. The non-single-crystal semiconductor layer 2 is constituted of, for instance, amorphous, microcrystalline or polycrystalline silicon. The non-single-crystal semiconductor layer 2 is doped with a hydrogen or a halogen such as fluorine, as a recombination center neutralizer in an amount of 1 atom% or more. The non-single-crystal semiconductor layer 2 is deposited over the entire area of its surface with, for example, 1000 Å thick gate insulating film 3 as of silicon nitride. A stripe-shaped gate electrode 5 G, which is formed of, for example, microcrystalline or polycrystalline silicon heavily doped with an N-type impurity such as phosphorus or arsenic, is formed, for instance, 0.3 μm thick on the gate insulating film 3 in such a manner that the gate insulating film 5 G separates the non-single-crystal semiconductor layer 2 into two, as viewed from above. In the non-single-crystal semiconductor layer 2 source and drain regions 5 S and 5 D, which are doped with an N-type impurity such as phosphorus or arsenic, are formed in regions on both sides of the gate electrode 5 G in such a manner to define therebetween a channel region 5 C.
In this instance, the marginal edges of the source and drain regions 5 S and 5 D on the side of the channel region 5 C laterally extend to positions right under the opposite marginal edges of the gate electrode 5 G, as shown in FIGS. 1 and 2, or to the vicinities of the abovesaid positions, as shown in FIGS. 3 and 4. Further, the source and drain regions 5 S and 5 D vertically extend past the non-single-crystal semiconductor layer 2 down to the insulating substrate 1 , as shown in FIGS. 1 and 3. Alternatively, the source and drain regions 5 S and 5 D vertically extend past the non-single-crystal semiconductor layer 2 but not down to the substrate 1 , as shown in FIGS. 2 and 4.
The two regions of the non-single-crystal semiconductor layer 2 on both sides of the gate electrode 5 G, as viewed from above, have formed therein crystallized regions 6 S and 6 D which define therebetween a non-crystallized region 6 C.
In this case, when the semiconductor layer 2 is constituted of an amorphous semiconductor, the crystallized regions 6 S and 6 D are formed of a microcrystalline or polycrystalline semiconductor, or a mixture thereof, a mixture of the microcrystalline and/or polycrystalline semiconductor and the amorphous semiconductor, or a single-crystal semiconductor. When the semiconductor layer 2 is constituted of the microcrystalline or polycrystalline semiconductor, the regions 6 S and 6 D are formed of the microcrystalline, polycrystalline or single-crystal semiconductor which has a higher degree of crystallization than does the starting microcrystalline or polycrystalline semiconductor.
The crystallized regions 6 S and 6 D vertically extend past the semiconductor layer 2 down to the insulating substrate 1 , for example, as shown in FIGS. 2 and 4. Alternatively, the regions 6 S and 6 D vertically extend past the semiconductor layer 2 but not down to the insulating substrate 1 , as depicted in FIGS. 1 and 3. The marginal edges of the regions 6 S and 6 D on the side of the non-single-crystallized region 6 C laterally extend across the source and drain regions 5 S and 5 D under the gate electrode 5 G, as shown in FIGS. 1 and 2. Alternatively, the abovesaid marginal edges of the regions 6 S and 6 D laterally extend but not across the source and drain regions 5 S and 5 D, as illustrated in FIGS. 3 and 4. The insulating substrate 1 has formed thereon an insulating film 7 which covers the semiconductor layer 2 , the gate insulating film 3 and the gate electrode 5 G.
The insulating film 7 is covered with interconnection layers 9 S and 9 D which make ohmic contact with the source and drain regions 6 S and 6 D through holes 8 S and 8 D made in the insulating film 7 . Further, on the insulating film 7 is formed an interconnection layer 8 G (not shown) which make ohmic contact with the gate electrode 5 G.
With such an insulated gate FET of the present invention as described above, when it is supplied with a control (gate) voltage across the source and gate regions 5 S and 5 G via the interconnection layers 8 S and 8 G in a state in which a DC power source (not shown) in connected across the source and drain regions 5 S and 5 G via a load (not shown), if the control voltage is higher than a certain threshold voltage which is negative relative to the side of the gate electrode 5 G, or zero or positive, then an N-type channel which extends between the source and drain regions 5 S and 5 D is formed in the channel region 6 C on the side of the gate insulating film 3 and a drain current is caused to flow across the drain region 5 D, supplying current to the load. The insulated gate FET in which the drain current flows when the gate voltage is higher than a certain negative threshold voltage is commonly referred to as a depletion type, and in this case, the drain current flows even if the gate voltage is zero. The insulated gate FET which causes the drain current flow when the gate voltage is higher than a certain positive threshold voltage is commonly referred to as an enhancement type.
When the gate voltage is lower than the abovesaid gate voltage, the FET remains in the OFF state and causes substantially no drain current to flow.
The channel forming region 5 C or non-crystallized region 6 C is doped with the recombination center neutralizer in a required and sufficient amount, and the source and drain regions 5 S and 5 D and the crystallized regions 6 S and 6 D are also doped with the recombination center neutralizer.
The crystallized regions 6 S and 6 D constitute the effective regions of the source and drain regions 5 S and 5 D. The regions 6 S and 6 D are lower in resistance than the non-crystallized region 6 C. Accordingly, such an excellent OFF characteristic as referred to previously in the “Summary” can be obtained, though not described in detail, and this permits a high-speed ON-OFF operation.
FIGS. 5A though SG illustrate the manufacturing method of the insulated gate FET of the present invention described previously in conjunction with FIG. 1 . In FIG. 5, the like parts corresponding to those in FIG. 1 are identified by the same reference numerals and no detailed description thereof will be repeated.
The manufacture starts with the preparation of the same substrate 1 as mentioned previously with respect to FIG. 1 (FIG. SA).
In the next step, a non-single-crystal semiconductor layer 2 ′ which contain the recombination center neutralizer in an amount of 1 atoms or more and which will ultimately form the non-single-crystal semiconductor layer 2 and an insulating layer 3 ′ which will ultimately form the gate insulating layer 3 , are formed in that order over the entire area of the surface of the substrate 1 by means of, for example, a light plasma CVD process holding the substrate 1 at 250° C., for instance (FIG. 5 B). In the formation of the semiconductor layer 2 ′, care should be taken so that oxygen, nitrogen or carbon, which will shorten the carrier lifetime in the ultimate layer 2 , is not contained therein in a large amount exceeding 5×10 18 atom/cm 3 in order to obtain a large drain current during the ON state of the ultimate FET and to prevent the introduction of a hysterisis characteristic in the gate voltage-drain current characteristic of the FET.
Next, the laminate member composed of the non-single-crystal semiconductor layer 2 ′ and the insulating layer 3 ′ is subjected to an etching process which employs a plasma obtainable at room temperature by exciting, for example, a gas mixture of CF 4 and oxygen at a high frequency of, for instance, 13.56 MHz. By this, the non-single-crystal semiconductor layer 2 and the insulating layer 3 , described previously with respect to FIG. 1 are formed (FIG. 5 C).
Next, a conductive layer 5 G′, which will ultimately form the gate electrode 5 G mentioned previously with respect to FIG. 1, is formed on the substrate 1 to cover the semiconductor layer 2 and the insulating layer 3 . Then a mask layer 15 G as of photo resist is formed in a pattern of the gate electrode 5 G on the conductive layer 5 G′ (FIG. 5 D).
After this, the conductive layer 5 G′ is selectively etched away through the mask layer 15 G, forming the abovesaid gate electrode 5 G (FIG. 5 E).
This is followed by the implantation of an N-type impurity ion, for example, a phosphorus ion, into the non-single-crystal semiconductor layer 2 using the laminate member composed of the gate electrode 5 G and the mask layer 15 G. By this, regions 5 S′ and 5 D′, which will form the activated source and drain regions 5 S and 5 D by the next step, are formed to leave therebetween the channel forming region 5 C described previously in connection with FIG. 1 (FIG. 5 F). In this case, the substrate 1 is held below 400° C. so that the recombination center neutralizer doped in the semiconductor layer 2 are not diffused to the outside thereof.
Next, the mask layer 15 G is removed from the gate electrode 5 G, after which the regions 5 S′ and 5 D′ are scanned all over them, together with the gate electrode 5 G, for example, at a rate of 5 to 50 cm/minute, by light 17 for annealing which is obtainable with, for instance, an ultra-high mercury lamp and which has a wavelength of 250 to 600 nm, a beam diameter of 15 mm and an output of 5 KW. By this, the crystallized regions 6 S and 6 D mentioned previously in conjunction with FIG. 1 are formed, and at the same time, the regions 5 S′ and 5 D′ are activated, providing the ultimate source and drain regions 5 S and 5 D (FIG. 5 G). The crystallized regions 6 S and 6 D thus obtained have a sheet resistance as low as 1×10 2 (Ωcm) −1 when the sheet resistance of the channel forming region is 4×10 −3 (Ωcm) −1 . In this case, the substrate 1 is held below 400° C. so that the recombination center neutralizer doped in the semiconductor layer 2 are not diffused to the outside thereof. Further, the light irradiation may also be effected intermittently with a view to prevent the semiconductor layer 2 from being heated to such a high temperature that causes the diffusion of the recombination center neutralizer to the outside of the layer 2 . In this instance, when the gate electrode 5 G is a phosphorus-doped non-single-crystal semiconductor layer, its degree of crystallization is higher than that before exposure to the light irradiation.
Next, the substrate 1 is coated with the insulating film 7 as depicted in FIG. 1, and then the contact holes 8 S, 8 D and 8 G (the hole 8 G being not shown) are made in the insulating film 7 . After this, the interconnection layers 9 S, 9 D and 9 G are formed on the insulating film 7 so that they make ohmic contact with the source and drain regions 5 S and 5 D and the gate electrode 5 G through the contact holes 8 S, 8 D and 8 G, respectively.
In the manner described above, the insulated gate FET mentioned in connection with FIG. 1 is fabricated.
With the insulated gate FET thus obtained, according to my experiments, the drain current obtained during the ON state was as large as 1×10 −5 to 2×10 −5 (A), whereas during the OFF state it was as small as 10 −10 to 10 −11 (A). Further, since the crystallized regions 6 S and 6 D laterally extend across the source and drain regions 5 S and 5 D to underlie the gate electrode 5 G, a high avalanche breakdown voltage can be obtained.
While the foregoing description has been given of the manufacture of the insulated gate FET of the present invention depicted in FIG. 1, it will be seen that the insulated gate FETs of the present invention shown in FIGS. 2, 3 and 4 can also be fabricated by method of the present invention similar to that described above.
It will be apparent that many modifications and variations may be effected without departing from the scope of the novel concepts of the present invention. | An insulated gate field effect transistor comprises a non-single-crystalline semiconductor layer formed on a substrate, a gate electrode is formed on a portion of the surface of said semiconductor layer, and a gate insulating film is disposed between said gate electrode and said semiconductor layer. A non-single-crystalline channel region is defined within said semiconductor layer just below said gate electrode. A source region and a drain region are transformed from and defined within said semiconductor layer immediately adjacent to said channel region in an opposed relation, said source and drain regions being crystallized to a higher degree than that of said channel region by selectively irradiating portions of said semiconductor layer using said gate electrode as a mask. | 8 |
BACKGROUND OF THE INVENTION
This invention pertains to a clip means and more particularly to a locking pinch clip useful for securing plastic bags or securing one article to another. The pinch clip can be securely locked and maintained locked while in use.
Means for securing plastic bags such as plastic food bags or plastic refuse bags are known but ordinarily are relatively simple structures, such as twisted wires or threaded plastics and the like, which serve the purpose, but quite often secure the bag inadequately. The contents weight of the bag for instance can cause the twisted wires to unravel or otherwise loosen. Similarly, simple attachment means for connecting one article to another or suspending an article from an overhead supporting means are known but quite often are unsightly and insecure.
It now has been found that a simple but efficient locking pinch clip consisting of integral rigid plastic construction comprising a base, an integral upright locking means and an integral hinged diagonal locking member provides a versatile clip for a variety of purposes. The pinch clip can be easily secured in locking engagement by pinching together the diagonal member and upright locking means but cannot be disengaged by reverse outward movement of the diagonal locking member. The locked pinch clip can be unlocked only by sliding the diagonal locking member laterally relative to the upright locking means. The pinch clip is simple in construction, easily secured in pinching engagement, and very secure in use, and useful for ornamental as well as utilitarian purposes. For instance, the pinch clip can secure the open end of a plastic bag or secure two items together. The base of the pinch clip can be adhered or otherwise secured to a surface such as a baseboard and hold an electrical wire or decorative cord. The pinch clip can be manufactured efficiently by thermoplastic molding of clear or colored rigid plastic. These and other advantages of this invention will become more apparent by reference to the drawings as well as the detailed description of the invention.
IN THE DRAWINGS
FIG. 1 is a perspective view of the rigid plastic pinch clip of this invention;
FIG. 2 is an enlarged side elevation view of the pinch clip shown in FIG. 1;
FIG. 3 is a side elevation view of the pinch clip in FIG. 2 showing the pinch clip in a stretched-out position;
FIG. 4 is a further enlarged partial view of the pinch clip in FIG. 3;
FIG. 5 is a side elevation view of a plastic refuse bag locked by the pinch clip in use; and
FIG. 6 is a side elevation view of a greeting card attached to an overhead string by the pinch clip shown in FIG. 1.
SUMMARY OF THE INVENTION
Briefly, the invention comprises a plastic pinch clip consisting of an integral rigid plastic structure comprising a base member integral with an upright locking means at one end and with a hinged diagonal locking means at the other end, where the hinged diagonal locking member is adapted to bend backwardly toward the base and engage the upright locking means. The upright locking means contains an inwardly directed locking tooth or teeth adapted to slideably engage the distal end of the diagonal locking member upon pinching the base and diagonal members together. The locking means irreversibly provides locking engagement of the distal end of the diagonal member with the locking tooth.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like characters designate like parts, shown in FIG. 1 is a perspective view of the pinch clip 10 of this invention.
In FIGS. 2 and 3, the pinch clip 10 is shown in an enlarged side elevation view comprising a base member 12 integral at one end with a right angle upright locking means 14 containing inwardly extended triangular teeth 16, 17 rigidly integral with the upright locking means 14. Each tooth 16, 17 comprises an angular or downwardly directed engaging surface 18 and a lower locking surface 20 disposed substantially parallel to the base 12. At the other end of the base 12, a resilient hinge means 22 integrally interconnects the base 12 with a diagonal locking member 30. The resilient hinge means 22 is adapted to flex or bend the diagonal member 30 backwardly toward the locking teeth 16, 17 and the base 12. The diagonal locking member 30 terminates in a pointed distal end 32 preferably comprising a downwardly directed slanted surface 34 as viewed in FIG. 3, whereby the slanted surface 34 is adapted to slideably engage the angular upper engaging surface 18 of the upper tooth member 16 upon bending the diagonal locking member 30 backwardly toward the right angular upright locking means 14 as shown in FIG. 2. The pinch clip 10 is locked by pinching the diagonal member 30 and base 12 together and forceably sliding the inverted slanted surface 34 of the diagonal distal end 32 downwardly over the angular upper engaging surface 16 and causing the pointed distal end 32 to engage the underside or lower locking surface 20 of the inwardly protruding triangular upper tooth 16, as viewed in FIG. 2. Preferably the diagonal locking member 30 is slightly oversize in length relative to the linear length of the base 12 to provide secure compressive locking engagement with the upright locking means 14.
In a preferred embodiment of this invention shown in the enlarged view in FIG. 4, the integral resilient hinge means 22 interconnecting the base 12 with the diagonal locking member 30 comprises a concave lower structure 26 on the outside of the base 12 and an opposed upper flat indent 24 on the inside of the base 12 to form an intermediate resilient hinged neck structure 36 which provides limited resiliency in the hinge section 22 of the otherwise rigid plastic pinch clip 10.
In use, the pinch clip 10 can be used to lock a plastic bag 40 such as a plastic food bag, plastic point of sale bag, or plastic refuse bag as shown in FIG. 5, or to secure one article to another such as attaching a greeting card 44 to an overhead cord or string 46 as shown in FIG. 6. Similarly, the exterior surface of the base 12 can be adhered or secured to a surface whereupon clipped items such as cards, wires or strings can be secured within the pinch clip 10. Pinch clips 10 can be molded rigid plastic produced by thermoplastic molding processes in an outstretched configuration as shown in FIG. 3. The pinch clip 10 can be molded from rigid thermoplastic materials such as polyethylene, polypropylene, or polyvinylchloride. The pinch clip 10 can be attached or secured to one or more articles by locating a part of the article or articles between the base 12 and the diagonal member 30 by bending the diagonal member 30 backwardly toward the upright locking means 14 and pinching the diagonal member 30 toward the base 12, whereby the distal end 32 slideably engages the downwardly depending upper angular surface 18 of the inwardly protruding triangular tooth 16. By applying an additional pinching force, the distal end 32 continues sliding engagement with the upper engaging surface 18 until the distal end 32 of the diagonal member 30 passes over the upper surface 18 and drops downwardly to provide locking engagement with the lower, horizontally disposed locking surface 20 of the locking tooth member 16, thereby locking the pinch clip 10 and securing the article or articles disposed within the pinch clip 10.
Tighter locking engagement of the pinch clip 10 can be achieved by applying additional pinching pressure and forcing the pointed distal end 32 in similar manner to engage the lower triangular tooth 17. Although the upright locking means 14 is shown to contain both an upper tooth 16 and a lower tooth 17, it is readily seen that a single tooth 16 or several teeth can be provided.
The drawings and foregoing detailed description illustrate preferred embodiments of the pinch clip of this invention but are not intended to be limiting except by the appended claims. | The invention pertains to a locking pinch clip useful for securing plastic bags or securing one article to another and the like. The pinch clip consists of integral rigid plastic comprising a base, an upright locking means, and a resiliently hinged diagonal member adapted to pinch toward the base to engage and lock with the upright locking means. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to U.S. Utility application Ser. No. 13/075,887 entitled “3D MOBILE USER INTERFACE WITH CONFIGURABLE WORKSPACE MANAGEMENT,” which was filed on Mar. 30, 2011, U.S. Provisional Patent Application No. 61/319,195 entitled “ZOOM 3D USER INTERFACE,” which was filed on Mar. 30, 2010, the contents of both of which are expressly incorporated by reference herein.
TECHNICAL FIELD
[0002] The present disclosure relates generally to a user environment and more particularly to a three-dimensional (3D) user environment of a mobile device.
BACKGROUND
[0003] With increased reliance on mobile devices in meeting the demands of daily lives and even more so for entertainment purposes, the already prevalent field of mobile applications and services continues to grow at an accelerated pace. There is no shortage of mobile ‘gadgets’ that a user can download to or access from his/her mobile device. An average user or consumer uses a portable device for a vast variety of functions, from checking email, texting, conducting/initiating conference calls, to finding restaurants, tracking flight status, and the like.
[0004] However, form factor of mobile devices or other portable devices remains a dominant factor in design goals to remain competitive in the marketplace. While screen size and resolution have increased in newer generation devices, there remains a struggle for a user to fit and organize all of his/her mobile ‘tools’ in an intuitive and easy to navigate manner on a mobile device. Users face similar challenges for non-portable electronic devices as well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates examples of devices with user environments having 3D-enabled user interfaces (e.g., or mobile user interfaces for mobile devices) with configurable workspace functionalities.
[0006] FIG. 2A depicts an example diagram showing a user interface with multiple indicators in the form of tiles which can be used to access various workspaces in the user environment.
[0007] FIG. 2B depicts another example diagram showing user interfaces with multiple indicators in the form of tiles which can be used to access various workspaces in the user environment.
[0008] FIG. 2C depicts another example diagram showing multiple user interfaces with multiple indicators in the form of tiles which can be used to access various workspaces in the user environment.
[0009] FIG. 3 depicts an example diagram showing multiple workspaces presentable in 3D in the user environment.
[0010] FIG. 4 depicts another diagram showing example workspaces configured for professional and personal functions, presentable in 3D in the user environment.
[0011] FIG. 5 depicts an example diagram showing navigation across workspaces.
[0012] FIG. 6 depicts a block diagram illustrating example components of a user environment manager which provides the 3D mobile user interface with configurable workspace management capabilities.
[0013] FIG. 7 depicts a flow chart illustrating example processes through which various workspaces with associated functions can be accessed in a user environment.
[0014] FIG. 8 depicts a flow chart illustrating an example process for navigating among workspaces shown in 3D without returning to the home screen.
[0015] FIG. 9 depicts a flow chart illustrating example process for a user to configure a workspace for a selected function in a user environment.
[0016] FIG. 10 shows a diagrammatic representation of a machine in the example form of a computer system within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed.
DETAILED DESCRIPTION
[0017] The following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, well-known or conventional details are not described in order to avoid obscuring the description. References to one or an embodiment in the present disclosure can be, but not necessarily are, references to the same embodiment; and, such references mean at least one of the embodiments.
[0018] Reference in 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 disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor, are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.
[0019] The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Certain terms that are used to describe the disclosure are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the disclosure. For convenience, certain terms may be highlighted, for example using italics and/or quotation marks. The use of highlighting has no influence on the scope and meaning of a term; the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. It will be appreciated that same thing can be said in more than one way.
[0020] Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, nor is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any terms discussed herein, is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any exemplified term. Likewise, the disclosure is not limited to various embodiments given in this specification.
[0021] Without intent to further limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions, will control.
[0022] Embodiments of the present disclosure include systems and methods of 3D user interfaces (for mobile and non-mobile devices) with configurable workspace management capabilities and related functionalities.
[0023] FIG. 1 illustrates examples of devices 102 A-D with user environments having 3D-enabled user interfaces (e.g., or mobile user interfaces for mobile devices) with configurable workspace functionalities.
[0024] The client devices 102 A-D can be any system and/or device, and/or any combination of devices/systems that is able to establish a connection with another device, a server and/or other systems such as host server 100 and/or application server/content provider 110 . Client devices 102 A-D each typically include a display and/or other output functionalities to present information and data exchanged between among the devices 102 A-D and/or the host server 100 and/or application server/content provider 110 .
[0025] For example, the client devices 102 A-D can include mobile or portable devices or non-portable devices and can be any of, but not limited to, a server desktop, a desktop computer, a computer cluster, or portable devices including, a notebook, a laptop computer, a handheld computer, a palmtop computer, a mobile phone, a cell phone, a smart phone, a PDA, a Blackberry device, a Treo, a handheld tablet (e.g., an iPad), a handheld console, a handheld gaming device or console, an iPhone, and/or any other portable, mobile, handheld devices, etc. In one embodiment, the client devices 102 A-D and host server 100 /app server 110 are coupled to a network 106 . In some embodiments, the devices 102 A-D and host server 100 may be directly connected to one another.
[0026] The input mechanism on client devices 102 A-D having 3D-enabled user interfaces can include touch screen keypad (including single touch, multi-touch, gesture sensing, etc.), a physical keypad, or a combination of the above. The 3D user interfaces and the configurable workspaces disclosed herein can be actuated and interacted with using any conventional or known input device including but not limited to physical keyboard, touch screen display, motion sensor, microphone, mouse, other types of pointer devices and any additional input device. The 3D user interface functionality can be provided locally by the client devices 102 A-D and used to access applications (e.g., including mobile applications), accounts, websites, services, documents, files, media, or any other content such as those provided by a third party host (e.g., application server/content provider 110 ).
[0027] 3D user interface (UI) functionality and the configurable workspace features of the user environment can be provided locally by the devices 102 through the mobile device manufacturer, provided through the device operating system, by a network service provider, through a downloaded widget from a third party site, network service provider, or from the host server 100 . The 3D UI and/or workspace configuration functionalities may also be provided and enabled on a per application/content basis based on the services provided by the application server/content provider 110 via a user environment manager. Functions and techniques performed by the user environment manager on devices 102 A-D for 3D UI rendering and workspace configuration/management and the related components therein are described in detail with further reference to the example of FIG. 6 .
[0028] In one embodiment, 3D UI and/or workspace configuration functionalities are in part or in whole provided remotely to the devices 102 A-D, for example by the host server 100 . For example, the host server 100 can include one or more user environment managers (e.g., such as that illustrated in the example of FIG. 6 ) accessible over the network 106 by devices 102 to enable 3D user interface features, such as those that will be described with further references to description associated with example FIG. 2-5 . The 3D rendering functionalities, when provided remotely, may be accessed by the devices 102 in the cloud. In addition, the 3D UI and workspace configured as a as result thereof, may be streamed to the devices 102 on demand, for example, based either on local processes occurring on the device 102 itself or based on processes driven by applications or services provided by the app server/content provider 110 .
[0029] Functions and techniques performed by the user environment manager for 3D UI rendering and/or workspace management/configuration, which can reside on the client devices 102 in part or in whole and/or or host server 100 in part or in whole and the components therein are described in detail with further references to the examples of FIG. 2 .
[0030] The network 106 , over which the client devices 102 A-D, the host server 100 , and/or app server 110 communicate, may be a cellular network, a telephonic network, an open network, such as the Internet, or a private network, such as an intranet and/or the extranet, or any combination thereof. For example, the Internet can provide file transfer, remote log in, email, news, RSS, cloud-based services, and other services through any known or convenient protocol, such as, but is not limited to, the TCP/IP protocol, Open System Interconnections (OSI), FTP, UPnP, iSCSI, NSF, ISDN, PDH, RS-232, SDH, SONET, etc.
[0031] The network 106 can be any collection of distinct networks operating wholly or partially in conjunction to provide connectivity to the client devices 102 A-D and the host server 100 and may appear as one or more networks to the serviced systems and devices. In one embodiment, communications to and from the client devices 102 A-D can be achieved by, an open network, such as the Internet, or a private network, such as an intranet and/or the extranet. In one embodiment, communications can be achieved by a secure communications protocol, such as secure sockets layer (SSL), or transport layer security (TLS).
[0032] In addition, communications can be achieved via one or more networks, such as, but are not limited to, one or more of WiMax, a Local Area Network (LAN), Wireless Local Area Network (WLAN), a Personal area network (PAN), a Campus area network (CAN), a Metropolitan area network (MAN), a Wide area network (WAN), a Wireless wide area network (WWAN), enabled with technologies such as, by way of example, Global System for Mobile Communications (GSM), Personal Communications Service (PCS), Digital Advanced Mobile Phone Service (D-Amps), Bluetooth, Wi-Fi, Fixed Wireless Data, 2G, 2.5G, 3G, 4G, IMT-Advanced, pre-4G, 3G LTE, 3GPP LTE, LTE Advanced, mobile WiMax, WiMax 2, WirelessMAN-Advanced networks, enhanced data rates for GSM evolution (EDGE), General packet radio service (GPRS), enhanced GPRS, iBurst, UMTS, HSPDA, HSUPA, HSPA, UMTS-TDD, 1xRTT, EV-DO, messaging protocols such as, TCP/IP, SMS, MMS, extensible messaging and presence protocol (XMPP), real time messaging protocol (RTMP), instant messaging and presence protocol (IMPP), instant messaging, USSD, IRC, or any other wireless data networks or messaging protocols.
[0033] FIG. 2A depicts an example diagram 200 showing a user interface 220 with multiple indicators 222 , 224 , and 226 in the form of tiles which can be used to access various workspaces in the user environment 210 .
[0034] The user environment 210 accessible on the device 202 (e.g., a mobile device) as shown includes a user interface 220 having indicators 222 , 224 , and 226 , each of which being associated with a workspace. The indicators can be selected (e.g., by touch screen, keypad, or pointer selection) to view, access, or otherwise interact with an associated workspace. In one embodiment, each of the first grouping of indicators are also viewable in the third dimension in the workspace (e.g., such as scrolling through a stack of icons/tiles representing applications in the z-direction (depth)). As further illustrated in the example of FIG. 3 , such workspaces can graphically be presented as having a 3D relationship to the user interface 220 . Multiple workspaces can also be depicted in the user environment as having a 3D relationship with one another (e.g., as different layers shown by having different ‘depths’).
[0035] In general, the user environment (UE) 210 can have multiple user interfaces, depicted as having a planar relationship (e.g., in the same plane or in a single layer) with one another. As shown in the example of FIG. 2B , the user environment 210 has multiple user interfaces 230 , 240 , 250 each having a planar relationship with one another, or shown in the same ‘layer’ in the user environment. Each UE can include indicators (e.g., the 232 , 234 , etc.) used for accessible workspaces which can be rendered in 3D (e.g., as having depth parameters). FIG. 2C depicts an example diagram showing multiple user interfaces 230 , 240 , 250 as having a 3D relationship with one another (shown in different depths) in the user environment 210 .
[0036] FIG. 3 depicts an example diagram 300 showing multiple workspaces 340 , 350 , and 360 presentable in 3D in the user environment 310 .
[0037] Each of the workspaces can be accessed by selecting the associated indicators 322 , 324 , or 326 in the user interface 320 . The user interface 320 can be the home screen or any other screen. When indicator 322 (e.g., tile, button, key, icon, drop down box, a list, or any other type of user interface component, etc. able to be detected/sensed by a user) is selected by a user and detected by the system, the associated workspace 340 can be presented in the user environment 310 , as having a third dimension (depth in the z-direction with the user interface 320 in the z-y plane). Indicators can be visually or audibly detectable.
[0038] In one embodiment, the workspace 340 can be associated with one or more services (e.g., mail, chat, applications, mobile apps, etc.). Such associated services can have indicators in the workspace 340 , which are selectable by a user to access a corresponding service. In some instances, the grouping of services associated with the workspace 340 , or any other workspaces 350 , 360 , and the like, can be set in default (by device manufacturer, by device operating system, by a particular service/application, or by a network service provider, or any other third party), user-specified, user configured, re-configured, or re-adjusted. Specific services may be added by a user to the grouping in a particular workspace 340 , 350 , or 360 . Each workspace may be created by a user with all or a partially customized selection of services associated with groupings of indicators.
[0039] In one embodiment, as shown in the example of FIG. 4 , a first workspace is associated with a first associated function (e.g., personal workspace) and a second workspace can be associated with a second associated function (e.g., professional workspace). Such functions can be linked by default or specified by the user. Each workspace can thus be linked to services, functions and/or applications related the specified function.
[0040] For example, the professional workspace 440 can be linked to a user's work email, Linked-in account, mobile application, or work-based IM chat services, and such services can be accessed by the user using the grouping of indicators accessible in the user environment through workspace 440 . Similarly, the user's personal workspace 450 can be linked to their personal mail accounts (e.g., Gmail, MSN mail, Yahoo! Mail, etc.), their personal social networking accounts (e.g., Facebook, Twitter feeds, etc.), and/or personal chat IM accounts, etc. Individual services may be set in factory default and subsequently modified by the user. For example, the user can add or remove individual accounts or services for a particular workspace such that a combination of default services and user-selected services are associated with a particular workspace.
[0041] In addition, entire workspaces can be created from scratch by the user. In some instances, based on the function for the workspace specified by the user, the system can suggest a set of services and their associated indicators to be graphically shown when the workspace is shown and the user can modify as desired.
[0042] Additional types of functions associated with a workspace may be specified or defined by the user or any other third party including but not limited to, service providers, applications, or by the device platform (hardware and/or software). For example, workspace 460 may be associated with a user's hobby, such as sports, and can include identifiers dedicated to the user's aggregation of services/applications used in association with sports (e.g., scores tracking applications, ESPN mobile, workout trackers, NBA.com, CBSSports, etc.). Workspace 460 may be associated with a gaming environment that is 3D enabled. Additional functions are contemplated and can include by way of example but not limitation, gaming functions, academic functions, entertainment functions, multimedia functions, music functions, movie functions, an online store, an online application store, etc.
[0043] In some instances, a particular workspace (e.g., workspace 460 ) may be dedicated to a single application, service, or function. For example, indicator 426 can be associated with the ESPN application, which when selected causes the workspace 460 o be graphically presented in the environment 410 . The workspace 460 can then include several indicators, each of which is selectable to access features and functionalities provided by the ESPN application (e.g., which may include latest scores in the NHL, NFL, NBA, latest trading news, playoff schedule, etc.). The indicators, when selected, can be used to access each individual service, which can be graphically presented in the user environment as a 2D interface or another 3D environment. Any number of workspaces can be presented in the user environment 410 with any number of them being shown in 3D (any number of layers of workspaces can be shown in the z-direction in the user environment 410 ) and with any number of them shown in 2D.
[0044] Note that, as shown in the example of FIG. 5 , individual workspaces 540 , 550 , and 560 can be accessed using their respective associated indicators 522 , 524 , and 526 from the common user interface 520 (which may be a home screen, desktop, or another screen). In addition, each workspace can be navigated between one another. For example, indicators in workspace 540 can be selected to access workspace 550 or 560 , indicators in workspace 550 can be selected to access workspace 540 or 560 , each of which, when graphically presented in the user environment 510 , can be shown as having a third dimension relative to the planar interface defined by the x-y surface. Indicators in the respective workspaces can be selected to navigate to other workspaces without first returning to the user interface 520 or home screen, for example.
[0045] FIG. 6 depicts a block diagram illustrating example components of a user environment (UE) manager 600 which provides the 3D user interface with configurable workspace management capabilities. The user environment (UE) manager 600 can include, for example, a workspace manager 602 , workspace configuration module 604 , 3D rendering engine 606 , and/or a platform compatibility module 608 . Additional or less components/modules/engines can be included in the UE manager 600 .
[0046] As used in this paper, a “module,” a “manager,” a “handler,” or an “engine” includes a general purpose, dedicated or shared processor and, typically, firmware or software modules that are executed by the processor. Depending upon implementation-specific or other considerations, the module, manager, handler, or engine can be centralized or its functionality distributed. The module, manager, handler, or engine can include general or special purpose hardware, firmware, or software embodied in a computer-readable (storage) medium for execution by the processor. As used in this paper, a computer-readable medium or computer-readable storage medium is intended to include all mediums that are statutory (e.g., in the United States or under 35 U.S.C. 101), and to specifically exclude all mediums that are non-statutory in nature to the extent that the exclusion is necessary for a claim that includes the computer-readable (storage) medium to be valid. Known statutory computer-readable mediums include hardware (e.g., registers, random access memory (RAM), non-volatile (NV) storage, etc.), but may or may not be limited to hardware.
[0047] In general, each of the workspace manager 602 , workspace configuration module 604 , 3 D rendering engine 606 and 3D zoom module, platform compatibility module 608 , and any additional modules/engines includes any combination of software agents and/or hardware modules (e.g., including processors and/or memory units) able to perform the respective functions.
[0048] The workspace manager 602 can associate services and/or applications and/or features with a particular workspace. When a workspace 602 is defined for specific functions (e.g., personal, work, gaming, media, etc.), the manager 602 manages the association of the services/apps for the defined function of the workspace 602 . In one embodiment, the manager 602 generates, identifies, aggregates, and/or depicts the indicators of the services/apps in the workspace 602 . Such services/apps may be associated with a defined function.
[0049] One embodiment of the user environment (UE) manager 600 includes a workspace configuration module 604 which can manage, track, configure, re-configure, and re-set the workspace for a specific function (i.e., based on any of or a combination of, device state, user definition, user behavior, user state, service provider constraints, application settings, device location, etc.). The workspace configuration module 604 can modify (add, delete, reset) the apps/services accessible through the workspace by adding or removing or other wise readjusting the indicators which can be accessible in the workspace.
[0050] The configuration module 604 can also determine the placement of indicators in respective workspaces according to any defined rules (e.g., frequency of access, type of application and/or type of service) and/or based on device default settings and/or user preferences. Configuration module 604 can also determine or configure the relative placement in 3D (depth or value in z-direction) of one workspace with another workspace, based on any defined rules and/or based on device default settings and/or user preferences. Workspaces can be turned on or off based on user settings. For example, if a user is on vacation, he/she may manually configure the user environment to turn “off” the professional workspace for a specific number of days, or for specific hours during the day.
[0051] The configuration module 604 can internally manage and track a set of rules (e.g., device, user, location, OS, and/or network provider based) that determines how the workspaces and the indicators are depicted/organized/placed relative to one another. For example, the configuration module 604 may automatically place the professional workspace on as the top layer during business hours and the personal workspace as the top layer during off hours and weekends.
[0052] Furthermore, based on location awareness, the configuration module 604 may predict that a user is more likely to access certain applications. For example, if the device is outside of its home location (e.g., if the user is traveling or driving), the configuration module 604 may place a mapping function, driving directions or other location search related apps in a top layer workspace for ease of access. The configuration module 604 can place, re-configure a related workspace (e.g., a “travel” workspace) according to real-time user activities. For example, the travel workspace may be moved to the top layer or shifted up in layers for ease of access if the user is determined to be traveling.
[0053] Similarly, if device location indicates that a user is physically at work, the configuration module 604 may place the user's personal workspace in a higher layer than the professional workspace for easier access.
[0054] The 3D rendering engine 606 can be utilized by the UE manager 600 in graphically presenting workspaces in a user environment as having a third dimension relative to a planar surface of the device (e.g., to an interface in the user environment). In one embodiment, workspaces are presented as having a third dimension via a zooming action, for example, by a 3D zoom module.
[0055] The platform compatibility module 608 can implement any of device manufacturer, network service provider, or device operating system specific features and ensure cross compatibility with the 3D user interface. For example, compatibility module 608 can integrate any indicators associated device features (e.g., settings, device configuration, screen settings, power settings, etc.) into a workspace for proper 3D rendering. Additionally, module 608 can ensure cross compatibility of 3D user interface features and/or workspace management configurability features with third-party applications.
[0056] The UE manager 600 represents any one or a portion of the functions described for the individual managers/engines. The UE manager 600 can include additional or less modules. More or less, functions can be included, in whole or in part, without deviating from the novel art of the disclosure.
[0057] FIG. 7 depicts a flow chart illustrating example processes through which various workspaces with associated functions can be accessed in a user environment.
[0058] In process 702 , a first indicator in a user environment selectable in operation of the mobile device is depicted. The first indicator is generally visually depicted (e.g., a button, icon, or tile) although the indicator may also be partially or wholly audible or otherwise perceivable by a user of the mobile device. The indicator may be depicted in a home screen in the user environment or another screen.
[0059] In process 704 , the workspace is defined for a first associated function. The function can be defined according to a rule, platform defined, or based on a user's configuration. For example, the associated function can be a professional function, a personal function, or any other functions including but not limited to, entertaining, gaming, shopping, news, etc. In process 706 , services corresponding to the first associated function are associated with the workspace.
[0060] In process 708 , selection of the first indicator (associated with the defined workspace) is detected. The selection of the first indicator can be input by the user in any known or conventional manner, including touch screen (single touch, multi-touch), via keyboard, mouse, voice command, gesture sensing, motion detection, etc.
[0061] In process 710 , the workspace in the user environment is presented as having a third dimension relative to an interface in the user environment. In one embodiment, the workspace is presented as having the third dimension (z-depth) via a zooming action in the user environment. Indicators or icons for services such as device features, applications, or mobile applications which can be accessed on the mobile device can be graphically associated with the workspace such that they become visible or otherwise perceivable by the user when the workspace is presented. In addition, the services corresponding to the first associated function is user-defined in part or in whole. In one embodiment, each of the indicators are also viewable in the third dimension (z-direction) in the workspace in the user environment.
[0062] In one embodiment, the workspace includes a first grouping of indicators, each of which is selectable to access a service corresponding to the first associated function. The grouping of indicators may be wholly or in part aggregated or selected by a user. The ordering and placement of the indicators in the workspace may also be partially or wholly configured by the user.
[0063] In process 712 , selection of an indicator in the first grouping of indicators is detected. As a result, another interface or workspace can be depicted, which may also have the third dimension (z-depth) in the user environment. This other interface or workspace can include another grouping of indicators each of which is selectable to access a corresponding service in the services corresponding to the first associated function. Similarly, processes 714 - 724 depict the flow of rendering another workspace in 3D in the user environment.
[0064] FIG. 8 depicts a flow chart illustrating an example process for navigating among workspaces shown in 3D without returning to the home screen.
[0065] In process 802 , first and second indicators are depicted in a home screen of a user environment selectable in operation of the mobile device to access a workspace.
[0066] In process 804 , selection of the first indicator is detected. In process 806 , a first workspace is graphically presented in the user environment as having a third dimension relative to an interface in the user environment. The first workspace can be minimized or shifted into the background when the user is not interacting with it.
[0067] In process 816 , selection of the second indicator is detected and in process 818 , a second workspace in the user environment as having a third dimension relative to an interface in the user environment. If the second workspace is still open, the user can navigate between the first and second workspaces without returning to the home screen (as shown diagrammatically in the example of FIG. 5 ). Alternatively, each workspace can include a return feature (e.g., accessible by a return indicator such as a button) allowing the user to return to the home screen to navigate between different workspaces. In one embodiment, the first and second workspaces are positioned in the user environment as having different depths, the ordering of which can be determined based on contextual data of the user or the mobile device.
[0068] While in the workspaces, the user can select the indicators to access additional interfaces or workspaces which have 3D relationships to one another, as illustrated in flows 810 - 812 and 822 - 824 . The user can also navigate among subsequent workspaces with or without first returning to the first or initial screen.
[0069] FIG. 9 depicts a flow chart illustrating example process for a user to configure a workspace for a selected function in a user environment.
[0070] In process 902 , identification of mobile applications to be associated with a workspace in the user environment to be accessed via the mobile device is received from a user.
[0071] In process 904 , the workspace is created in the user environment. Note that the workspace can be associated with a specific user account and, in some instances, different workspaces having different application associations are created for different user accounts on the mobile device. In process 906 , the workspace is associated with a graphical indicator.
[0072] In process 908 , the workspace is associated with application indicators each associated with one of the mobile applications identified by the user. Multiple workspaces can be created and can operate in the user environment, each with an associated set of mobile applications, for example. The associated set of mobile applications selected by the user or set in default is based on a device or OS platform.
[0073] In process 910 , the graphical indicator selectable by the user to access the workspace is depicted in the user interface. In process 912 , selection of the graphical indicator is detected. In process 914 , the workspace is graphically presented in the user environment. The workspace can include the application indicators each of which is selectable to access mobile applications.
[0074] FIG. 10 shows a diagrammatic representation of a machine in the example form of a computer system within which a set of instructions, causing the machine to perform any one or more of the methodologies discussed herein, may be executed.
[0075] In alternative embodiments, the machine operates as a standalone device or may be connected (e.g., networked) to other machines. In a networked deployment, the machine may operate in the capacity of a server or a client machine in a client-server network environment, or as a peer machine in a peer-to-peer (or distributed) network environment.
[0076] The machine may be a server computer, a client computer, a personal computer (PC), a user device, a tablet PC, a laptop computer, a set-top box (STB), a personal digital assistant (PDA), a cellular telephone, an iPhone, an iPad, a Blackberry, a processor, a telephone, a web appliance, a network router, switch or bridge, a console, a hand-held console, a (hand-held) gaming device, a music player, any portable, mobile, hand-held device, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine.
[0077] While the machine-readable medium or machine-readable storage medium is shown in an exemplary embodiment to be a single medium, the term “machine-readable medium” and “machine-readable storage medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable medium” and “machine-readable storage medium” shall also be taken to include any medium that is capable of storing, encoding or carrying a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the presently disclosed technique and innovation.
[0078] In general, the routines executed to implement the embodiments of the disclosure may be implemented as part of an operating system or a specific application, component, program, object, module or sequence of instructions referred to as “computer programs.” The computer programs typically comprise one or more instructions set at various times in various memory and storage devices in a computer that, when read and executed by one or more processing units or processors in a computer, cause the computer to perform operations to execute elements involving the various aspects of the disclosure.
[0079] Moreover, while embodiments have been described in the context of fully functioning computers and computer systems, those skilled in the art will appreciate that the various embodiments are capable of being distributed as a program product in a variety of forms and that the disclosure applies equally regardless of the particular type of machine or computer-readable media used to actually effect the distribution.
[0080] Further examples of machine-readable storage media, machine-readable media, or computer-readable (storage) media include but are not limited to recordable type media such as volatile and non-volatile memory devices, floppy and other removable disks, hard disk drives, optical disks (e.g., Compact Disk Read-Only Memory (CD ROMS), Digital Versatile Disks (DVDs), etc.), among others, and transmission type media such as digital and analog communication links.
[0081] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.
[0082] The above detailed description of embodiments of the disclosure is not intended to be exhaustive or to limit the teachings to the precise form disclosed above. While specific embodiments of, and examples for, the disclosure are described above for illustrative purposes, various equivalent modifications are possible within the scope of the disclosure, as those skilled in the relevant art will recognize. For example, while processes or blocks are presented in a given order, alternative embodiments may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or subcombinations. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, or may be performed at different times. Further any specific numbers noted herein are only examples; alternative implementations may employ differing values or ranges.
[0083] The teachings of the disclosure provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.
[0084] Any patents and applications and other references noted above, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the disclosure can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments of the disclosure.
[0085] These and other changes can be made to the disclosure in light of the above Detailed Description. While the above description describes certain embodiments of the disclosure, and describes the best mode contemplated, no matter how detailed the above appears in text, the teachings can be practiced in many ways. Details of the system may vary considerably in its implementation details, while still being encompassed by the subject matter disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the disclosure should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the disclosure with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the disclosure to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the disclosure encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the disclosure under the claims.
[0086] While certain aspects of the disclosure are presented below in certain claim forms, the inventors contemplate the various aspects of the disclosure in any number of claim forms. For example, while only one aspect of the disclosure is recited as a means-plus-function claim under 35 U.S.C. .sctn. 112, 6, other aspects may likewise be embodied as a means-plus-function claim, or in other forms, such as being embodied in a computer-readable medium. (Any claims intended to be treated under 35 U.S.C. .sctn. 112, 6 will begin with the words “means for.”) Accordingly, the applicant reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the disclosure. | A mobile terminal is provided. The terminal includes a display unit configured to display a three-dimensional image comprising at least a plurality of objects, a memory unit configured to store property information for a plurality of applications, wherein each of the plurality of applications corresponds to a one object of the plurality of objects, and a controller. The controller is configured to detect a selection of the plurality of objects, execute the plurality of applications corresponding to the selected plurality of objects, generate priority information to determine priority levels for the executed plurality of applications based on the property information, and control the display unit to arrange a display of the executed plurality of applications on the three-dimensional image based on position information mapped to the generated priority information. | 6 |
BACKGROUND OF THE INVENTION
Diamond is the hardest substance known to man. It is optically transparent, and electrically nonconductive. Therefore, diamond is a highly desirable and widely used material with both decorative and broad technological applications in a variety of industries. Industrial diamond uses include cutting, drilling, polishing of hard-to-work-with objects as well as geological drilling and cutting of ceramics, tungsten, carbides, etc. Other industrial uses are in the field of electronics, where diamond wafers utilize diamond's unique combination of electrical and thermal properties. It has been determined by crystallographers that the unique properties of diamond are because of the particular arrangement of carbon atoms within the diamond crystal. Such crystallographic structure is known as a "Cubic Face Centered", and is designated "A-4". Compared to other substances, diamond is relatively expensive.
On the other hand, graphite crystallizes in totally different systems known by crystallographers as either Hexagonal (designated "A-9"), or Rhomboedric (designated "D5,3"). Conversely to diamond, graphite is quite soft, is optically opaque, and conducts electricity. Graphite is produced in millions of tons annually in a variety of shapes from bars to fibers to powders. Diamond, conversely, is produced with great difficulty, and in a minuscule amount in comparison to graphite.
Historically, the first attempts to manufacture diamond for industrial use centered on reproducing natural geological conditions, which are believed to be the application of extreme pressures of layers of rocks and temperatures to graphite existing deep in the earth's crust. It is still believed that these conditions transformed graphite to diamond in the earth over geological periods of time. In any event, all existing industrial methods and processes of diamond making are technically complex, require highly sophisticated equipment, are cost intensive, and require a high level of academic knowledge.
Many currently used industrial diamond making processes utilize the principle of high energy delivered either by mechanical or chemical means. The majority of such methods are hazardous since they are conducted within massive, superstrong enclosures often placed in mine shafts. Typical high energy methods of diamond making are shown in Hall U.S. Pat. No. 2,947,608 and Iazu et al. U.S. Pat. No. 4,632,817.
There are a few other methods of diamond making such as the crystal growth from solution method disclosed in Custers et al. U.S. Pat. No. 3,124,422 and Satoh et al. U.S. Pat. No. 4,836,881. An electrical discharge method of diamond making is shown in Inoue U.S. Pat. No. 3,207,582. The epitaxial crystal growth diamond making method is illustrated in a number of U.S. patents including Fedoseev et al U.S. Pat. No. 4,104,441 and Kamo U.S. Pat. No. 4,989,542.
The laser beam application in diamond making can be seen in Ohsawa U.S. Pat. No. 5,066,515, and the low-pressure, partial vacuum, vapor phase synthesis and plasma deposition diamond making method is shown in Angus U.S. Pat. No. 3,607,061 and in Ota et al. U.S. Pat. No. 5,074,245.
The chemical methods of diamond making are typically shown in Eversole U.S. Pat. No. 3,030,187 and St. Pierre et al. U.S. Pat. No. 4,220,455.
The explosive diamond making method can be seen in DeCarli U.S. Pat. No. 3,238,019 and Shulzhenko et al. U.S. Pat. No. 3,676,068.
A diamond making process in which electrical current heating is applied is illustrated in Brayman U.S. Pat. No. 3,328,841 and Inuzuka et al U.S. Pat. No. 3,436,182.
The electrical discharge diamond making process is shown in Ktyoshi U.S. Pat. No. 3,207,582.
The mixed chemical-pressure-temperature diamond making process may be seen in a number of U.S. Patents, including Horton U.S. Pat. No. 3,597,158 and Masae Wakatsuki et al U.S. Pat. No. 3,436,183.
None of the prior art processes for making diamond provide a process which offers low capital investment and simplicity, is inexpensive and is capable of transforming graphite to diamond in a variety of shapes and forms such as powders, solid bars, fibers, ribbons, etc. The principal object, therefore, of this invention is to provide a new method of industrial diamond making that will overcome the deficiencies of the prior art processes.
SUMMARY OF THE INVENTION
This invention relates generally to a method or process and an apparatus for making industrial diamond by transforming graphite to diamond with the application of supercritical electrical current of a duration of microseconds. The allotropic transformation of graphite to diamond requires energy, and using the principles of the invention, energy is delivered to graphite exclusively in the form of an electrical current. In the preferred embodiment of the invention, a high voltage electrical current generator, which stores energy in a charged capacitor, is used. This high voltage generator provides a means of rapid discharge of an electrical current of supercritical densities. Such current is directed to flow through a graphite specimen to transform it to diamond. A critical current density is defined as resulting from an internal electrical field in graphite equal to one thousand volts per centimeter. Consequently, the supercritical current densities should be understood as resulting from the strength of an internal electrical field in graphite greater than one thousand volts per centimeter.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with its objects and the advantages thereof may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like referenced numerals identify specific figures and elements and in which:
FIG. 1 is a view, partially in cross section, of the reactor used in carrying out the principles of the invention;
FIG. 2 is a schematic illustration of the high voltage power supply by which an electrical discharge of the capacitor delivers powerful electrical current pulse to carry out the principles of the invention; and
FIGS. 3 through 5 depict oscillograms of an electrical current for three possible and distinctively different conditions of the power supply discharge.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
It was discovered in researching this invention, and furthermore is postulated theoretically, that the allotropic transformation of graphite to diamond occurs simultaneously under the supercritical current conditions by weakening the valent bonds in graphite crystals. This crystal bond weakening lasts a very short time. However, the heat and pressure associated with the supercritical current allow the allotropic transformation to diamond by valent electrons rearrangement while maintaining the original shape of the specimen. In the preferred embodiment of the invention, the commercially available opaque graphite fibers become light transparent diamond fibers.
Several restrictive conditions must exist in order to allow the process to take place. In the free space filled with gas such as air, the superhigh electrical charge delivered to the graphite specimen tends to flash over the graphite surface rather than to flow through the cross-section of the specimen. In order to utilize the invention to its full extent, one must therefore disallow the electrical charge flash over to happen. This may be achieved in several non-exclusive ways: first, by placing the graphite specimen such as a rod, compressed powder, or a bundle of graphite fibers tightly inside the ceramic reactor; second, by using vacuum lower than 0.1 millitorr inside the reactor filled with graphite; third, by filling the gap between the ceramic reactor and the graphite specimen with dielectric fluid; or fourth, by coating or covering the graphite specimen with the dielectric substance such as teflon or jacksting it in an epoxy-like film. It is important likewise that the electrical connection between the power supply and the reactor be short, and its design is guided by the rules of the high frequency circuit in which either the coaxial cable or a twisted pair of insulated wires is used. Note that the supercritical current phenomenon lasts a short time. A short time current event should comply with the high frequency circuit design principles.
Referring now to the drawings, and first to FIG. 1, the cross section of a cylindrical reactor 10 is shown. The reactor 10 is used to house the graphite specimen that will be transformed into diamond. This specific design of the reactor 10 that is shown is by way of illustration, and it should be understood that other designs can be employed in carrying out the method of diamond making of the invention.
A highly compression-resistant ceramic tube 12, preferably made of 99.5% alumina, is brazed or otherwise attached inside a soft steel cylinder 14 that forms the outside surface of the reactor 10. The tube 12 provides a cylindrical chamber 16 into which a graphite element (not shown) is placed for conversion to diamond. A capillary tube 18 containing a valve 20 extends from chamber 16 through the tube 12 and cylinder 14, and tube 18 is connected to a standard vacuum pump (not shown) for the purpose of evacuating the chamber 16 of the reactor 10. The chamber 16 inside ceramic tube 12 is hermetically sealed by upper and lower platinum seals 22 and 24. Evacuation of chamber 16 to a pressure of 0.01 millitorr is recommended.
The reactor 10 includes an upper steel plate 26 and a lower steel plate 28 that engage the upper and lower seals 22 and 24, respectively. Plate 28 is connected by means of a suitable electrical conductor 30 to the ground electrode 31 of a suitable power supply, indicated generally by the reference numeral 33 (FIG. 2). Plate 26 is electrically connected by conductor 32 to the high voltage electrode 35 of the power supply 33. The conductors 30 and 32 to the power supply 33 must be suitable for the high frequency electrical network of the power supply 33 which utilizes matched impedance. For example, the connections could be by coaxial cable or a twisted pair of insulated conductors.
Two electrical insulating gaskets 34 and 36 provide electrical insulation between the upper and the lower seals 22 and 24 and the metal cylinder 14. Consequently, all metallic parts in physical contact with seals 22 and 24 are insulated, thus allowing a high electrical potential difference to be maintained between the seals 22 and 24.
In order to apply pressure to seal the reactor 10, upper plate 26 is engaged by the upper jaw 38 of a standard hydraulic press (not shown) while lower plate 28 is engaged by the hydraulic actuator or piston 40 of the press. A hydraulic press with a 10 ton limit is suitable for a small laboratory reactor. The larger the reactor 10, the larger the press capacity needs to be to maintain a sufficiently strong hermetic seal between the components of the reactor 10 and the platinum seals 22 and 24. An insulating member 42 is preferable positioned between the jaw 38 and the upper plate 26 in order not to upset the previously described electrical conditions of the reactor 10. If the insulting member 42 were not present, an electrical short may occur via the hydraulic press, causing the reactor 10 to fail to operate under the conditions necessary to carry out the invention.
Referring now to FIG. 2, the high voltage power supply 33 is shown schematically. The primary side of a high voltage step-up transformer 44 is connected to a standard A.C. power supply providing an exemplary 110 volts of power. Transformer 44 will increase the voltage output on the secondary coils to a range of 10-20 kilovolts, and a pair of high voltage diodes 46 and 48 charge the high voltage capacitor 50. A high voltage spark gap 35 is built into the output of the power supply 33 in FIG. 2. A 100 microohm exemplary resistor 52 is used in serial connection with the capacitor 50 to monitor the current of the discharge. Typically, a current monitor such as the storage oscilloscope is connected to terminals 53 and 54 which determine the beginning and the end of the resistor 52. When the voltage on capacitor 50 reaches a predetermined air gap breakdown value, a sudden electrical current discharge occurs, and consequently a powerful current pulse flows to the reactor 10. The values of voltages and capacitances will depend upon the overall size of the reactor 10. Preferably, voltages should be no lower than 5 kilovolts and capacitances no smaller than 1 microfarad. The lower values are suitable for a reactor 10 used for demonstration purposes while the higher values will be required for reactors used for the industrial production of diamond. Voltage changes across the resistor 52 are monitored and are digitally stored and displayed by means of a high speed digitizing oscilloscope (not shown).
In order to demonstrate the principles of the invention, I have shown examples of characteristic voltages in the oscillograms of FIGS. 3, 4 and 5 for three possible situations in which an electrical discharge of the reactor 10 can occur. I have termed these as crowbar short, thin metallic wire short, and graphite specimen short. The first case exists when the output of the high voltage power supply 33 is shorted by a metallic crowbar. FIG. 3 illustrates an oscillogram of the electrical discharge current recorded by the digitizing storage oscilloscope for this case. The current of the discharge has a "ringing" character and lasts approximately 50 microseconds. The electrical current of the shape and duration shown in FIG. 3 will not produce diamond from a graphite specimen contained in the reactor 10.
The second case exists when the output of the high voltage power supply 33 is shorted by a suitable metallic wire exploding upon the electrical charge flow. For example, using a 2" long copper wire with a 0.010" diameter (5 cm and 0.25 mm respectively) to short the output of the power supply 33, the electrical discharge will last 5 microseconds. The oscillogram of FIG. 4 illustrates this case, and like the first case, the electrical current thus created will not produce diamond from a graphite specimen in the reactor 10.
FIG. 5 illustrates the oscillogram of an exemplary current discharge via a graphite specimen which is placed inside the reactor 10 and subjected to an electrical current according to the principles of the invention. Note that the electrical current oscillograms of FIG. 3 and 4 are quite different from the oscillogram of FIG. 5 for the supercritical current flow through the graphite specimen. The current flow preferably lasts only four microseconds, and during this short time interval, a total conversion of graphite to diamond occurs. It is believed that the allotropic transformation of graphite to diamond takes place by the supercritical current flow.
To carry out the transformation of graphite to diamond according to the principles of the invention, the reactor 10 is loaded by placing a suitable graphite specimen inside the chamber 16 of the ceramic tube 12 and then the chamber 16 is sealed by applying pressure using the hydraulic press. The air from chamber 16 is then evacuated through tube 18. Upon evacuation to the desired pressure, the valve 20 is closed. As an alternative to evacuating chamber 16, the chamber 16 of the reactor 10 may be filled with a common dielectric fluid of high purity, such as glycerol, silicon oil, or synthetic petroleum oil. Furthermore, no vacuum or dielectric fluid need be used if certain precautions are taken. In such a case, the graphite specimen must fit tightly inside chamber 16 of the ceramic tube 12 between the platinum seals 22 and 24 leaving less than 1% of the total volume of chamber 16 for air. As a further alternative, the surface of the graphite specimen either may be coated with a dielectric substance (such as thermosetting or U.V. curable resin) or placed inside a dielectric secondary enclosure (not shown), thereby tightly surrounding the graphite specimen with an electrical insulator. Regardless of the particular alternative used to insulate the graphite specimen, the transformation of graphite to diamond will occur upon supercritical current flow if the steps of the invention are properly carried out. Conversely, however, if the electrical flash over the graphite specimen surface is permitted by not properly following the above recommended alternatives, the graphite specimen will be pulverized and diamond will not be produced.
It is believed that the application of the supercritical current to the graphite specimen results in loosening the valent bonds in the graphite, thus creating the plausible conditions to allow phase transformation from graphite to diamond and to carbon fullerines C-60. The invention provides a simple process based on passing a single large electrical charge through graphite. Because the method and apparatus is strictly electrical, a process employing the principles of the invention can be precisely monitored electrically and precisely tuned to yield optimum manufacturing conditions. The process of the invention therefore eliminates the large variability and difficulty of setting process parameters so common for mechanical or chemical methods of diamond making. The process of the invention thus yields diamond of the highest possible purity, yielding complex carbon conglomerates containing 60 atoms of carbon and called either "Buckminster Fullerines" or "Bucky Balls". The process of the invention also is economical to perform since it permits fast reloading of the reactor chamber with graphite, while providing the flexibility of diamond making in a single shot or in a repetitive fabrication.
Although the invention has been described in connection with certain preferred embodiments, these are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details disclosed. For example, the invention has been described as applied to the allotropic tansformation of graphite to diamond. However, it will be understood that the principles of the invention can be applied to produce allotropic transformation of any electrically conductive matter or substance, such as metals or alloys, having exemplary elements such as carbon, beryllium, cerium, tin, zirconium, cobalt, lanthanum, lithium, manganese, nickel, polonium, praeozdymium, rhodium, selenium, thallium, uranium, calcium, iron and tungsten. For example, tin exists both in the form of white tin or grey tin, and the invention can be used to convert the tin from white to grey without changing the shape. The proper application of the principles of the invention will produce a change only in the existing crystalline structure of the conductive substance. It will also be understood that this invention may be embodied in other specific forms, and that various revisions and modifications can be made to the preferred embodiments by persons skilled in the art without departing from the spirit of and scope of the invention. It is my intention, however, that all such revisions and modifications that are obvious to those skilled in the art will be included within the scope of the following claims. | Human-made diamond, as well as naturally found diamond, is a transparent, superhard, crystalline, and electrically nonconductive form of carbon. In this invention, an electrical current of supercritical density alone produces the transformation of graphite to diamond. The entire graphite-to-diamond transformation requires only a few millionths of a second. Using the principles of the invention, diamond can be produced in a variety of shapes, such as loose debris, rods, fibers, bars, dust, etc. In addition to diamond, Buckminster Fuller Balls, known also as C-60 carbon fullerines, are produced using the process and apparatus of the invention. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to an improved faucet, in particular to an improved faucet which provides all the required functions of a faucet under the control of a single control arm.
Conventional faucets generally utilize a means, generally a control arm, to control the output of water either to a downward outlet, i.e., the tub, or to a shower head. However, conventional faucets still need another means to selectively regulate the output and ratio of hot and cold water. It is quite inconvenient to control two control arms at the same time during usage of a faucet.
The present invention provides an improved faucet which offers a single control arm which satisfies all of control functions required by a faucet.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved faucet with a control arm to determine the output destination and regulate the output temperature of water.
It is another object of the present invention to provide an improved faucet with a truncated cone having several water passages to control the output and temperature of water.
These and additional objects, if not set forth specifically herein, will be readily apparent to those skilled in the art from the detailed description provided hereunder, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an improved faucet in accordance with the present invention;
FIG. 2 is an exploded view of the faucet of FIG. 1 in accordance with the present invention;
FIG. 3 is a cross-sectional view taken along plane 3--3 of FIG. 1, in which a cap and a washer are removed to show a compartment in the faucet according to the present invention;
FIG. 4 is a cross-sectional view of a truncated cone provided in the faucet, showing the inner passages therein;
FIG. 5 is a cross-sectional view of the truncated cone taken along line 5--5 of FIG. 4;
FIG. 6 is a cross-sectional view of the truncated cone taken along line 6--6 of FIG. 4;
FIG. 7 is a cross-sectional view similar to FIG. 3 in which the truncated cone is positioned in the compartment;
FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 1 in which a control arm is in a neutral position and the faucet is closed;
FIG. 9 is a cross-sectional view similar to FIG. 8 in which the control arm is in a leftward position; and the passages of the faucet is communicated with a shower head; and
FIG. 10 is a cross-sectional view similar to FIG. 8 in which a control arm is in a rightward position and the passages of the faucet communicate with a tub outlet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 through 3, the faucet according to the present invention comprises a substantially T-shaped body 10 composed of a cross portion 12 and a vertical portion 14. A substantially truncated cone-shaped compartment 16 is formed in a middle portion of the cross portion 12. An upper end of the compartment 16 has a diameter larger than that of a lower end of the compartment. Furthermore, the compartment 16 has an extended portion 161 below the lower end thereof, and extends transversely, which will be discussed in detail later.
The compartment 16 has a cold water inlet 162 formed on an inner wall surface thereof. The cold water inlet 162 communicates with a cold water passage 172, which communicates with a cold water pipe 182. The cold water pipe 182 is communicated to a cold water source (not shown) through an inlet 186. An adjusting screw 187 is provided on the cold water pipe 182 for regulating the inlet pressure of cold water.
The compartment 10 also has a hot water inlet 164 formed on the annular wall surface thereof, opposite to the cold water inlet 162. The hot water inlet 164 communicates with a hot water passage 174 which communicates with a hot water pipe 184. The hot water pipe 184 communicates with a hot water source (not shown) through an inlet 188. An adjusting screw 189 is provided on the hot water pipe 184 for regulating the inlet pressure of hot water.
The compartment 16 also has a first outlet 166 formed on a bottom surface thereof, directly communicating with a tub outlet 16 via a vertical passage 152 formed in the vertical portion 11. The compartment 16 also has a second outlet 170 formed on the inner wall surface thereof, above the two water passages 172 and 174. The second outlet 170 communicates with to a shower head (not shown) via a horizontal passage 13 attached to the cross portion 12. The compartment 16 extends upwardly to form an opening 168, which is defined by an annular flange 17 protruding from top wall 100 which encloses the compartment 10, through which a truncated cone 20 is passed and received into the compartment 16. The annular flange 17 is threaded at an outer wall thereof.
Referring to FIG. 2 and FIGS. 4 through 6, the truncated cone 20 comprises a first annular protrusion 22 protruding from a top surface thereof, at which a first shoulder 21 is formed. A second annular protrusion 24 protruding from a top surface of the first annular Protrusion 22 at which a second shoulder 23 is formed. A hole 241 is Provided on the second flange 24 by means of which a control bar 27 is attached thereto.
Referring to FIG. 7, the truncated cone 20 is pivotally disposed in the compartment 16. The extended portion 161 remains unoccupied. The second shoulder 23 is at the same level as the top surface of the annular flange 17. A washer 26 is placed on the first shoulder 21 and fills an annular space between the annular flange 17 and the first protrusion 22. An inner threaded cap 26 is provided to engage with the outer threaded wall of the annular flange 17 (see FIG. 2). A plurality of fixing holes 171 is provided on an upper surface of the annular flange 17 for fixing the cap 26 by means of a screw 261 passing through a hole 262 on the cap 26 into one of the holes 171.
Referring to FIGS. 1, 2, 4, 5, 6 and 8, the truncated cone 20 has a first cold water path 30, a first hot water path 32, and a shower head path 38, which communicate with one another. Both the first cold water path 30 and the first hot water path 32 are at the same level as the cold water passage 172 and the hot water passage 174. The outlet of the shower head path 38 is at the same level as the second outlet 170 of the compartment 16, which communicates with a shower head.
The truncated cone 20 also has a second cold water path 36 and a second hot water path 34, in which the upper ends of the two paths 34 and 36 are at the same level as the cold water passage 172 and the hot water passage 174. The second cold water path 30 communicates with an annular recess 40 formed on a bottom portion of the truncated cone 20 through a first vertical path 42. The second hot water path 34 also communicates with the annular recess 40 through a second vertical path 44. The annular recess 40 communicates with the tub outlet 15 via the first outlet 166 of the extended portion 161 and the vertical passage 152.
As shown in FIGS. 1 and 2, the control arm 27 is attached to the threaded hole 241 of the second protrusion 24 of the truncated cone 20 by means of thread connection. Accordingly, the truncated cone 20 is pivotable through a pivotal movement of the control arm 27.
Referring to FIG. 8 in which the control arm 27 is in a neutral position. Neither of the hot water paths 32, 34, or the cold water paths 30, 36 communicates with the cold water passage 172 or the hot water passage 174. Consequently, no water is directed to the shower head via the second outlet 170, or the tub head via the first outlet 15.
During use, when the user desires cold water outputs to the shower head, the user ca slightly pivot the control arm 27 leftwards from the neutral position. Initially, the first cold water path 30 partially communicates with the cold water passage 172 and the shower head path 38 partially communicates with the second outlet 170 of the truncated cone 20, while the first hot water path 32 does not yet communicate with the hot water passage 174. Cold water begins to flow to the shower head via the cold water pipe Z, the cold water passage 171, the first cold water path 30, the shower head path 170, and the horizontal passage 13. The more the control arm 27 is pivoted leftwards, the more the first cold water path 30 communicates with the cold water passage 172, and therefore, a greater amount of cold water is outputted to the shower head.
When the first cold water path 30 completely communicates, i.e., is totally aligned, with the cold water passage 172, the first hot water path 32 is just about to communicate with the hot water passage 174; therefore, the faucet has a maximum output of cold water to the shower head. After that, if the control arm is further pivotally moved to the left, the first cold water path 30 is gradually blocked while the first hot water path 32 gradually opens. The temperature of the water output to the shower head gradually increases due to gradual opening of the first hot water path 32 and gradual closing of the first cold water path 30. The faucet has a maximum output of hot water to the shower head when the control arm 27 moves to its leftwardmost position (see FIG. 9 for reference).
When the user desires a cold water output to the tub head, the user can slightly pivot the control arm 27 rightwards from the neutral position shown in FIG. 8. At the beginning, the second cold water path 36 partially communicates with the cold water passage 172 while the second hot water path 34 does not yet communicate with the hot water passage 174. Cold water begins to flow to the tub head via the cold water pipe Z, the cold water passage 171, the second cold water path 36, the first vertical path 42, the annular recess 40, the extended portion 161 of the truncated cone 20, the vertical passage 152, and the first outlet 15. The more the control arm 27 is pivoted rightwardly, the more the second cold water path 36 communicates with the cold water passage 172, and the greater amount of cold water is outputted to the tub head.
When the second cold water path 36 completely communicates with the cold water passage 172, the second hot water path 34 is just about to communicate with the hot water passage 174; therefore, the faucet has a maximum output of cold water to the tub head. After that, if the control arm 27 is further pivotally moved to the right, the second cold water path 36 is gradually blocked while the second hot water path 34 gradually opens. The temperature of the water output to the tub head gradually increases due to gradual opening of the second hot water path 34 and gradual closing of the second cold water path 36. The faucet has a maximum output of hot water to the tub head when the control arm 27 moves to its rightwardmost position (see FIG. 10 for reference).
Incidentally, the provision of the extended portion 161 makes the present faucet more durable since small particles, such as sand or the like, which may cause blockage of the faucet and wear between the outer periphery of the truncated cone 20 and the inner periphery of the compartment 16, will fall into the extended portion 101 without interfering with the operation of the faucet.
While the present invention has been explained in relation to its preferred embodiment, it is to be understood that various modifications thereof will be apparent to those skilled in the art upon reading this specification. Therefore, it is to be understood that the invention disclosed herein is intended to cover all such modifications as fall within the scope of the appended claims. | A faucet with a single control arm for regulating water temperature and determining output destination includes a hot water passage, a cold water passage, a shower head outlet and a tub outlet which are communicable by the control arm which pivots a truncated cone received inside a T-shaped faucet body. If the shower head is the desired destination, then the control arm is moved to the left and the water paths inside the truncated cone align unsimultaneously with the water passages, therefore the water temperature can be adjusted. When the tub is the desired output, then the control arm is moved to the right, and the same is true for water temperature regulation. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to a gain control method and device for a bursty data frame reception system in a high speed digital radiocommunication system, in particular for high definition video (HDTV) links between a mobile source that needs to be controlled remotely and a fixed receiver where the controller of the source is also located. More specifically, this invention applies to the case of a wireless video link between a camera generating the video stream and a studio where an operator needs to regularly intervene remotely on certain camera parameters. This invention also relates to a gain control method and device for a reception system with antenna diversity.
[0002] Implementing a bidirectional link is equivalent to accessing the transmission channel in a shared way to ensure that the uplink and downlink accesses do not disturb each other.
DESCRIPTION OF THE PRIOR ART
[0003] There are, today, three main channel access techniques for implementing a bidirectional link. These are FDMA (Frequency Division Multiple Access) type access, TDMA (Time Division Multiple Access) type access and, finally, CDMA (Code Division Multiple Access) type access.
[0004] FDMA type access is well suited to our application, and is moreover implemented in the current systems. Its principle is particularly simple: the uplink and the downlink use different frequency channels. The two transmissions are continuous, of broadcast type. They are therefore particularly robust. In practice, once the initialization phase is finished at the receiver end, the automatic gain control loop and the equalizer are particularly stable so ensuring a good reception quality.
[0005] However, in the context of a system that is strongly asymmetrical in terms of bit rate to be transmitted, in order to be effective, FDMA type access requires the parallel implementation of two different communication systems, one being suited to the high bit rates and the other to the lower bit rates and therefore with a narrower bandwidth.
[0006] As for the TDMA type access, the principle of this is to share time on one and the same frequency channel between the uplink and the downlink. In the case of an asymmetrical system, the temporal split is made in favour of the link requiring the higher bit rate. The distribution in time of the bursts of data can be organized within a structure called a frame, or even be organized more randomly. In the latter case, there are numerous protocols for defining access to the channel. However, none of them can guarantee the quality of service and efficiency obtained with frame-oriented systems. As an illustration, it can be noted that the GSM networks are bursty frame systems whereas the WiFi type wireless local area networks are random access systems.
[0007] The systems corresponding to TDMA type access do, however, present a major defect originating from the discontinuity of the signals. In practice, conventionally, at the start of each data burst, the gain level of the RF stage of the receiver and the equalizer must be reset. To ensure good system efficiency, this so-called locking-on phase must be as short as possible.
[0008] The bursts of data, as represented in FIG. 1 , normally begin with one or more special symbols called preambles. The IEEE802.16 standard also introduces the concept of midamble. Midambles are special symbols inserted in the middle of the bursts which, like the preambles, enable the equalizer to be reset and the automatic gain control (AGC) loop to be readjusted. In the direction in which the largest quantity of data needs to be transported, a frame comprises several adjoining bursts transmitted in succession. While a data burst is being received, the gain of the RF (radio frequency) amplifier is not readjusted. The equalizer on its own tracks the trend of the channel, both with regard to its impulse response (or frequency response in the case of a multiple-carrier modulation) and its average attenuation. In the case of a link. where the level of the channel changes rapidly, the preambles must be repeated frequently in order to enable the equalizer to remain in its operating band. However, frequently repeating system resets tends to lower overall system performance.
[0009] In the context that we are interested in, the simplest way of combining the advantages of a continuous link without resetting of the equalizer and of the gain of the tuner stage of the receiver with those of a better suited bursty frame link in the case of a bidirectional system, entails splitting a frame into two bursts of unequal lengths, the longer being used to transport video data and the shorter being used in the other direction to control the source. The video burst then comprises only a preamble at its start in order to ensure the requisite initializations. Then, during the burst, the equalizer and the gain of the IF (Intermediate Frequency) stage are adjusted regularly.
[0010] However, this method does not afford sufficient flexibility of use.
[0011] Another system where the adjustment of the gain is done using two variable gain. stages is described by document US2003/0083030. FIG. 2 shows the simplified architecture of the tuner stage of the receiver of this system. The input signal IN is applied to a variable gain RF amplifier 1 to be amplified, then this amplified signal is mixed with a reference signal REF at a determined frequency on a mixer 2 in order to obtain a resultant intermediate frequency IF signal. The latter is filtered by a filter 4 and amplified again by a linear variable gain IF amplifier 3 to form the desired output signal OUT. This signal is then applied to a demodulator as is known to those skilled in the art. The controls 5 , 6 of the RF and IF amplifiers are given by a control circuit receiving an RSSI (received signal strength indication) from the output signal (not shown). The RF amplifier is switched to a so-called “low gain” position or to another so-called “high gain” position depending on the control. This document does not describe the problems caused by switching the RF amplifier from one position to the other.
[0012] As illustrated in FIG. 3 which represents a level diagram of the two gains, RF and IF, according to the input signal strength, the RF stage can comprise an adjustable gain amplifier which presents a high dynamic range but also strong discontinuities of the order of 10 to 15 dB and the IF gain can be adjusted continuously. By combining the two gain controls, the overall gain is obtained.
[0013] However, when the RF gain is adjusted, the signal can be subjected to major transient disturbances, both on the phase and on the amplitude. In practice, to ensure the continuity of the adjustment, when adjusting the RF gain, an adjustment of the IF gain is essential. Since the RF and IF variable gains are applied either side of the surface acoustic wave filter which presents a high latency, it is theoretically possible to avoid damaging transient phenomena by sending the RF control before the IF gain control. In practice, it is not possible to completely avoid the transient disturbances on the signal and it is difficult to guarantee to the latter good characteristics in terms of noise and linearity in the context in which we are interested where a high wide dynamic range is necessary.
[0014] Furthermore, these disturbances have a harmful effect on the equalizer of the demodulator, making it lose its synchronization and therefore its ability to compensate for the effects of the transmission channel. This ultimately leads to the appearance of bit errors on the decoded signal.
SUMMARY OF THE INVENTION
[0015] To overcome these drawbacks, the invention proposes a gain control method for the RF and IF amplification stages of a bursty data frame reception system, each burst comprising frame structure symbols called preamble or midamble.
[0016] Following a step for evaluating the received signal strength, a gain recovery band enables the gain adjustment step of the RF amplification stage to be temporarily deferred until a frame structure symbol is received, during which the IF gain adjustment step takes place at the same time as that of the RF gain while retaining an overall gain linearly dependent on the input signal strength.
[0017] By combining the two gain controls, the advantage of the invention is to obtain an adjustment with the required high dynamic range while retaining good RF performance levels.
[0018] Furthermore, this method has the advantage of making it possible to improve the stability and robustness of a TDMA system in terms of equalization and AGC.
[0019] Preferably, the width of the recovery band corresponds to the possible trend of the strength of the received signal during one frame.
[0020] Preferably, following the change of gain of the RF amplifier, a reset indication is sent to the equalizer element of the demodulator of the reception system.
[0021] The invention also proposes an RF and IF gain control device of the amplifiers of a bursty data frame reception system, each burst comprising special frame structure symbols called preamble or midamble. This device comprises a control element which generates an RF and IF gain amplifier control signal, enabling the adjustment of the gain of the RF amplifier to be temporarily deferred until a frame structure indication is received, in a gain recovery band during which the adjustment step of the IF gain takes place in parallel with that of the RF gain, while retaining an overall gain linearly dependent on the input signal strength.
[0022] The control element generates a signal enabling the demodulator of the reception system to be reset following the modification of the RF gain.
[0023] The control element comprises a delay element for temporarily deferring the control of the IF gain amplifier relative to the control of the RF gain amplifier according to the delay introduced by the filtering element located between the two RF and IF amplifiers.
[0024] The control element comprises a switchable filter for filtering the control of the IF gain amplifier when the adjustment of the RF gain is not necessary.
[0025] The invention also relates to a method of controlling the gains of the RF and IF amplifier stages of a bursty data frame reception system with a plurality of antennas N, each burst comprising special frame structure symbols called preamble and midamble, and comprising a step for adjusting the gains of the RF stage and of the IF stage. Following a step for evaluating the received signal strengths of each of the N reception subsystems associated with each of the N antennas, gain recovery bands enable the step for adjusting the RF amplification gain of each subsystem to be temporarily deferred until a frame structure indication is received, during which the corresponding IF gain adjustment step takes place at the same time as that of the RF gain, while retaining for each subsystem an overall gain linearly dependent on the input signal strength.
[0026] Preferably, a single RF gain of one of the reception subsystems is modified on the current preamble, any other RF gain adjustments of the other reception subsystems taking place during subsequent preambles.
[0027] The invention also relates to a bursty data frame reception system with a plurality of antennas, each burst comprising special frame structure symbols called preamble or midamble, comprising N reception subsystems associated with the N antennas and a control device of the RF and IF gain amplifiers of the N reception subsystems. The device comprises a control element which generates N control signals for the RF and IF gain amplifiers enabling the adjustment of the gain of the RF amplifier of a reception subsystem to be temporarily deferred until a frame structure indication is received in a gain recovery band during which the IF gain adjustment step takes place in parallel with that of the RF gain, while retaining an overall gain linearly dependent on the input signal strength.
[0028] Preferably, following the change of the RF gain of one of the reception subsystems, the control element generates a signal enabling the demodulator of the system to be reset. The resetting of the demodulator takes place either on the equalizer element corresponding to this subsystem of the demodulator or on the combination or selection element of the demodulator.
DESCRIPTION OF THE DRAWINGS
[0029] The abovementioned characteristics and advantages of the invention, and others, will become more clearly apparent from reading the description that follows, given in relation to the appended drawings, in which:
[0030] FIG. 1 , already described, represents the structure of a bursty data frame;
[0031] FIG. 2 , already described, represents the simplified architecture of the tuner stage of the receiver of this system according to the state of the art;
[0032] FIG. 3 , already described, is a diagram representing the principle of adjustment of the overall gain of the tuner stage according to the state of the art;
[0033] FIG. 4 is a diagram representing the principle of adjustment of the overall gain of the tuner stage according to the invention;
[0034] FIG. 5 is an exemplary implementation of the system according to the invention;
[0035] FIG. 6 represents another exemplary implementation of the invention with multiple-antenna reception; and
[0036] FIG. 7 is a diagram representing the operating mode of the various adjustments in the case of multiple-antenna reception.
[0037] To simplify the description, the same references will be used in these latter figures to denote elements fulfilling the same functions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] There now follows a description, with FIG. 4 , of the principle of adjustment of the overall gain of the tuner stage according to the invention.
[0039] The adjustment of the gain of the stage is divided into two gain controls (RF and IF) each delivered to the tuner stage. The IF gain is represented by a solid line. This gain decreases linearly as a function of the input signal strength. This IF gain is adjusted regularly, on each symbol received as in a continuous system.
[0040] The RF gain is represented by a broken line. It is constant in the areas I, II and III and varies in successive levels. Now, the adjustment of this RF gain is allowed only if the received symbol is a preamble or a midamble. If the symbol is a data symbol, the adjustment of the RF gain is put back until the next preamble or midamble.
[0041] The overall gain, which is the sum of the RF and IF gains, decreases linearly when the input signal strength increases, so that there is, at the output, a constant strength signal. This figure shows the presence of a signal strength recovery band P delimited by a minimum value P 1 and a maximum value P 2 making it possible to obtain the same overall gain with two different RF and IF gain combinations. The values of the thresholds P 1 and P 2 are, for example, determined such that they correspond to the trend of the input signal strength during the transmission of a burst of data between two preambles/midambles.
[0042] These bands can be used to delay the adjustment of the gain between the moment when it is considered necessary, that is, on reception of a data symbol, and the moment when a preamble or midamble is received when this adjustment takes place. The adjustment of the RF gain is triggered when the signal strength reaches one of the limit values of the recovery bands P 1 , P 2 .
[0043] If the input signal strength is increasing then, at the threshold P 1 , the adjustment of the RF gain is considered necessary. The change of gain of the RF amplifier from the value G 1 to the value G 2 can take place only on the next preamble/midamble so as not to lose data during transient disturbances. A certain time delay corresponding to the time between which the adjustment decision has been taken and the next preamble/midamble will elapse before the adjustment of the RF gain takes place. During this time, the input signal strength continues to change within the recovery band, possibly reaching a value close to P 2 . On a preamble/midamble of the burst of data, the gain of the RF amplifier will therefore switch from the value G 1 to G 2 . Consequently, the IF gain will be switched to a value close to its maximum value.
[0044] When the input signal strength is decreasing, the gain adjustment process will be triggered when the signal strength reaches the. value P 2 and applied on the preamble/midamble following this triggering. The gain of the RF amplifier changes from the value G 2 to G 1 whereas the gain of the IF amplifier will switch to a value close to its minimum value.
[0045] This recovery band therefore makes it possible to adjust the gains only at the moment when this adjustment is allowed without disturbing the linearity of the overall gain. The width of this recovery band is calculated as a function of the trend of the signal strength between two preambles/midambles. The maximum signal strength variation difference between two preambles/midambles therefore corresponds to the width P 2 -P 1 of the recovery band.
[0046] In parallel, each other recovery band will have corresponding different input signal strength limit values and different gain levels G 2 , G 3 . A delay between the moment when the adjustment of the RF gain is deemed necessary and is allowed will therefore be possible.
[0047] FIG. 5 is an exemplary implementation of the device according to the invention. The stages of the reception subsystem affected by the invention are represented in this diagram. The OFDM (Orthogonal Frequency Division Multiplexing) modulated received signal is applied to the input of the tuner stage 40 . This signal is amplified by a variable gain RF amplifier 41 then applied to a mixer 42 which transforms the RF signal into an intermediate frequency IF signal. This signal is then filtered by a surface acoustic wave SAW filter 43 , then reamplified by a variable gain IF amplifier 44 at intermediate frequency. These amplifiers have gain controls originating from a control element (driver) 46 .
[0048] The amplified and filtered IF signal obtained from the tuner element 40 is applied to the demodulator 45 via an analogue-digital converter ADC 51 to be demodulated. The level of the adjustment required for the gain of the tuner stage 40 is calculated by the demodulator 45 . The input interface (or digital front end (DFE)) stage 45 - 1 of the demodulator makes it possible to evaluate the received strength of the signal from the tuner stage. This data is transmitted to the control element 46 on each new OFDM signal received.
[0049] An FFT (Fast Fourier Transform) demodulator stage 45 - 2 is used to demodulate the signal.
[0050] The signal is then equalized by the equalizer 45 - 3 , controlled by a signal emitted by the driver element 46 . A data processing (bit processing) circuit 45 - 4 , well known to those skilled in the art, is used to emit the desired demodulated signal.
[0051] For each new symbol, the measurement of the input signal strength is transmitted to the control element 46 which is responsible for generating the RF and IF gain controls sent to the tuner stage 40 .
[0052] There are two possible cases:
In the first case, the measurement of the input signal strength indicates that the adjustment of the RF gain is not necessary, which corresponds to the great majority of cases, so only the gain of the IF stage is adjusted on each symbol received regularly as in a continuous system and regardless of the type of symbol received (data or preamble). The IF gain control is filtered by the filter 48 in order to avoid excessively strong discontinuities on the strength level of the signal present at the input of the demodulator. Such level discontinuities could also disturb the equalizer. The selector 50 of the tuner element is therefore in the “filter” position. The filtered and selected signal is then applied, via a digital-analogue converter (DAC) 52 , as control of the IF amplifier 44 .
[0054] The equalizer 45 - 3 is then only updated in a manner well known to those skilled in the art by using, for example, a least mean squares (LMS) algorithm. In the case of a preamble, this update can be done with specific parameters providing the equalizer with a greater robustness.
In the second case, the value of the measured signal input strength is between a threshold P 1 and a threshold P 2 , so that adjustment of the RF gain is necessary, but the latter is allowed only if the received symbol is a preamble or a midamble. A frame indication is therefore transmitted to the control element 46 and makes it possible to await the presence of a preamble or midamble.
[0056] In the absence of a preamble or midamble, that is, if the adjustment is requested on reception of a data symbol, only the RF gain is modified as stated previously and the adjustment of the RF gain is put back until the next preamble/midamble. This is made possible by the recovery band P.
[0057] In the presence of a preamble/midamble, an RF gain adjustment control is emitted by the control element. In parallel, an IF gain adjustment control is emitted by the gain generator 47 . The selector 50 of the tuner element switches to the second position. A delay element 49 can be used to temporarily defer the IF gain adjustment control by a time T corresponding to the latency of the surface acoustic wave SAW filter inserted between the two amplifiers. The potential transient disturbances on the signal are thus compensated to the maximum.
[0058] Furthermore, this dual adjustment can take place only when a preamble is received, so the equalizer is not simply updated but completely reset.
[0059] In the case where the received signal strength varies little and is located around an area where the modification of the RF gain is necessary, it is possible to limit these modifications by applying the well known hysteresis mechanism.
[0060] By avoiding numerous pointless resets of the equalizer and using the latter in order to avoid the appearance of bit errors on the decoded signal on adjusting the RF gain, this method of updating the equalizer and of adjusting the gain of the RF stage makes it possible to improve the stability and the robustness of the demodulator and so to significantly improve its overall performance levels in terms of bit error ratio on the received signal.
[0061] FIG. 6 represents an exemplary implementation of the invention on reception with a plurality of antennas.
[0062] This invention can also be extended to the . case of a reception with a plurality of antennas with, for example, MRC (Maximum Ratio Combining) type combination or with selection. The implementation of the invention for reception with third order MRC type combination is represented in FIG. 6 . It could, obviously, be implemented for a different order MRC: either 2, or a number higher than 3. It can be seen that the presence of three independent reception channels # 1 , # 2 and # 3 , each channel respectively comprising a tuner element T, an analogue-digital converter ADC circuit and elements that are part of the demodulator 141 : a digital front-end element DFE, an FFT demodulation element and an equalizer E. The MRC (Maximum Ratio Combining) element for combining the different reception channels to optimize reception and the data processing circuit are, of course, common to the different reception channels. Each of the interface elements DFE of the channels # 1 , # 2 and # 3 sends a set point to the control circuit (driver) 146 which respectively manages the controls of the RF and IF amplifiers of the three tuners in the manner described using FIGS. 4 and 5 and notifies either the equalizer concerned or the MRC element when the modification of an RF gain of one of the reception channels is implemented to perform a reset.
[0063] In the recovery bands (see FIG. 3 ) of the IF and RF gains, the performance levels of the system are, for example, also optimized by allowing only a single RF gain modification at a time, at the time of the current preamble/midamble. The other adjustments take place at the time of the subsequent preambles/midambles. The control circuit 146 also manages the succession of these adjustments.
[0064] FIG. 7 is a diagram showing an example of an operating mode for which the priority in the order of the adjustments of the amplifiers is given as a function of the IF gain values. In practice, if the gain generation block (see FIG. 5 ) needs to modify several RF gains, then just one of them is modified on the current preamble. The order in which the RF gains are modified can be determined, for example, as a function of the IF gain values. The RF gain associated with the IF gain closest to a limit of its operating band is modified first. Other orders of priority of modifications of the RF gains can be envisaged. The input signal strength of the amplifiers can, for example, also bring about a priority order. This diagram represents the input signal strengths of the different channels # 1 , # 2 and # 3 , according to the trend of the data over time. The vertical lines symbolically represent the presence of preamble/midamble in the bursty data frame. The signal strength limit boundaries P 1 , P 2 delimit the recovery bands. The trend of the signal strength of the channel # 2 makes it possible to symbolically envisage a change of gain of the RF amplifier on the preamble 4 , the signal strength having reached the threshold value P 1 during the data preceding this preamble. The change of RF gain of the channel # 1 and of the channel # 3 would make it possible to symbolically envisage a change of gain of the RF amplifier on the preamble 5 . These changes should, therefore, take place simultaneously, but that of the channel # 3 is delayed so as to prevent the simultaneous changes of gain causing disturbances. The RF gain associated with the IF gain closest to a limit of its operating band is modified first. The change of RF gain of the channel # 3 will be delayed and will take place with the preamble 6 . The performance levels of the system are thus optimized.
[0065] The equalizer of the channel concerned is automatically reset following the change of the RF gain of this channel.
[0066] A variant entails sending to the MRC combination block an indication for it temporarily to disregard the data originating from the equalizer concerned, which can slightly simplify the algorithms involved at the equalizer level. | The gain control method for the RF and IF amplification stages of a bursty data frame reception system enables, following a step for evaluating the received signal strength, the gain adjustment step of the RF amplification stage to be temporarily deferred until a frame structure symbol is received, during which the gain adjustment step of the IF amplification stage takes place simultaneously with that of the RF gain, while retaining an overall gain linearly dependent on the input signal strength. The corresponding device comprises a control element 46 which generates the control signal for the RF and IF gain amplifiers | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application and claims the benefit of U.S. application Ser. No. 11/735,384, filed on Apr. 13, 2007. The above applications are hereby incorporated by reference as though set forth in full.
FIELD OF THE INVENTION
[0002] The present invention relates, in general, to a water capture/drainage and treatment system and a method of using the same. More particularly, the present invention relates to a modular system which captures, controls flow, and removes pollutants from water and treats stormwater runoff or other grey water. The system combines drainage infrastructure, a wetlands ditch and multi-level treatment in one linear modular unit.
BACKGROUND OF THE INVENTION
[0003] Water treatment systems have been in existence for many years. These systems treat stormwater surface run-off or other polluted water. Stormwater surface runoff is of concern for two main reasons: one because of the effects of its volume and flow rate, and two, because of the pollution and contamination it can carry. The volume and flow rate of stormwater is important because high volumes and high flow rates can cause erosion and flooding. Pollution and contamination are important because stormwater is carried into our rivers and streams, from there into our lakes and wetlands, and furthermore because it can eventually reach our oceans. Pollution and contamination that is carried by stormwater can have adverse affects on the health and ecological balance of the environment.
[0004] Beginning in 1972 with the passage of the Clean Water Act the federal government through the Environmental Protection Agency has mandated progressively tighter controls over the quantities of pollutants and contaminants that are allowed to be released into our nation's waters. These progressively tighter mandates also encompass control of peak flows and/or volumes and the rate at which they can be discharged into existing water ways or drainage infrastructures. These resulting mandates and controls have given birth to new programs and procedures collectively referred to as stormwater management. Devices and procedure that remove or reduce the pollutants and contaminates and/or control peak flows and volumes are often referred to as best management practices or BMPs. BMPs utilize natural means, artificial or man-made means, and even combinations of either and/or both. Some examples of these BMPs include trash filters, sedimentation basins, retention and detention ponds, wetlands, infiltration trenches, grass swales, various types of media filters, and various types of natural filter systems including sand filters, and aggregate filters including natural and artificial wetlands. These BMPs typically use one or more mechanisms to remove the pollutants and contaminates. These mechanisms include sedimentation, filtration, absorption, adsorption, flocculation, stripping, leaching, bioremediation, and chemical process including oxidation reduction, ion exchange, and precipitation.
[0005] Furthermore, stormwater treatment systems can also be classified in relationship to the treatment level in which they are being used. In this respect the term treatment is generally used to describe the unit processes that that are used to reduce the quantities of pollutants and containments in stormwater runoff. For example, basic or pre-treatment typically refers to the removal of gross solids, sediments and larger debris through the processes of settling and screening, while enhanced or advanced treatment typically refers to processes for reducing targeted pollutants; filtration being the main form of enhanced treatment for stormwater. Filtration utilizes a combination of physical, chemical, and biological processes. Types of filtration greatly vary dependent on the media use. Medias can be both inert and/or sorbent and are also strongly linked to natural biological processes that thrive in and/or around the media environment. Advanced filtration techniques especially include chemical and biological processes and generally include, but are not limited to processes that bring stormwater in contact with plants including both macrophytes and microphytes, plants that are both visible and invisible to the naked eye. One type of stormwater treatment system that is especially effective at advanced treatment is known as a wetlands system or often simply referred to as wetlands.
[0006] When creating a constructed wetlands, the objective is to minimize the size of the media to maximize the surface area of the media and to also maximize contact time with possible biofilm which can grow on the media, but also to provide media sufficiently large so that the interspacing will not be occluded with the sedimentation that is being carried in the treated water. Accordingly, as a matter of practicality it makes sense to remove as much sediment as possible before allowing the water to enter the wetlands system. In this respect the design of an effective treatment system would contain sufficient screening to remove trash and debris, sufficient sedimentation to remove sediment to a level sufficient to maximize the use of the wetlands. To preserve efficient operation of the system, the system should be operated at an appropriate flow rate that maintains and preserves the life and operation of the system as a whole. The average or mean time that water remains in contact with the wetlands system is termed the hydraulic resident time or HRT of the wetlands.
[0007] Given uniform flow through the sediment chamber, the sedimentation HRT is proportional to the volume of the chamber and inversely proportional to the flow rate. The time required for a particle to settle a specific distance is often referred as the settling time for that particle size and density. Because deeper settling chambers require a greater distance for particles to settle, deeper settling chambers have longer respective settling times. And, because the volume of a sediment chamber is also proportional to the depth of the chamber, increasing the depth increases both the volume (and thereby the HRT) and the settling time. Therefore, increasing the depth of the chamber increases the HRT, but may not increase settling efficiencies since the distance to settle increases proportionally with increase in HRT. Accordingly, the overriding principle of achieving effective sedimentation is to provide the maximum surface and floor areas in the chamber as possible. Other considerations are to increase the path length through the sediment chamber to increase the uniformity of the flow and to prevent high flow rate conditions from re-suspending existing sediment (often referred to as scouring).
[0008] In a similar manner, the basic separation principles that apply to the settling of particles more dense than water apply to particles that are less dense than water except that the particles float to the surface rather than settle to the bottom of the chamber. Because oils and hydrocarbons are typically less dense than water, because these products can often be separated mechanically by flotation, and because the products can create adverse biological demands on a wetlands system placed downstream of the sedimentation and flotation chamber, it makes sense to allow the floatable products to remain in the chamber and to remove the out-flow water from below the surface.
[0009] Because the objective of a sedimentation and flotation chamber is to remove sediment and floatable products from the incoming water, the accumulated sediment and floatable products will require periodic removal. Systems that are configured to allow easy removal of these products will undoubtedly provide reduced maintenance costs.
[0010] Flow-rate control is another consideration. Because the performance of some BMPs like sedimentation and flotation chambers and wetlands systems is dependent on hydraulic resident times (HRTs), optimum performance can be obtained by having sufficient control to not allow flow rates to vary excessively beyond certain limits. Devices that can be used to control the flow rate include bypass controls and inlet and outlet control systems.
[0011] Because some treatment locations may have high levels of specific pollutants and contaminates, specific configurations using additional BMPs may provide benefits and advantages above typical or standard configurations. Such BMPs may include additional filter systems, additional media chambers, aeration, bioremediation systems, irrigation systems, and mixing manifolds. Any system that can be configured to accommodate additional devices and methods of pollution and contaminate removal is by definition a more versatile BMP. Due to the lack of ground area for treatment systems in urban areas there is also a need for a system which can be placed in parking lots or other cement covered areas.
[0012] There is, thus, a need for a wetlands stormwater treatment system which can treat high levels of specific pollutants and contaminants and can be easily placed in urban concrete covered areas.
SUMMARY OF THE INVENTION
[0013] This invention involves a process and method for manufacturing and using a complete stormwater management system, which performs both drainage (infrastructure and flow control) and treatment (multi-level and multi-stage) tasks, and incorporates a wetlands water treatment system (“system”) which is reliable, dependable, effective, low maintenance and structurally sound. This is a self-contained storm water management system incorporating a wetlands treatment system. It can be placed in parking lots, on the side of a road, on the side of a free way, under a road way or in another area where polluted run-off needs to be captured and treated.
[0014] This is a system and method wherein the influent, which includes but is not limited to storm water, run-off water, polluted water or other liquid, is passed through a stormwater grate or curb opening, and/or inflow pipes located on the side of the catch basin. The influent which flows into the stormdrain is directed into a screening type catch basin insert filter, the influent next flows into a preliminary wet basin, then the pretreated influent will pass through the primary filtering devices, this treated influent then enters an enhanced subsurface flow gravel wetland which can be created by a ditch, hole or man made chamber. The influent passes through the wetland where additional pollutants and particulate matter is removed. The treated influent is discharged at a controlled rate from the wetland through an outlet flow control device known as the variable level treatment component (VLT Component). The VLT Component is designed in such a way to offer variable discharge rates and thus variable treatment levels over a range of flows. The system is also designed with an internal component and system bypass, which allows higher flows to bypass the wetlands in situations of high water run-off. The internal bypass eliminates loss of previously captured pollutants and particulate matter. The bypass pipes are configured with perforations to offer component bypass, which will offer isolated component bypass in the case of one component becoming clogged. The system performs the tasks of capturing (drainage infrastructure), treatment (multi-level and multi-stage), controlling flow, and bypassing higher flows (internally), which makes the system inherently a complete stormwater management device. This invention removes trash, litters, debris (organic and non organic) solids, sediment, total suspended solids (“TSS”), metals (dissolved/particulate), nutrients (dissolved/particulate), oils, hydrocarbons, polycyclic aromatic hydrocarbon (“PAH”), and pathogenic bacterium contaminants from the influent.
[0015] This system can be placed underground, below concrete, such as parking lots or park areas. The system top can also be placed at grade so as to function as an island to be filled with plants in the middle of a parking lot, its perimeter or other area. The systems shape is specifically designed to be easily used given the space constraints on development sites given the current standards of land use, including landscape requirements and current drainage infrastructure configurations. Segments can be added to the wetlands portion such as digging additional ditches or holes, increasing the length of the ditch or adding man made chamber of this system to increase its length and filtration capacity. These ditches or segments can be added at an 90 degree or less angle from one another thus allowing the wetlands chamber to be configured in various shapes for example an L, S or U shape. The system is designed to work with current parking lot and street designs, including drainage, logistics and landscape. The systems long length and capability to have a narrow width make it ideal for street rite-of-ways, including landscaped and or sidewalk/walkway areas. The system is specifically designed to be used as part of the layout of current parking lot islands. The system's landscaped wetland element adds to the aesthetics and current design of parking lot islands and perimeters. Many cities' regulations require that parking lots which cover large surface areas have an islands and perimeters which incorporate plants or trees. This system is able to meet this need as well as functioning as the water drainage and treatment structure.
[0016] This system is self contained in its own housing and has the ability to utilize the natural environment. The system and housing is easy to maintain and construct. The system and system housing can be fabricated, built, and assembled in a broad range of sizes and materials to accommodate and treat a broad range of influent flow rates. The functional components of the system can be selected, sized, tailored, and assembled to provide a range of performance and options from basic configurations to customized configurations which provide levels of performance suited to specific or individual situations which may require various unique solutions to treat stormwater or even other wastewater.
[0017] The system is capable of treating large volumes of polluted or contaminated water. Contaminated water or run-off can include urban run-off, agricultural run-off, and urban, agricultural, commercial or industrial wastewater. This system is beneficial and can be used in many locations, some locations are residential subdivisions, commercial developments, retail and industrial sites, roads and highways, reconstructions, habitat restorations, lake shores, marinas and landings, collection pools, parking lots, transportation terminals and maintenance facilities. The system configuration is adaptable to the local conditions permitting its effective use wherever water treatment is needed or desired. This system is designed to be its own drainage collection structure and to connect to existing drainage collection structures. The system can be manufactured in various depths, lengths, and widths. It contains a vegetative submerged bed, which houses the wetlands system, where plants may grow. The vegetative submerged bed can be contained in a ditch, hole or manufactured chamber. The system has a variable discharge rate (1-450 gal/min) allowing it to be used in any type of soil and both landscaped and hardscaped areas. The variable and adjustable discharge rate will also meet possible hydromodification requirements (volume based) and/or be sized as a flow based treatment system. Thus, in these types of situations the unit will not only provide treatment, but also necessary flow control. The system also has an internal bypass component that will bypass higher flows around the different treatment components.
[0018] In this system, the influent enters into a catch basin chamber, containing various treatment filters. From the catch basin chamber, influent flows through pipes into the vegetative submerged bed of the wetlands chamber. As influent flows through the root zone of the vegetative submerged bed microbes metabolize petroleum hydrocarbons, nitrogen and other pollutants. The pollutants are attenuated via the process of filtration, absorption, adsorption, bio-accumulation and bio-remediation. Precipitation of metals and phosphorous occurs within the wetland substrate while biochemical reactions, including decomposition, provide treatment of stormwater prior to discharge.
[0019] Influent flows into or is piped into the catch basin where the screening device captures larger sediment and gross solids. Screened influent flows to the bottom of the settling chamber where particles fall out to the bottom of this chamber. The catch basin may also contain filtration panels which contain filtration media for additional particulate filtration. The lowest 6 inches of this chamber are below the pipes which flow into the vegetative submerged bed. The influent flows outward through the perimeter filters media walls and in some embodiments through the added filtration panels. The treated influent flows from the settling chamber through water transfer perforated pipes into the vegetative submerged bed. The pipes extend a distance into the vegetative submerged bed and each contains vertical and horizontal slits for the influent to flow uniformly into the media, this set-up allows the influent to be easily distributed over a large surface area. The influent then flows through the filtration media and exits the system through a slotted exit pipe. The exit pipe is formed in an elbow shape allowing each end to extend through the concrete wall and express the treated influent into the discharge chamber. The discharge treatment chamber is covered with fiber glass or steel doors so as to allow easy access to clean out this chamber. The treated influent flows from this discharge chamber through the outflow pipe into the surrounding soils or through a pipe into a secondary storage facility or discharges to the existing drainage discharge infrastructure.
[0020] The set-up of this system allows it to process a large volume of storm or grey water. There are outlet control valves on the pipes leading from the wetland chamber to the discharge chamber. This valve can be used to set the desired discharge rate over a range of varying head pressures. It can also be closed to contain pollutants or maintain sufficient influent in the system. The outlet control valve can be a simple ball type valve which can limit the amount of influent which can be discharged from the system. The influent from the control valves flows unrestricted through the outflow pipe. The system can sit either below ground, flush with the ground or at any level above ground. In a system that sits flush with ground level, the filtration media can be planted with various types of plants, trees or shrubs.
[0021] The catch basin chamber and the discharge chamber as well as the embodiments which contain a wetlands chamber in underground configurations, rather than a ditch, are equipped with hatches to allow access for cleaning or maintenance of the system. In a system which sits a distance below the ground, three access ports for the catch basin/pre-treatment chamber, wetland chamber and discharge chamber are allowed through either a manhole or a tube extending upward to the ground surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the objects, advantages, and principles of the invention. In the drawings:
[0023] FIG. 1 is a top plan view of an embodiment of an in-line wetlands water treatment system;
[0024] FIG. 2 is a top plan view of an embodiment of an in-line wetlands water treatment system where the wetlands chamber is a ditch;
[0025] FIG. 3 is a front elevational view of an embodiment of an in-line wetlands water treatment system;
[0026] FIG. 4 is a front elevational view of an embodiment of an in-line wetlands water treatment system where the wetlands chamber is a ditch;
[0027] FIG. 5 is a left side elevational view of the catch basin/pre-treatment chamber of the in-line wetlands water treatment system shown in FIG. 1 ;
[0028] FIG. 6 is a perspective view of an exemplary environment for the in-line wetlands water treatment system of FIG. 1 and shows the in-line wetlands water treatment system placed in the ground;
[0029] FIG. 7A is a perspective view of the in-line wetlands water treatment system with breaks in the wall and the floor to allow the addition of wetlands segments;
[0030] FIG. 7B is a perspective view of the in-line wetlands water treatment system pulled apart to show where additional wetlands segments can be added;
[0031] FIG. 7C is a perspective view of the in-line wetlands water treatment system pulled apart with a wetlands segment being added;
[0032] FIG. 7D is a perspective view of the in-line wetlands water treatment system with the addition of a elbow-shaped wetlands segment;
[0033] FIG. 8 is a perspective view of the in-line wetlands water treatment system placed in the ground with the addition of wetlands segments to allow it to be configured in various shapes;
[0034] FIG. 9A is side view of the catch basin of the in-line wetlands water treatment system showing two filtration panels inserted; and
[0035] FIG. 9B is a filtration panel which can be used in the wetlands water treatment system or other water treatment systems.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] After reading this description it will become apparent to one skilled in the art how to implement the invention in various alternative embodiments and alternative applications. However, all the various embodiments of the present invention will not be described herein. It is understood that the embodiments presented here are presented by way of an example only, and not limitation. As such, this detailed description of various alternative embodiments should not be construed to limit the scope or breadth of the present invention as set forth below.
[0037] With reference to FIGS. 1 and 2 two embodiments of an in-line wetland water treatment system (“system”) 100 are shown and will be described. This system 100 is composed of three main congruent compartments set-up in a linear fashion, a catch basin/pre-treatment settling chamber (“catch basin”) 200 , enhanced sub surface flow “SSF” wetlands chamber (“wetlands chamber”) 300 or wetlands ditch 305 ( FIG. 2 ), and a discharge chamber 400 . In one embodiment, the wetlands chamber 300 ( FIG. 1 ) or ditch 305 ( FIG. 2 ) can be modular so that additional segments or ditches can be added to lengthen this chamber.
[0038] In one preferred embodiment the catch basin 200 is covered by a grate 210 or other permeable covering into which the influent, including but not limited to storm water, run-off water, polluted water or other liquid, flows. Influent can also enter the catch basin 200 through one or more inflow pipes 220 . The catch basin 200 has walls and a floor. Some embodiments contain an inflow pipe, while others do not. Once the influent enters the system 100 it flows through a series of filters which will be described in detail in FIGS. 2 , 3 and 7 and then exits the catch basin 100 through two or more inlet transfer pipes 230 . The inlet transfer pipes 230 pass from the catch basin 200 through the separation divider 240 into the wetlands chamber 300 ( FIG. 1 ) or ditch 305 ( FIG. 2 ). The inlet transfer pipes 230 are perforated once they enter the wetlands chamber so that influent can flow out. The inlet transfer pipes 230 extend a distance into the wetlands chamber 300 and make a 90-degree angle to form a “U” shaped pipe within the wetlands chamber 300 .
[0039] The catch basin 200 is specifically designed with a high flow bypass 320 to direct flow around the treatment components at flows higher than intended for the treatment component(s) or in the case of clogging of one component. The system 100 is equipped with two component bypass pipes 320 in instances when the inflow of the influent coming in is too high. The bypass pipes 320 transfer the influent past the wetlands chamber 300 directly to the discharge chamber 400 once it passes through the first level of filtration. The bypass pipes 320 have sections of perforation 325 ( FIG. 3 ) to allow some influent to flow into the surrounding wetlands filtration media. These perforations allow for individual component bypass.
[0040] The wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) is a treatment chamber containing a vegitative submerged bed 370 which is a combination of rock substrate and various media mixtures, which can be configured with two or more baffles 310 to isolate pollutant movement from the inlet to outflow ends of the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ). The wetlands chamber 300 ( FIG. 1 ) has walls and a floor. The wetlands ditch 305 ( FIG. 2 ), also referred to as a gravel pit, infiltration pit or bio swale, is a hole or ditch dug in the ground and then filled with filtration media and other components set forth in more detail with reference to FIGS. 3 and 4 to comprise the vegitative submerged bed 370 .
[0041] In one embodiment additional segments can be added to the wetlands chamber 300 . The walls of the chamber contain a break 505 (FIG. 7 A,B) where they fit together and are latched or clamped for connection to one another. A new wetlands chamber segment 530 ( FIG. 7C ) or multiple segments can be added to increase the length of the system. The segments can also be manufactured to form a corner or elbow FIG. 7D . When a segment is formed in a corner or elbow configuration a transfer chamber 540 ( FIG. 7D ) is added at the joint. In the case of a wetlands ditch 305 ( FIG. 2 ) additional ditches can be dug and the discharge chamber 400 can be moved to the end to the new ditch segments. In the case of wetlands ditches 305 ( FIG. 2 ) a transfer chamber 540 ( FIG. 7D ) can be added between the interconnected ditches. The transfer chamber 540 allows water to pass between the two portions of the wetland segment or ditches. The transfer chamber 540 may also be covered by a man hole or other access part to allow entry into the transfer chamber 540 . A corner or elbow segment allows the system to be formed into a L, U, or S shape FIG. 8 . By adding wetlands segments or ditches to the system the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ), size, length, the HRT, and flow path are increased, thus increasing pollutant removal efficiencies and system treatment capacity. The segments can be built or the ditches can be dug at a fraction of the cost of the entire system, and, as a result, an increased performance can be offered for minimal cost. In the case of a wetlands chamber 300 the wetlands segments 530 lock together with various joint configurations making assembly time efficient and easy.
[0042] The wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) is designed with both aerobic and anaerobic zones to enhance removal of different pollutants of concern. The wetlands chamber 300 ( FIG. 1 ) or ditch 305 ( FIG. 2 ) incorporates various levels of stonewool media slabs 350 ( FIGS. 3 and 4 ) that create propagation zones for plants. The physical characteristics of the stonewool media 350 will help maintain higher moisture levels throughout the height of the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ). Higher moisture levels will help maintain the living biofilm throughout the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ). The media will also create an environment that will allow prediatorial bacteria to flourish, thus raising the ability of the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) to treat specific pollutants. The media will also be configured in such a way to provide restrictions on the vertical flow of passing influent. This will help provide further filtration and protection of captured pollutants during higher flow conditions.
[0043] Once influent enters the wetlands chamber 300 ( FIG. 3 ) or wetlands ditch 305 ( FIG. 4 ) through the inlet transfer pipes 230 it travels horizontally through the wetlands chamber 300 ( FIG. 3 ), wetlands ditch 305 ( FIG. 4 ), which contains gravel or other filtration media which makes up the vegitative submerged bed 370 ( FIGS. 3 and 4 ). This media creates an aerobic and an anaerobic treatment zone within the rock and various media that is suitable to different types of bacteria (including predatorial and protozoons). These organisms play a critical role in the capture, destruction, and transfer of various pollutants of concern. Influent flows through the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) and exits through the exit influent transfer perforated pipes 330 at the distal end. The influent flows into the discharge chamber 400 . From the discharge chamber 400 , the influent exits the system through the outflow pipe 410 .
[0044] FIGS. 3 and 4 are a cross-sectional perspective view of two embodiments of the in-line wetlands water treatment system. The influent that passes through the grate 210 flows first into a catch basin insert filter 250 . The catch basin insert filter's 250 function is to provide pre-treatment of incoming polluted stormwater. The filters within the insert filter 250 act as an screening and absorbing device targeting gross solids, sediments, letter, trash and other debris (organic and non-organic). The sediments, TSS and associated pollutants settle out of the rising influent column to the floor of the catch basin 200 . The system's 100 proportions are designed to allow sufficient surface area in the catch basin 200 to enhance settling of TSS typically found in stormwater runoff. The sedimentation component of the system 100 is followed by the primary filtration component of the described device. In one embodiment primary filtration is accomplished through a catch basin perimeter filter 260 . In an alternative embodiment primary filtration is accomplished through added filtration panels 700 ( FIG. 9A ), or alternatively through both the perimeter filter 260 and filtration panels 700 ( FIG. 9B ). This perimeter filter 260 is constructed of a metal mesh cage or plastic porous panels that are mounted to the floor or the walls of the concrete catch basin 200 . The metal mesh cage or plastic panels have four walls and in some instances a floor, each of the walls and the floor have an inner and outer metal mesh wall or plastic porous panel or shield; the outer wall is configured around the inner perimeter of the catch basins internal walls. The distance between the catch basin 200 walls and outer metal mesh or plastic panel wall of the perimeter filter 260 ranges from a few centimeters to several feet. The inner and outer metal mesh or plastic porous panel walls act as housing for filter media, which is contained between the two walls. The distance between the inner and outer metal mesh walls can vary between 2 cm and several feet in order to house media of varying thicknesses.
[0045] FIG. 4 is a cross-sectional view of the catch basin/pre-treatment chamber 200 of the system 100 . FIG. 4 shows a side view of the insert filter 250 and the perimeter filter 260 . The holes for the bypass pipes 320 are shown at the upper half of the catch basin.
[0046] Referring to FIGS. 3 and 4 the perimeter filter 260 is designed specifically to house stonewool filtration media slabs and/or other media. The slabs will be inserted between the inner and outer metal mesh or porous plastic walls of the perimeter filter. The perimeter filter 260 can vary in height between a few inches to 10 feet. The perimeter filters 260 is designed and configured to maximize filter surface area within the constraints of the structure it is housed, both in perimeter and height. This catch basin perimeter filter 260 forms a pervious barrier/chamber between the inner and outer areas of the catch basin 200 . The design of the perimeter filter 260 is to maximize internal metal mesh or porous plastic wall and thus media surface area, while minimizing distance between the inner wall of the catch basin 200 and outer metal mesh or porous plastic wall of the perimeter filter without inhibiting flow and/or access to the catch basin 200 outer chamber with standard cleaning/VAC equipment.
[0047] The influent entering the system 100 and then treated by the catch basin insert filter 250 will next enter the inner chamber of the catch basin 200 . The influent in this chamber will flow through the perimeter filter 260 and its housed media 260 to the wetlands chamber 300 . Through the process and related device of passing influent through the media, various pollutants are captured and thus removed from the flow stream. The stonewool media has specific physical and chemical properties that allow for high flow rates through its structure and also high level of removal efficiencies for various pollutants including but not limited to: TSS, phosphorous (particulate and dissolved), nitrogen (various forms and states), heavy metals, dissolved metals, and pathogenic bacterium.
[0048] Referring to FIGS. 3 and 4 , as the influent level rises in the catch basin 200 , head pressure builds and thus increases the flow rate through the perimeter filter 260 . Influent filtered by the prior components will then enter the enhanced SSF wetland chamber 300 ( FIG. 1 ) of enhanced SSF wetlands ditch 305 ( FIG. 2 ) of the treatment system 100 . The wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) houses the vegetative submerged bed 370 . The prior treatment components provide protection from overloading and potential clogging of the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ). The wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) contains rock or other filtration media. The rock and other various media substrate within the chamber play a critical role in the physical, chemical, and biological treatment of inflowing influent. The media, both inert and absorptive, not only treat the influent, but also creates an environment that allows for the growth and accumulation of bio film and various predatorial bacteria.
[0049] Additionally, the treatment in the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) is enhanced by vegetation 340 , which can be planted throughout the surface of the wetlands chamber 300 . As the vegetation 340 propagates and grows, the root zone establishes throughout the width, length and depth of the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ). The root zones help the following: transfer oxygen from the surface, create an ecological environment that enhances pollutant removal, and cause plant uptake, which has its own independent treatment benefits.
[0050] In the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ), sedimentation will continue to occur. Relatively larger particles will become trapped within the void space between the filtration media particles. Smaller particles and dissolved pollutants will be captured, transformed, consumed by the following biological and chemical processes. Biological nitrification and denitrification will occur in the vegetative submerged bed 370 , as may natural unassisted precipitation of dissolved pollutants on media, in particular phosphorus and metals. Vegetation 340 will develop on the filtration media surface. The vegetation 340 is sustained by dissolved organic compounds in the influent and contributes to biological intake, absorption, and trapping of pollutants. The vegetation 340 enhances removal of fine sediments, metals, nutrients, bacteria and viruses. The vegetation 340 also increases the rate of bioaccumulation of pollutants within the vegetative submerged bed 370 . Dependent on the specific characteristics of the filtration media and the amount of plant/root matter within the bed, the processes of ion exchange, adsorption, and absorption will occur. Dependent on the type and ratios of filtration media used, variations in the amount and effectiveness of the above processes will vary.
[0051] The wetland component is further enhanced by the incorporation of stonewool media slabs 350 . The media slabs 350 have multiple purposes: first, to help propagate the plants and to create zones throughout the depth of the chamber, second, to provide enhanced ecological zones for bacteria communities, water supply zones for plants, root establishment, and bioaccumulation zones that will capture pathnogenic bacteria, and, lastly, to allow for enhanced filtration for influent which exits the perforation sections 325 in the by-pass pipes 320 . The media slabs 350 can be placed anywhere in the vegetative submerged bed, at any depth or any angle. Among other pollutants, the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) of the system 100 increases the ability to remove nitrogen with the addition of an anaerobic environment in the lower half of the wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) which promotes denitrification.
[0052] Influent flow and discharge rate through the system 100 is controlled by the variable flow rate discharge (VFRD) component 420 . This component is located in the discharge chamber 400 of the system. The wetlands chamber 300 ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) and discharge chamber 400 are separated by a baffle 360 . Influent treated from the wetlands chamber ( FIG. 1 ) or wetlands ditch 305 ( FIG. 2 ) enters through perforations in a series of exit influent transfer pipes 330 which pass through the baffle 360 into the variable flow rate discharge riser (“VFRD”) 420 . The VFRD 420 is constructed of piping with multiple outlets and varying heights. Each of the multiple outlets is controlled by a flow control valve and/or flow control orifice 440 .
[0053] The VFRD 420 along with the systems component isolated bypass pipes 230 allows this system to offer variable level treatment (VLT). The influent then exits the system 100 through the outflow pipe 410 . By offering variable levels of treatment the system 100 has the ability to treat different intensity storm events, first flushes, and designated treatment flows at variable levels. By offering variable levels of treatment the system 100 is designed to properly treat specific pollutants of concern during the critical flow ranges of that specific pollutant. This design allows for treatment that maximizes not only efficiency but also feasibility. The systems component isolated bypass pipes 230 offers protection of system effectiveness if one component should clog or fail. By having components connected both in series and in parallel, the components can operate in both in series and independently.
[0054] FIG. 6 is a perspective view of an exemplary environment for the system 100 and shows the system 100 placed in the ground. This system 100 has been placed in a parking lot and the vegetation 340 has been planted on the surface. The influent would flow into the system 100 through the grate 210 . After the water passes through the catch basin 200 , the wetlands chamber 300 and the discharge chamber 400 , it exits the system 100 through the outflow pipe 410 .
[0055] Referring to FIGS. 9A and B filtration panels 700 are shown and displayed. A filtration panel 700 is composed of a parallel and perpendicular 360 degree (vertical and horizontal) flow matrix structure with maximized openings which allow water to freely flow through the panel in all directions. All walls of the filtration panel 700 are permeable to water allowing it to flow through. The matrix structure maximizes void space on all six sides while maintaining a high level of void space, greater that 50%. The filtration panel 700 houses filtration media which in a preferred embodiment has a thickness of 2 cm to several meters and is composed of fibers obtained from a melt of composition of about 80 to 90% diabase material and about 10 to 20% lime. The fibers of the media are very small with at least a majority having a diameter less than 15 microns. The filtration media is permeable to water allowing it to freely flow through the filtration panel 700 . The filtration panel 700 which houses the filtration media can accept and discharge water from all directions. The filtration panel 700 B can be mounted on the walls and/or floor of the catch basin 200 and/or it can be free standing within the catch basin. The filtration panel 700 provides structural support and protection for the media from incoming flows and helps to distribute flow over the entire surface of the filter. One or more filtration panels 700 can be added to the catch basin and can be easily removed and replaced.
[0056] The system 100 can be fitted with many optional components in various embodiments. Some of the optional components of the system 100 can be fitted with one or more of: a trash filter system, an up-flow sedimentation filter, an aeration system, a biomediation system with metering system, a media packaging system, a separate oil (floatable liquids) removable system, an adjustable flow curve outlook control valve, and/or a single or multi-staged advanced treatment filtration modules.
[0057] The above description of disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to the embodiments will be readily apparent to those skilled in the art, the generic principals defined herein can be applied to other embodiments without departing from spirit or scope of the invention. Thus, the invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principals and novel features disclosed herein. | A complete storm water management system and process which incorporates a wetlands water treatment system. This system creates an infrastructure, flow control which is multi-level and multi-stage. This is a modular system which includes three or more chambers and/or ditches through which the storm water or other influent passes and is cleaned. The influent which flows into a storm drain, curb inlet, or inflow pipe into the system is directed first into a screening type catch basin inset filter within the first chamber of the system. The influent is treated within the first chamber before it passes out of this chamber into the incorporated wetlands system. The water flows through the wetlands chamber or ditch where it is further filtered and decontaminated through both an aerobic and anaerobic process. In situations of high runoff there is a bypass component. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 272,578, filed on July 17, 1972 now abandoned.
BRIEF SUMMARY OF THE INVENTION
A coal solvent is injected into a seam of coal and the coal dissolves in the solvent. The coal solution is removed from the seam zone, conveyed to ground level, and is heated. One portion of the heated solution is recycled into the coal seam, and the other portion is processed to separate the coal from the solvent which is recycled to the coal seam.
For a further understanding of the invention and for features and advantages thereof, reference may be made to the following description and to the drawing which illustrates a preferred embodiment of equipment in accordance with the invention which is suitable for practicing the method of the invention.
DETAILED DESCRIPTION
Referring to the drawing, a coal seam 11 is shown at some finite distance beneath the ground level surface 13, and it is desired to extract the coal from the seam, without resorting to conventional shaft mining. In accordance with the method of the invention, a first tubular conduit or casing 15 is installed in a bore-hole 17 in the earth and the lower end portion 19 of the conduit 15 is perforated, as at 21, to allow fluid carried by the conduit to flow therefrom into the coal seam 11.
The tubular conduit or casing 15 is cemented in place, as at 23 in the manner oil-well casing is cemented in place. The tubular conduit or casing 15 is associated with one or, preferably, more similar tubular conduits or casings 25 spaced some distance away from the casing 15 and arranged in a manner disclosed in the prior art.
The tubular conduit or casing 25 is also cemented in a bore-hole 27, as at 29, and its lower end portion 31 is also perforated, as at 33, to admit fluid and coal solution to enter the casing 25.
The conduit or casing 15 is fluidly connected above the gound level surface 13 to the discharge side of a suitable pump 35 which is fluidly connected at its suction side to a conduit 37. The conduit 37 is fluidly connected by means of conduit 39 to a heater 41 of conventional construction that receives fluid and coal solution from the tubular conduit or casing 25, and to a solvent still 43 by means of conduit 45.
The solvent still 43 receives both coal in solution and solvent from a centrifuge or filter 47, which is an optional piece of equipment and from which, when used, mineral cake is removed through a conduit 49. Solvent that is separated from the coal in the solvent still 47 flows in a conduit 51 back into the pump 35 and is then forced down the tubular conduit 15 again. The coal product that is separated from the solvent flows from the solvent still through a conduit 53 into other apparatus (not shown) available for processing the coal. In order to regulate the flow of solvent and coal in solution into the centrifuge 47, a valve 55 is provided in conduit 57 connecting conduit 39 and the centrifuge 47.
In some applications it is desirable to add hydrogen from a convenient source of supply 59 to the pump 35, which hydrogen mixes with the solvent recycle being pumped down the conduit 15. The hydrogen aids in the digestion or solution of the coal and it also prevents the coal from coking while being processed and handled in accordance with the invention.
In operation, it is desirable and necessary, in order to effect any solution of the coal in the seam, to bring the coal-solvent interface to a temperature of at least 250° C. (480° F.) and, preferably, to a temperature in the range of 300° - 400° C. (570° - 750° F.). At the higher end of the temperature scale, the rate of dissolving coal is greater than at the lower end of the temperature scale.
Also, it is desirable and necessary in order to contact as much surface of the coal with the solvents as possible, to fracture the coal seam in the vicinity of the conduits 15, 29 according to well-known conventional techniques. The drawing suggests such a fractured coal seam between the conduits 15, 29.
In accordance with the present invention, once the method has become operative, a certain amount of solvent and coal are, after heating, returned to the pump through conduit 37, and the balance of the solvent and coal are diverted through the centrifuge 47 and the still 43. Then, the recycle solvent is returned to the pump through the conduit 51.
A benefit derived from the method of the invention is that heat is brought rapidly to the coal seam face and the pumping action provides agitation that enhances dissolving the coal.
It is contemplated that as much as 85 to 95% or more coal can be dissolved in accordance with the method of the invention, depending upon the coal itself and the solvent used. However, in order to avoid pumping new viscous digestion, it is proposed to operate in the range of from 10 to 20% coal solution.
By using one tubular conduit 15 to inject the hot solvents into the coal seam, and the other conduit 25 to carry the coal solution to the surface and to separating equipment, a great deal of coal surface is exposed to the solvent which results in fast dissolution of the coal.
Further, in accordance with the present invention, there is a minumum loss of solvent, and even at the termination of production from a particular coal seam, the residual solvent can be recovered by chasing it out with steam or hot water.
It is known from the prior art to hydrogenate coal underground with a hydrogenating agent. The hydrogenation is carried out at an elevated temperature and pressure which may be controlled from above ground. The hydrogenation reaction produces a liquid product which is readily recovered as a relatively heavy oil that may be further treated to produce motor fuels and other desired products.
The prior art teaches using free hydrogen or an organic compound capable of liberating hydrogen. Hydroaromatic oils act as solvents in the liquefaction of coal due primarily to their ability to transfer hydrogen to the coal. A typical liquid product obtained by underground hydrogenation comprises 60 to 70% liquid hydrocarbons and 10 to 30% gaseous hydrocarbons.
In contrast to the known prior art teachings, the method of the present invention includes the extraction of the in situ coal by dissolving and not by liquefying. That is to say, the method of the present invention dissolves and extracts coal in almost its original form whereas the liquefying method known from the prior art extracts a liquid product, not coal, comprising the liquid and gaseous hydrocarbons mentioned previously.
In accordance with one aspect of the present invention, the solvent is an aromatic hydrocarbon or creosote or heavy oil. The molecular configuration of the aromatic solvent is important. Phenanthrene and other 3 and 4 angular member ring compounds, such as fluoranthene, pyrene and chrysene, and N-containing 3-membered ring aromatics, like carbazole and acridine are suitable as solvents. These solvents can dissolve 85 to 95% or more coal, while linear aromatics, such as anthracene and fluorene can dissolve less than 25% coal. For example, phenanthrene will dissolve up to 95% of the organic matter in coal, whereas anthracene will dissolve only 24%. For this reason, a middle oil fraction, having a boiling point between 325° and 400° C. is usually preferred. While tetralin has proven to be a good coal solvent, it acts as a hydrogen donor, reverting partially to naphthalene, and for this reason it is impractical commercially.
The solvent can be any one of the preferred compounds or their mixtures (eutectic composition preferably) and should be heated to above the melting point, or dissolved in a suitable carrier liquid such as heavy oil, using a minimum of 5% of the preferred solvent in the heavy oil.
Those skilled in the art also will understand that the amount of coal which can be dissolved depends on the rank of the coal as well as the molecular configuration of the solvent. Using the solvents mentioned previously herein, up to about 95% of the organic matter is dissolved, thus permitting the separation of mineral matter and fusain. A substantial portion of sulphur is concomitantly removed.
From the foregoing description of one embodiment of the invention, those skilled in the art should recognize many important features and advantages of it, among which the following are particularly significant:
That the solution mining method of the invention is relatively simple and much less costly than conventional coal mining;
That there is a significant saving in plant and equipment for extracting coal by such solution mining from underground seams;
That the undesirable environmental results of conventional coal mining, like refuse piles, refuse fires, washery air and water effluents, should be eliminated with adoption of the solution mining method of the invention;
That the coal seam, with proper care and technique, should be sealed during and after completion of the solution coal mining so that acid mine drainage, a result of conventional mining practice, should not be a serious problem;
That the solution mining method of the invention could replace conventional strip mining practice with its serious environmental damage; and
That the personnel hazards of conventional coal mining are obviated by adoption of the solution mining method of the present invention.
Although the invention has been described herein with a certain degree of particularity, it is understood that the present disclosure has been made only as an example and that the scope of the invention is defined by what is hereinafter claimed. | A solvent of coal is pumped through pipes drilled into the earth to a coal seam. The coal is digested or dispersed into the solvent and solvent recycle, and is thereafter pumped as a solution up to the surface and processed to remove the coal from the solvent. The method produces low-ash coal, stripped of all the extraneous ash, leaving the inherent ash, and stripped of all the sulfur except the organic type. The method comprises making a coal solution in situ and bringing it to the earth surface economically, without the hazards and environmental problems of conventional coal mining and without the need of coal washing facilities. | 4 |
[0001] The present application claims priority to U.S. Provisional Application Ser. No. 61/524,208, filed Aug. 16, 2011, which is incorporated herein by reference.
FIELD OF INVENTION
[0002] Provided herein is technology relating to collecting and preparing samples. For example, the technology relates particularly, but not exclusively, to devices, systems, and kits that allow for the collection and preparation of a fecal sample for analysis.
BACKGROUND
[0003] Over 100,000 persons per year in the United States are afflicted with a cancer of the colon and rectum. When the number of colon and rectal cancers occurring each year is combined with the number of cancers occurring in other digestive organs, including the esophagus and stomach, cancers of the digestive system account for more occurrences of cancer than any other single form of the disease. Contrary to many other forms of cancer, early diagnosis and treatment of digestive tract cancer results in a cure rate of 80% to 90%. If, however, the disease is not detected until its later stages, the cure rate drops significantly. Thus, early detection of the disease is important for the successful treatment of digestive tract cancer.
[0004] Most cancers of the digestive tract bleed to a certain extent. This blood is deposited on and in fecal matter excreted from the digestive system. The presence of blood in fecal matter is not normally detected, however, until gross bleeding occurs—that is, until the blood is visible to the naked eye. Gross bleeding, however, is symptomatic of advanced cancers.
[0005] Early-stage digestive tract cancers, including pre-cancerous polyps, also tend to bleed, which produces occult (hidden) blood in the fecal matter. Other pathological conditions, such as Crohn's disease and diverticulitis, also produce occult blood in the fecal matter. Accordingly, test equipment and test procedures have been developed for use by physicians in testing for the presence of occult blood in fecal matter as an aid for diagnosing these and other medical conditions.
[0006] For example, a commonly used test for screening for colorectal cancer is a fecal occult blood test, which tests for the presence of hemoglobin in feces. The presence of hemoglobin in feces is an indicator of intestinal bleeding, which is frequently associated with colorectal cancer. When such fecal blood is detected, a patient can be referred for further medical testing.
[0007] Fecal immunochemical testing (FIT) is one type of assay used to detect hemoglobin indicative of fecal occult blood. FIT uses an antibody specific to the human globin protein of hemoglobin to measure the amount of blood in feces. To perform FIT on feces one first obtains a defined quantity of feces and suspend the sampled feces in a suitable liquid to prepare a feces suspension appropriate for testing. There is a need for a device that provides for an easy acquisition of a defined quantity of feces by a user and for the preparation and testing of a portion of the sample by a human or automated tester.
SUMMARY OF THE INVENTION
[0008] Accordingly, provided herein is a device for obtaining a fecal sample and preparing a suspension of the feces suitable for analysis, e.g., FIT. For example, in some embodiments, the technology comprises a device for collecting a sample, the device comprising a sample collection chamber bounded on a distal end by a penetrable seal and bounded on a proximal end by a septum, the septum comprising an aperture; a sampling rod adapted to fit through and seal the aperture, the sampling rod comprising a proximal portion having a proximal end, a distal portion having a distal end, an angled tip at the distal end, and at least one metering ridge near the distal end; and a solution comprising approximately 20 mM Tris (pH 7.4), 10% bovine serum albumen, 0.10% Tween-20, 0.095% sodium azide, 140 mM sodium chloride, 10 mM EDTA, and 15 μg/ml gentamicin. The metering ridge is designed for two primary purposes: first, the metering ridge provides a surface that facilitates the efficient acquisition of a fecal sample from a stool; second, the geometry of the metering ridge provides for the acquisition of a defined quantity (e.g., a volume or mass) of feces for the analysis. Embodiments of the metering ridges have particular designs and geometries that are advantageous for use of the sampling rod. For example, in some embodiments the metering ridge comprises a frustum of a cone, e.g., a right circular cone. Some embodiments provide that an axis of the frustum is coaxial with a longitudinal axis of the sampling rod and a base of the frustum faces the proximal end of the sampling rod. Moreover, in some embodiments the radius of the base of the frustum is approximately the same as the radius of the proximal end of the sampling rod. Some embodiments provide a series of metering ridges arranged in a “sawtooth” or “fish scale” pattern, e.g., in some embodiments the device comprises a plurality of stacked coaxial frusta to form a plurality of metering ridges.
[0009] During the development of particular embodiments of the technology, it was discovered that particular characteristics of the sampling rod are advantageous for use of the sampling rod. For example, in some embodiments the sampling rod is flexible, e.g., to allow it to bend. In some embodiments a cap is attached to the proximal end of the sampling rod, e.g., to seal the device, and in some embodiments a distal portion of the sampling rod has a radius approximately the same as the radius of the aperture and a proximal portion of the sampling rod has a radius larger than the radius of the aperture, e.g., to seal the aperture. That is, in some embodiments a junction of the distal portion with the proximal portion forms a stopper that seals the aperture when the distal portion is fully inserted through the aperture.
[0010] In some embodiments the device is designed to provide a metered sample for analysis. Specifically, after capturing a sample on the metering ridge, inserting the sampling rod through the aperture removes excess sample from the sampling rod and leaves a metered sample within the depressions of the metering ridge. The device is designed to provide access to the suspension of feces so that a portion is taken for testing by a human or an automated tester. Accordingly, in some embodiments the penetrable seal is penetrable by a pipette tip or needle. During the design of some embodiments of the device, it was discovered that an inserted pipette tip or needle sometimes collided with the sampling rod in the sample collection chamber. Such collisions may occur when a human is using a pipette or needle to obtain a portion of the suspension or when withdrawing the sample is automated, for example, by using robotics, and can result in errors in sampling or damage to sampling devices. As such, in some embodiments, the angled tip of the sampling rod deflects a pipette tip or needle that penetrates the penetrable seal. In some embodiments, the sampling rod is flexible and thus is able to move, e.g., to flex or bend in response to force, when a pipette tip or syringe needle collides with it.
[0011] The device is not limited in the types of samples that are obtained and prepared. Thus, while in some embodiments the device is used to sample feces, the sample in some embodiments is, for example, environmental matter (e.g., mud), biological matter (e.g., food), and industrial matter (e.g., sludge). Such examples are meant to be merely illustrative and not limiting and many other materials are suitable for sampling with the device.
[0012] The geometrical design of the device may take many forms. For example, in some embodiments the body is tubular, though it may also be square, rectangular, triangular, elliptical, or any other shape suitable to provide the required functions, e.g., manipulation of the device by a user and acquisition of a sample. Furthermore, the sampling rod may assume many forms. For example, in some embodiments the sampling rod is cylindrical.
[0013] In one aspect the device is designed for a user to provide a sample in one end and for a human or machine (e.g., a robot) tester to acquire a portion of the fecal suspension at the other end. Thus, embodiments provide devices comprising a penetrable seal through which a portion of the suspension is obtained. Some embodiments provide that the seal is made from foil. However, other materials are appropriate for the device provided the material seals the sample collection chamber while also being penetrable (e.g., by a pipette tip or by a syringe needle) such that a human or machine obtains a portion of the contents sealed within the sample collection chamber (e.g., a suspension of fecal matter in a solution). Some non-limiting examples of materials provided in various embodiments include paper, rubber, wax, and plastic.
[0014] Embodiments of the device have various physical characteristics with respect to materials and/or design. For example, embodiments of the device are made from, for example, polypropylene, polyethylene, polystyrene, and polytetrafluoroethylene. Moreover, in some embodiments the sample collection chamber has a volume of approximately 1-2 milliliters, in some embodiments the metering ridge provides a fecal sample of approximately 20 milligrams.
[0015] The devices provided herein find use in systems and kits for providing a fecal sample for testing. For example, some embodiments of the technology provided herein are systems for collecting a sample. These systems comprise a chamber functionality for holding a sample re-suspension solution, a penetrable seal functionality for sealing the chamber on one end and allowing access to the chamber by penetrating the seal functionality, a sampling functionality for contacting the sample and acquiring a portion of the sample, and a metering functionality for providing into the chamber functionality a defined volume of the acquired portion of the sample. Furthermore, the technology provides kits, embodiments of which comprise embodiments of the devices provided herein and an instruction for use. Moreover, in some embodiments the kits comprise a package in which to mail the collected sample.
[0016] Additional embodiments will be apparent to persons skilled in the relevant art based on the teachings contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other features, aspects, and advantages of the present technology will become better understood with regard to the following drawings:
[0018] FIG. 1 is a side view of an embodiment of the device provided herein.
[0019] FIG. 2 is a side section view of an embodiment of the device provided herein, comprising a body ( 1 ) and a cap ( 12 ), the body ( 1 ) comprising proximal chamber ( 11 ) and a distal sample collection chamber ( 10 ). The distal sample collection chamber ( 10 ) is bounded on a distal end by a penetrable seal ( 2 ) on a sealing surface ( 13 ) on the body ( 1 ), and is bounded on a proximal end by a septum ( 3 ), the septum comprising an aperture ( 4 ). The cap ( 12 ) is affixed to the proximal end of a sampling rod ( 5 ) adapted to fit through and seal the aperture ( 4 ). The sampling rod ( 5 ) comprises a proximal portion ( 6 ), and a distal portion ( 7 ) having an angled tip ( 8 ) at the distal end and at least one metering ridge ( 9 ) near the distal end.
[0020] FIG. 3 is an isometric section view of an embodiment of the device provided herein.
[0021] FIG. 4 is an exploded view of an embodiment of the device provided herein.
[0022] FIG. 5 is in a side view of an embodiment of the body component.
[0023] FIG. 6 is a side section view of an embodiment of the body component.
[0024] FIG. 7 is an isometric section view of an embodiment of the body component.
[0025] FIG. 8 is a side view of an embodiment of the sampling rod component.
[0026] FIG. 9 is a side section view of an embodiment of the sampling rod component.
[0027] FIG. 10 is an isometric section view of an embodiment of the sampling rod component.
[0028] FIG. 11 is an isometric view of an embodiment of the sampling rod component.
DETAILED DESCRIPTION
[0029] Provided herein is technology for acquiring a sample (e.g., a fecal sample) and preparing a suspension of the sample for analysis (e.g., a fecal immunochemical test). The device comprises two ends—one (proximal) end that is accessed by the user who acquires the sample and introduces it into the device for preservation and storage and the other (distal) end that is accessed by a human or automated tester for removing a portion of the resuspended sample for analysis. The features and components described herein combine to provide such functionality in a simple device that produces preserved and stable metered fecal samples for analysis (e.g., by FIT).
DEFINITIONS
[0030] To facilitate an understanding of the present technology, a number of terms and phrases are defined below. Additional definitions are set forth throughout the detailed description.
[0031] As used herein, “a” or “an” or “the” can mean one or more than one. For example, “a” widget can mean one widget or a plurality of widgets.
[0032] As used herein, a “penetrable seal” hermetically closes an opening of a chamber or enclosed space while the component is intact and is capable of being pierced or breached (e.g., by a needle or a pipette tip) to allow access to the contents sealed inside.
[0033] As used herein, the term “metered” means having a reasonably reproducible measured quantity.
Embodiments of the Technology
[0034] Although the disclosure herein refers to certain illustrated embodiments, it is to be understood that these embodiments are presented by way of example and not by way of limitation.
[0035] As shown by FIGS. 1-11 , the device comprises as principal components a sampling rod, a body comprising a septum and a penetrable seal, and a solution. Embodiments of the device, particularly in reference to the interactions of these and other components, are described below.
1 Sampling Rod
[0036] The device comprises as a first component a sampling rod ( 5 ). As illustrated, e.g., in FIG. 2 , the sampling rod ( 5 ) comprises a distal portion ( 7 ) and a proximal portion ( 6 ). In some embodiments the sampling rod is approximately 2.5 inches long. In certain preferred embodiments, the sampling rod is substantially circular in cross section for most of its length. The proximal portion ( 6 ) of the sampling rod ( 5 ) is adapted for manipulation by a user and the distal portion ( 7 ) is adapted to acquire a metered sample. In some embodiments, a cap ( 12 ) is attached to the proximal end. In preferred embodiments, the cap ( 12 ) is adapted to mate with and close the proximal end of the body ( 1 ) (see below), for example, by mated threads on the cap ( 12 ) and body ( 1 ), by a snap closure, by a friction seal, or by other closures by which a cap securely closes a vessel to seal contents inside the vessel. In some embodiments, mated threads on the cap ( 12 ) and body ( 1 ) provide for securing the sampling rod ( 5 ) with a half-turn screw fit to the body ( 1 ). In some embodiments, the cap ( 12 ) comprises textured features that facilitate gripping and manipulating the sampling rod ( 5 ) by the user.
[0037] One or more metering ridges ( 9 ) is/are located near the tip (distal end) of the distal portion ( 7 ) of the sampling rod ( 5 ) (see FIGS. 2 , 4 , 5 , and 8 ). In certain embodiments, each metering ridge is shaped like the frustum of a cone (e.g., a right circular cone, truncated by a plane parallel to the base). In preferred embodiments, the frustum has its base facing toward the proximal end of the sampling rod ( 5 ), and has its axis aligned with the longitudinal axis of the sampling rod. As is seen in the embodiments shown in the figures (e.g., FIG. 8 ), in some embodiments a series of axially aligned frusta are joined in some embodiments to make notched depressions in the distal end of the sampling rod (e.g., to form a serrated, saw tooth, or fish scale structure). In preferred configurations, the bases of the frusta have radii approximately the same as the radius of the distal portion of the sampling rod; thus, the radii of the tops of the frusta are smaller than the radius of the sampling rod.
[0038] The notched depressions of the metering ridges provide a structure within which to acquire a metered sample (e.g., a sample of approximately 20 milligrams). In use, rubbing and/or scraping the area comprising the metering ridges ( 9 ) on the stool to be sampled captures a mass of stool that covers the metering ridges ( 9 ) on the distal portion of the sampling rod. Furthermore, the metering ridges provide an effective way to collect a reasonably reproducible and defined volume and/or mass (e.g., approximately 20 milligrams) of feces for the sample. In particular, feces captured in the notched depressions remain associated with the sampling rod when the sampling rod is passed through a hole or aperture that is approximately the same radial size as the radius of the distal portion ( 7 ) of the sampling rod ( 5 ) (e.g., the aperture of the body septum as described below). The metering ridges comprise notched depressions having a defined volume for collecting a sample of a defined mass. Thus, when excess feces that is not present in the space defined by the notched depressions is scraped or rubbed from the sampling rod, e.g., by passage through an aperture, the feces remaining in the notched depressions has a volume defined by the size and shape of the notched depressions.
[0039] The sampling rod ( 5 ) is adapted to be inserted into the body ( 1 ), and, in particular, the sampling rod ( 5 ) is designed to fit through the body septum aperture, (a feature described in more detail below). Moreover, when inserted into the body ( 1 ), the sampling rod ( 5 ) is designed to seal the aperture ( 4 ) at the end of travel and thus seal the body sample collection chamber ( 10 ) (see below). In some embodiments, the device is designed to provide a seal at the aperture ( 4 ) that holds a minimum of 30 psi when internally pressurized with air. In particular, the sampling rod ( 5 ) comprises a proximal portion ( 6 ) and a distal portion ( 7 ). In certain preferred embodiments, the distal portion ( 7 ) has a radius that is smaller than the radius of the proximal portion ( 6 ) (see, e.g., the embodiment shown in FIGS. 2 and 8 ). Furthermore, in relation to the aperture ( 4 ) in the body septum ( 3 ), the radius of the distal portion ( 7 ) of the sampling rod ( 5 ) is smaller than the radius of the aperture ( 4 ) (e.g., very slightly smaller, such that excess feces is removed from the sampling rod ( 5 ) when the distal portion ( 7 ) passes through the aperture ( 4 )), and the radius of the proximal portion ( 6 ) is larger than the radius of the aperture ( 4 ). Consequently, the junction of the proximal and distal portions of the sampling rod ( 5 ) forms a plug or stopper that seals the aperture ( 4 ) (and thus the sample collection chamber ( 10 )) when the sampling rod ( 5 ) is substantially fully inserted into the body at the end of travel. In some embodiments, tightening the cap ( 12 ) onto the body ( 1 ) (e.g., by screwing) further secures the seal.
[0040] In some embodiments, the distal tip ( 8 ) of the sampling rod is angled or beveled (see, e.g., ( 8 ) in the embodiments shown in FIGS. 2 and 8 ). When inserting a pipette tip or syringe needle into the distal end of the body ( 1 ) to withdraw an aliquot of the feces suspension (as described below), the tip or needle may sometimes collide with the sampling rod and consequently interrupt or otherwise compromise the withdrawal of the proper amount and/or damage the apparatus or machine used to withdraw the sample. While this is problematic for a human operator, a trained human can realize what has occurred and makes another attempt at withdrawing the proper volume as an aliquot for assay. However, in an automated setting wherein an autonomous robot or semi-autonomous system retrieves the aliquot, collision with the sampling rod may damage the machine and/or cause improper sampling. Consequently, an improper volume will be tested and produce an inaccurate and potentially misleading result (e.g., a false negative or false positive result). To minimize or eliminate such episodes, embodiments of the technology provide a sampling rod ( 5 ) with an angled tip ( 8 ) that, when inserted into the body ( 1 ) after acquiring a fecal sample, deflects collisions with an inserted pipette tip, syringe needle, or other implement inserted through the penetrable seal ( 2 ) e.g., to withdraw an aliquot of the fecal suspension. Moreover, in some embodiments, the sampling rod is made from a material that is flexible, so that it flexes or bends out of the way when a collision occurs. Deflection and/or flexing minimizes or eliminates the mechanical stress and trauma to the sampler and/or improper sampling that is associated with collisions and thus aids in maximizing the reproducibility of sampling and testing.
2 Body
[0041] The device comprises as another component a body ( 1 ). The body comprises a proximal chamber ( 11 ) and a distal sample collection chamber ( 10 ) (see, e.g., FIG. 2 ). The two chambers are separated by a septum ( 3 ), and the septum comprises an aperture (e.g., a hole, ( 4 )) near its center that is just slightly large enough to allow passage of the distal portion ( 7 ) of the sampling rod ( 5 ) through it (see FIGS. 2 and 3 ). The long axis of the body has a length appropriate to contain the entirety of the sampling rod when the sampling rod is fully inserted into the body. In some embodiments, the outer diameter of the body is approximately 14 millimeters. When the sampling rod ( 5 ) is substantially fully inserted into the body ( 1 ) (e.g., at its end of travel into the body), the metering ridge ( 9 ) (and substantially all the acquired sample present within the notched depressions of the metering ridge) is located completely within the sample collection chamber ( 10 ) and thus is exposed there to any solution contained therein (see below). In preferred embodiments, the device is designed such that the sample contained within the metering ridge ( 9 ) contacts the solution in the sample collection compartment regardless of the orientation of the device.
[0042] The sample collection chamber ( 10 ) is bounded laterally by the body wall and on the proximal and distal ends by the septum ( 3 ) and by a penetrable seal ( 2 ) (see below, and FIG. 2 , e.g.), respectively. In some embodiments, the proximal end of the body ( 1 ) is adapted to mate with a cap ( 12 ) attached to the proximal end of the sampling rod ( 5 ), for example, by means of mated threads on the cap and body (e.g., for securing the cap and sampling rod to the body with a half-turn screw), a snap closure, a friction seal, or other features by which a cap securely closes a vessel. See, e.g., body ( 1 ) and cap ( 12 ) in FIG. 2 .
[0043] The body ( 1 ) is open on the distal end, e.g., the body comprises a hole on the distal end. The body ( 1 ) comprises a sealing surface ( 13 ) that is adapted to accept a penetrable seal on the distal end to cover the hole. See, e.g., sealing surface ( 13 ) in FIGS. 2 , 3 , and 6 . In some embodiments the penetrable seal ( 2 ) is recessed. In certain preferred embodiments, the penetrable seal ( 2 ) is recessed approximately 0.125 inches with respect to the distal end of the body. In some embodiments the distal end of the body is adapted to accept a removable cover or cap, e.g., a pop-off cap, to protect the penetrable seal. In preferred embodiments, the diameter of the hole in the distal end of the body ( 1 ) is smaller than the width of the distal end of the body so that a ring of material is present on the distal end surrounding the hole, providing a surface on which to apply a penetrable seal ( 2 ). See, e.g., the sealing surface ( 13 ) in FIGS. 2 and 7 . By affixing the penetrable seal ( 2 ) to the distal end of the body over the hole, the penetrable seal ( 2 ) hermetically closes the distal end of the body.
[0044] The sample collection chamber (e.g., sample collection chamber ( 10 ) in FIGS. 2 and 3 ) is adapted to hold a solution (e.g., the solution described below). In some embodiments, the sample collection chamber is adapted to hold a solution having a volume of approximately 2 milliliters. In some embodiments, when the sample collection chamber contains a solution, sample introduced into the chamber on the sampling rod is covered with the solution regardless of the orientation of the device. Furthermore, in certain preferred embodiments, when the sample collection chamber contains a solution, the sample collection chamber also holds a volume of air that allows for mixing of the sample with the solution. When the penetrable seal is secured to the distal end and the sampling rod is substantially fully inserted into the body to seal the aperture (e.g., at the end of travel for the sampling rod into the body), the solution is contained within the sample collection chamber such that it will not leak from the sample collection chamber.
[0045] In some embodiments, the seal formed at the aperture holds a minimum of 30 psi when the device is internally pressurized with air. In some embodiments of the technology provided herein (e.g., embodiments of kits), the device is supplied to the end user in this type of a configuration (e.g., preloaded with solution and sealed by the sampling rod and penetrable seal).
3 Penetrable Seal
[0046] A third feature of the device is a penetrable seal. In preferred embodiments, the penetrable seal ( 2 ) is affixed to the distal end of the body to cover the hole on that end, thus sealing the sample collection chamber ( 10 ) on that end (and thus preventing the escape of any solution and/or sample that is contained inside). See, e.g., penetrable seal ( 2 ) in FIGS. 2 , 3 , and 4 . The penetrable seal ( 2 ) is affixed to the body by any suitable means that adequately seals the distal end of the body, e.g., by an adhesive, crimping, friction, physical incorporation into the body when the body is molded, etc. For example, in some embodiments the penetrable seal is affixed to the body such that it provides a seal of the distal end that holds a minimum of 30 psi when the device is internally pressurized with air.
[0047] Furthermore, the penetrable seal is made from a material that can be penetrated, e.g., by a syringe needle or a pipette tip, to allow access to the sample collection chamber by a human user or an automated or semi-automated robot or other machine. Materials that are appropriate for the penetrable seal include, but are not limited to, foil, paper, rubber, plastic, and wax. The penetrable seal is made from a material that is chemically and biochemically compatible with the solution and samples that contact the device. The penetrable seal is strong enough to contain a solution securely (e.g., without leaking (e.g., the seal holds a pressure of 30 psi when internally pressurized with air)) within the sample collection space, while also being penetrable upon application of a low to moderate amount of force by a needle or pipette tip (e.g., a 1-milliliter pipette tip) pressed against the penetrable seal by a user, machine, or robot. For example, in some embodiments the penetrable seal comprises a laminated foil comprising a foil layer of approximately 0.001 inches and a polyester layer of approximately 0.005 inches. Such a foil product is available from commercial vendors (e.g., Hi-Tech Products). In some embodiments, other products are used that are suitable to meet the shelf life and sealing requirements.
4 Solution
[0048] The device comprises a solution in the sample collection chamber. In certain embodiments, the solution comprises Tris buffer, bovine serum albumin, Tween-20, sodium azide, sodium chloride, EDTA, and gentamicin. In preferred embodiments, the solution comprises the following components approximately in the indicated amounts and/or concentrations:
20 mM Tris buffer (pH 7.4) 10% bovine serum albumen 0.10% Tween-20 0.095% sodium azide 140 mM sodium chloride 10 mM EDTA 15 μg/ml gentamicin
[0056] The solution comprises components to break up, solubilize, and/or suspend the sample such that withdrawal of a portion provides an aliquot suitable for analysis. In addition, the solution comprises components to stabilize, preserve, and/or protect the resulting suspension so that the analytes to be tested (e.g., globin) do not degrade or become damaged between the time the sample is acquired and the time the sample is tested. The solution thus helps to ensure that the analysis of the sample (e.g., a FIT) accurately reflects the analytes (e.g., globin) present in the sample when the sample was acquired.
5 Materials
[0057] The body ( 1 ), sampling rod ( 5 ), and cap ( 12 ) are made from a material that provides structural soundness to the device and that is chemically and biochemically compatible with the solution and samples that contact the device. Embodiments of the device are made from plastics such as, e.g., polypropylene, polyethylene, polystyrene, and polytetrafluoroethylene. The sampling rod ( 5 ) is made from a material that provides sufficient strength to the rod for collecting from relatively rigid samples. For example, in some embodiments the sampling rod is made from an opaque polypropylene and in some embodiments the sampling rod is made from a filled polypropylene. In some embodiments, the sampling rod is flexible and is thus made from a material that provides the appropriate flexibility, e.g., a flexible polypropylene. In some embodiments, the cap ( 12 ) and the body ( 5 ) are made of the same material. Moreover, in some embodiments the body is made from a transparent polypropylene. Different materials may be suitable for different applications and sample types, and, in some embodiments, the body and sampling rod are made from the same material and in some embodiments the body and sampling rod are made from different materials. In some embodiments, the materials and composition of the solution are chosen to provide a shelf-life for the device of approximately 2 years.
6 Use of the Device
[0058] The device is designed to provide an easy way to collect and produce fecal samples for analysis such as FIT. Accordingly, it is designed for use by both the sample taker and the sample tester. The sample taker may be, in some uses of the device, a person who does not have medical or clinical training, and thus the device is easy to use for such lay users in acquiring the sample. Thus, in some embodiments the body is composed of opaque material, or is covered, e.g., with a label, such that the interior components (e.g., the proximal and distal chambers, the septum, and the inserted sampling rod) are substantially blocked from view of a user, e.g., to avoid confusion regarding the proper use of the device.
[0059] At the same time, the device is designed within the appropriate tolerances and with a design that allows for precise and accurate analysis of the sample by a human or machine tester. Generally, the device will be provided to the sample provider in an assembled form—e.g., the sample collection chamber is filled with a volume of solution, the distal end of the body is sealed with the penetrable seal, and the sampling rod is fully inserted into the body such that the aperture is sealed.
[0060] Upon producing a stool, the sample provider removes the sampling rod ( 5 ) from the body ( 1 ) and scrapes or spears the stool with the sampling rod ( 5 ) to cover with stool the distal portion ( 7 ) of the sampling rod ( 5 ) comprising the metering ridge ( 9 ). The sampling rod ( 5 ) is then placed back into the body ( 1 ) by inserting the sampling rod ( 5 ) through the aperture ( 4 ) and securing the cap ( 12 ) to the body ( 1 ) (e.g., by screwing it onto the body by means of mated threads). When the sampling rod ( 5 ) is inserted through the aperture ( 4 ) in the body ( 1 ), stool not present in the notched depressions of the metering ridge ( 9 ) (e.g., excess stool) is rubbed and/or scraped from the sampling rod such that it remains in the proximal chamber ( 11 ) and outside the sample collection chamber ( 10 ). Consequently, only the feces associated with the metering ridge ( 9 ) is introduced into the sample collection chamber ( 10 ) and the solution present therein. The solution then acts to break up, solubilize, and/or suspend the sample. In addition, the solution comprises components to stabilize, preserve, and/or protect the suspension. The user then returns the device to a laboratory, clinic, or other location for analysis. In some embodiments, the device is designed to be appropriate for return by mail.
[0061] Next, the testing facility retrieves a portion of the feces suspension for analysis (e.g., by FIT). A user or machine penetrates the penetrable seal ( 2 ) (e.g., by a syringe needle or a pipette tip) to withdraw an aliquot of the suspension. The device is designed for manipulation by a human tester, an autonomous machine or robot, and/or a semi-autonomous machine, as appropriate for the analysis. After the required aliquot of the suspension is withdrawn, the device and remaining fecal sample suspension may then by discarded as appropriate.
[0062] All publications and patents mentioned in the above specification are herein incorporated by reference in their entirety for all purposes. Various modifications and variations of the described compositions, methods, and uses of the technology will be apparent to those skilled in the art without departing from the scope and spirit of the technology as described. Although the technology has been described in connection with specific exemplary embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention that are obvious to those skilled in pharmacology, biochemistry, medical science, or related fields are intended to be within the scope of the following claims. | Provided herein is technology relating to collecting and preparing samples. For example, the technology relates particularly, but not exclusively, to devices, systems, and kits that allow a subject to collect and prepare a sample for analysis. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to rod assemblies; and, more particularly, to a rod assembly adapted to be mounted under a shelf or ceiling and receive hangers thereon.
2. Description of the Prior Art
Rod assemblies for hanging clothes or the like in a closet are well known in the art. There is a need for such assemblies which can be mounted under a shelf or ceiling and having an elongated tubular bar for receiving a plurality of hangers thereon. Many such assemblies have been suggested in the past. However, such assemblies take a considerable amount of weight since clothes are relatively bulky and heavy. Thus, various means have been suggested for assembling such devices and supporting them. For example, in U.S. Pat. No. 3,239,070, a hang rod assembly is disclosed. This assembly receives a mid support in the elongated tubular rod to support the same. However, an elongated channel must be formed in the rod to receive the support member which is expensive and weakens the rod. Further, hangers cannot slide along the rod past such support members.
U.S. Pat. No. 3,286,850 to Ruhnke discloses a similar arrangement and is likewise deficient. U.S. Pat. No 3,034,758 to Vagi shows a connector mechanism having a bracket connected to a shelf having a curved portion fitting into a pole. The parts cannot be quickly and easily disassembled, require careful machining of parts and do not allow hangers to move therepast.
There is thus a need for a rack assembly which can be quickly and easily manufactured, assembled and installed under a shelf or ceiling which provides firm mid support, yet allows hangers to move therepast.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a rod assembly which can be mounted under a shelf or ceiling having firm mid support.
It is a further object of this invention to provide such a rod assembly which allows hangers to move along the rod thereof past the mid support.
It is still further an object of this invention to provide such a rod assembly where the hangers can move along the rod without dislodgement of the midsupport from the rod should the hanger strike the mid support.
These and other objects are preferably accomplished by providing a rod assembly adapted to be mounted underneath a shelf ceiling having an elongated support bar for hanging thereon clothes or the like from hangers. The bar is supported at its mid position by a support member which provides firm support but allows the hangers to pass thereover without dislodgement if the hanger strikes the support member.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view showing the rod assembly of the invention mounted underneath a shelf or ceiling structure showing a portion of a conventional coat hanger mounted thereon;
FIG. 2 is a view taken along lines II--II of FIG. 1;
FIG. 3 is a view taken along lines III--III of FIG. 1;
FIG. 4 is a view taken along lines IV--IV of FIG. 2; and
FIG. 5 is a view taken along lines V--V of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 of the drawing, a rod assembly 10 is shown mounted to the underside of a shelf 11. It is to be understood that assembly 10 can also be mounted to a ceiling or the like, if desired. Assembly 11 is comprised of a pair of end brackets 12, 13. Brackets 12 and 13 are identical and each, such as bracket 12 (see also FIG. 2), includes a flange 14, which may have one or more cut-out areas 15, 16 to reduce weight and for aesthetic reasons, extending from a mounting plate 17. Each mounting plate 17 includes a plurality of apertures or holes 18 therethrough (FIG. 1) for receiving screws 19 or the like (FIG. 3) for securing plate 17 to shelf 11. The other end of flange 14 terminates in a cylindrical member or collar 20 (see also FIG. 4) receiving therein one end of an elongated rod 21. Rod 21 is of course also cylindrical to conform to the inner cylindrical surface 22 of collar 20 and may be of any suitable configuration with the interior of collar 20 likewise configured to receive rod 21 telescopingly therein. Rod 21 is preferably hollow on its interior 23 (FIG. 4) and closed off at its open end 24 by an end cap 25 (FIG. 4). End cap 25 includes an outer flanged cap portion 26 having a plurality of resilient fingers 27 extending interiorly into rod 21 and thus resiliently retained therein. As seen in FIG. 2, a set screw 28, such as in allen-type set screw, may be provided threaded into an aperture 29 in collar 20 to screw rod 21 to collar 20. Also, as seen in FIG. 2, although collar 20 and flange 17 may be separate pieces secured to flange 14, preferably the entire end bracket 12 is one integral piece.
As seen in FIG. 1, rod 21 extends between collars 20 in each end bracket 12, 13 as shown. In use, it is desirable, and necessary when rod 21 is relatively long and/or great weight is placed thereon, to provide some mid support for the rack assembly 10. Thus, one or more mid support brackets, such as bracket 30, may be provided on rack assembly 10. Bracket 30 (see also FIG. 3) includes a flange 31 preferably having one or more cut-out sections 32 leading from a mounting plate 33. Plate 33 includes a plurality of holes 34 (FIG. 1) receiving therein screws 35 (FIG. 3). Flange 31 terminates in an upwardly curved end 36 extending generally normal to the longitudinal axis of flange 31 having a L-shaped cylindrical pin 37 (FIG. 5) mounted thereon. Pin 37 thus includes a first elongated portion 38 secured to end 36 and preferably extending at a slight angle thereto and a second angled portion 39 extending from portion 38, preferably normal to the axis thereof. As seen in FIG. 5, rod 21 has a hole or aperture 40 in the wall thereof, preferably in its undersurface, with pin 37 received therethrough (FIG. 5). In assembling bracket 30 to rod 21 preferably after assembly of end brackets 12, 13 thereon, angled portion 39 is inserted into hole 40 (with the remaining portion of bracket 30 extending on the same side of rod 21 as brackets 12, 13,) then bracket 30 is twisted so that angled portion 39 has its longitudinal axis extending parallel to the longitudinal axis of rod 21 (FIG. 5). In this manner, bracket 30 is quickly and easily secured to rod 21.
As seen in FIGS. 1 and 3, a portion of a conventional coat hanger (not shown), such as hook portion 41, is shown disposed on rod 21. As seen in FIG. 3, hook portion 41 can slide along rod 21 and past bracket 30 without being obstructed thereby. Also, the positive lock provided by pin 37 and hole 40 does not result in dislodgement of the bracket 30 from rod 21 should the hanger hook or the operator's hand abut thereagainst. Thus, the bar 21 can't be lifted up and the angled pin 37 stops bar 21 from coming off bracket 30 if it is hit. Once bracket 30 is installed as heretofore disclosed, it must be twisted off to remove it from bar 21.
Bracket 30 can also be of separate interconnected parts but preferably is of one piece. Also, any suitable materials may be used, such as the various plastics, wood, metals, etc.
The rack assembly disclosed herein is a complete unit and can be quickly and easily put together and installed. The unique suspension for mid bracket 30 assures adequate strength and support for the bar 21 while providing for unobstructed hanger movement for the entire length of rod 21 between the end brackets 12, 13.
The invention herein results in a lightweight inexpensive assembly and eliminates the need for a solid bar. The rod 21 may be of a relatively small diameter yet won't collapse when carrying a heavy load.
There is thus disclosed a unique closet rod assembly which can be quickly and easily manufactured, assembled and installed yet provides great support and enables a plurality of coat hangers to be mounted thereon without interference from the mid support. In addition, accidental dislodgement of the rod from the mid support bracket is prevented. | A rod assembly adapted to be mounted underneath a shelf or ceiling having an elongated support bar for hanging thereon clothes or the like from hangers. The bar is supported at its mid position by a support member which provides firm support but allows the hangers to pass thereover without dislodgement if the hanger strikes the support member. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to and claims the priority benefit of German Patent Application No. 10 2015 114 329.1, filed on Aug. 28, 2015 and German Patent Application No. 10 2015 121 503.9, filed on Dec. 10, 2015, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a method for the automated production of a glass body comprising a diaphragm for a potentiometric sensor—in particular, for a pH sensor or another ion-sensitive sensor.
BACKGROUND
[0003] A conventional potentiometric sensor for detecting a measurement of a measuring fluid, such as a pH sensor for detecting the pH value of a measuring fluid, comprises a glass body with two glass tubes arranged coaxially to one another, wherein the outer glass tube is connected at one end to the inner glass tube, so that the outer glass tube is closed at this end. In a pH sensor with a glass electrode, the inner glass tube is closed at this end with a pH-sensitive glass membrane. The end section of the sensor that comprises the connection point of the inner glass tube with the outer glass tube and, in the case of a pH sensor with a glass electrode, the glass membrane, is designed to be brought into contact with the measuring fluid—by immersion, for example. This end section of the glass body comprises at least one diaphragm, via which an electrochemical connection is ensured between a reference electrode, which is arranged in the chamber formed between the outer glass tube and the inner glass tube, and a medium surrounding the sensor.
[0004] Conventionally, the production of such glass bodies requires a lot of manual labor and is very time-consuming. EP 1 692 080 B1 describes a method for the automated production of a glass body for potentiometric pH sensors. The method comprises the loading of a first spindle of a glass lathe with an outer glass tube and an inner glass tube, wherein the outer glass tube and the inner glass tube are arranged coaxially to one another and to an axis of rotation of the first spindle of the glass lathe, the inner glass tube and the outer glass tube each exhibit an end on the medium side, and the two medium-side ends are positioned at a defined axial position toward one another; the loading of a second spindle with an auxiliary glass tube, wherein the axis of rotation of the second spindle is coaxially arranged to the axis of rotation of the first spindle; the approach of the auxiliary glass tube to the outer glass tube; the fusion of the outer glass tube with the auxiliary glass tube; the creation of a connection between the outer glass tube or the auxiliary glass tube and the inner glass tube; the removal of the remains of the auxiliary glass tube; the creation of a medium-side opening of the inner glass tube; and the formation of a medium-side edge of the opening.
[0005] In the method described in EP 1692 080 B1, the outer glass tube may comprise a ceramic diaphragm in its medium-side end section, which diaphragm may be fused with the medium-side front face and which diaphragm is integrated, by fusing the medium-side end of the outer glass tube with the inner glass tube, into the outer tube of the glass body thus formed. The fixation of the diaphragm to a front face of the outer glass tube is thus a step that is upstream of the automated production method for the glass body, which, on the one hand, requires time and, on the other, a certain amount of logistical effort, in order to ensure that all of the outer glass tubes inserted into the spindle of the glass lathe are provided with a diaphragm that also meets the desired production tolerances.
BRIEF SUMMARY OF THE INVENTION
[0006] It is now the object of the present disclosure to provide a method for the automated production of a glass body that comprises a diaphragm and overcomes the disadvantages of the prior art. This object is solved by the method according to claim 1 and the device according to claim 13 . Advantageous embodiments are specified in the dependent claims.
[0007] The method according to the present disclosure for the automated production of a glass body comprising a diaphragm for a potentiometric sensor comprises providing a glass assembly, which comprises an outer tube and at least one inner tube running inside the outer tube, wherein the inner tube and the outer tube are arranged coaxially and wherein one end of the inner tube is sub stance-to-substance bonded to—in particular, fused with—a tube wall of the outer tube; producing at least one aperture running through the tube wall of the outer tube; positioning a porous diaphragm body, which comprises a coating of glass in at least one section, into the aperture; and creating a substance-to-substance bond between the tube wall of the outer tube and at least the section of the diaphragm body comprising the coating of glass. The diaphragm body preferably consists of a porous ceramic. The coating of glass is preferably closely connected or connected in a gap-free manner with the diaphragm body. All the steps described are preferably carried out automatically.
[0008] By introducing the diaphragm body into an aperture in the tube wall of the outer tube and by creating a substance-to-substance bond between the tube wall and the glass coating facilitating the substance-to-substance bond between the tube wall and the diaphragm body, the step of introducing the diaphragm into the glass assembly can be carried out in an automated manner together with further steps for the automated production of the glass assembly. It is not necessary to prepare the outer tube for the automated production of the glass assembly by affixing the diaphragm prior to loading the outer tube into a machine.
[0009] The substance-to-substance bond between the tube wall of the outer tube and the section of the diaphragm body comprising the coating may be produced by fusing the tube wall of the outer tube with the diaphragm body—in particular, by fusing the tube wall with the coating of glass of the diaphragm body.
[0010] In at least one embodiment, the glass assembly is arranged in a workpiece holder of a spindle of a lathe that can be rotated about an axis of rotation, so that the tube axis of the inner tube and the tube axis of the outer tube coincide with the axis of rotation, and wherein, in order to create the at least one aperture through the tube wall of the outer tube and to produce the substance-to-substance bond between the tube wall of the outer tube and the ceramic body, one or more gas burners and/or lasers are used, which are fixed on a tool slide that can be moved relative—in particular, orthogonally—to the axis of rotation of the spindle. The tool slide and the burner holder or laser holder arranged thereon are advantageously aligned orthogonally to the axis of rotation.
[0011] The step of creating the aperture running through the tube wall of the outer tube may comprise the following steps: local heating—in particular, melting—of the tube wall of the outer tube by means of a first gas burner or laser; and applying an overpressure in a space enclosed between the inner tube and the outer tube. The overpressure in the space enclosed between the inner tube and the outer tube causes the locally heated or locally melted region of the tube wall to burst, so that an aperture through the tube wall of the outer tube is formed.
[0012] The step of introducing the porous ceramic body into the aperture may comprise the following steps: automatic holding of at least one diaphragm body by means of a holding device arranged, in particular, on a second tool slide that is movable relative to the glass assembly held in the workpiece holder; and inserting the diaphragm body into the aperture by means of the holding device, wherein the holding device and the glass assembly are moved relative to each other in order to insert the diaphragm body into the aperture.
[0013] The step of creating a substance-to-substance bond between the tube wall of the outer tube and at least the section of the diaphragm body comprising the coating of glass may include the fusion of the coating of glass by means of a heat source—for example, by means of a burner flame or by means of a laser beam guided around the diaphragm body inserted into the aperture. The glass assembly may comprise two inner tubes arranged coaxially, one behind the other, in the outer tube, wherein the inner tubes are substance-to-substance bonded to—in particular, fused with—the outer tube at their end facing the respective other inner tube. The ends of the outer tube may be held respectively by a workpiece holder of rotatable spindles of a lathe that are opposite each other, wherein the inner tubes are connected to the outer tube at a region of the outer tube that is arranged centrally between the ends of the outer tube.
[0014] A first inner tube of the two inner tubes may be connected to the outer tube at a first connection point, wherein a second—viz., the other—inner tube is connected to the outer tube at a second connection point that is axially spaced apart from the first connection point with respect to the axis of rotation of the outer tube, and wherein the creation of at least one aperture running through the tube wall of the outer tube, the introducing of the diaphragm body into the opening, and the creation of a substance-to-substance bond between the diaphragm body and the tube wall of the outer tube are carried out simultaneously at a first position in the wall of the outer tube, which is arranged between the first connection point and the first end of the outer tube located on the side of the first connection point facing away from the second connection point, and at a second position in the wall of the outer tube, which is arranged between the second connection point and the second end of the outer tube located on the side of the second connection point facing away from the first connection point.
[0015] Between the first connection point and the first end of the outer tube, several apertures may be created, a diaphragm body positioned into each aperture, and a substance-to-substance bond each created between the diaphragm bodies and the tube wall of the outer tube, wherein the same number of apertures is created between the second connection point and the second end of the outer tube, a diaphragm body positioned into each aperture, and a substance-to-substance bond each created between the diaphragm bodies and the tube wall of the outer tube, as between the first connection point and the first end of the outer tube.
[0016] After connecting all diaphragm bodies to the tube wall of the outer tube, the glass assembly may be divided into two separate glass bodies by means of a heat source, such as a dividing flame or a laser beam, that acts on the outer tube at a point arranged between the ends of the inner tubes connected to the outer tube. In this way, two glass bodies, which may each be further processed into a potentiometric sensor, may be produced simultaneously in an automated manner and provided respectively with one or more diaphragms.
[0017] The method may be carried out by means of an automatic controller, in particular an electronic controller comprising a processor which is designed to control a drive of a rotational movement of the spindle, one or more drives of the tool slide, and/or one or more gas burners or lasers, and/or one or more drives of the holding device. The controller can comprise software comprising algorithms for this control task.
[0018] The present disclosure also relates to a device for the automated production of a glass body comprising a diaphragm for a potentiometric sensor—in particular, in accordance with the method described above. The device comprises: a lathe with at least one spindle that is rotatable about an axis of rotation and that comprises a workpiece holder; one or more gas burners and/or lasers fixed on a first tool slide that can be moved relative—in particular, orthogonally—to the axis of rotation of the spindle; one or more drives for driving a rotational movement of the spindle and a movement of the first tool slide; a controller that is designed to control the burners and/or lasers and the one or more drives to carry out the method—in particular, in accordance with one of the method variants described above.
[0019] In at least one embodiment, the device further comprises a holding device, which is designed to automatically hold one or more diaphragm bodies from a supply of similar diaphragm bodies and which is arranged—in particular, on a second tool slide—so as to be movable relative to the axis of rotation of the rotatable spindle of the lathe, wherein the controller is designed to control the movement of the holding device.
[0020] In an embodiment that allows for the simultaneous production of two glass bodies that may each be further processed into a potentiometric sensor, the device comprises a second spindle that is rotatable about the axis of rotation and that comprises an additional workpiece holder, wherein the workpiece holders are arranged so that they are opposite each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the following, the present disclosure is explained in further detail on the basis of the exemplary embodiments shown in the figures. The figures show:
[0022] FIG. 1 shows a diaphragm body according to exemplary embodiments of the present disclosure;
[0023] FIGS. 2A and 2B show a section of a tube wall of an outer tube of a glass assembly with an aperture, into which a diaphragm body according to FIG. 1 is inserted and substance-to-substance bonded to the wall tube of the outer tube according to exemplary embodiments of the present disclosure;
[0024] FIG. 3 shows a glass body for a potentiometric sensor with an outer tube, in the tube wall of which two diaphragms are arranged according to exemplary embodiments of the present disclosure;
[0025] FIG. 4A shows a forming of two apertures in one wall of an outer tube of a glass assembly according to exemplary embodiments of the present disclosure;
[0026] FIG. 4B shows a introducing of a diaphragm body in each aperture in the wall of an outer tube according to exemplary embodiments of the present disclosure;
[0027] FIG. 4C shows a fusing of diaphragm bodies positioned into apertures of a wall of an outer tube with the wall of the outer tube according to exemplary embodiments of the present disclosure; and
[0028] FIG. 4D shows a division of a glass assembly into two separate glass bodies according to exemplary embodiments of the present disclosure.
DETAILED DESCRIPTION
[0029] FIG. 1 schematically shows a cylindrical diaphragm body 1 that is made of a porous ceramic and comprises a coating 2 of glass in a central section. The glass coating is closely connected in a gap-free manner to the surface of the diaphragm body 1 .
[0030] FIG. 2A schematically shows a section of a wall of a glass tube 3 that could be an outer tube of a glass assembly for a potentiometric sensor, as described in more detail below in connection with FIGS. 3 and 4 . The wall of the glass tube 3 includes an aperture 4 with a circular cross section. The diaphragm body 1 with the coating 2 of glass as shown in FIG. 1 is introduced into the aperture 4 .
[0031] A substance-to-substance bond between the diaphragm body 1 and the wall of the glass tube 3 may be created by melting by means of a gas burner. The melting is facilitated by the glass coating of the diaphragm body 1 . For this purpose, a heat source—in the present example a gas burner flame—is guided circularly around the diaphragm body 1 in order to connect the glass coating with the glass wall of the glass tube 3 . Alternatively, a laser beam may also be used. FIG. 2B shows the diaphragm body 1 substance-to-substance bonded in this manner to the wall of the glass tube 3 . The diaphragm body 1 now forms a diaphragm serving as an electrochemical bridge between a medium contained within the glass tube 3 and a medium located outside the glass tube 3 .
[0032] FIG. 3 schematically shows a glass body 100 for a potentiometric sensor. The glass body 100 comprises an inner tube 106 and an outer tube 103 , which are arranged coaxially with respect to their common cylinder axis Z. In a tube wall of the outer tube 103 , two diaphragms 101 are arranged and are substance-to-substance bonded to the tube wall of the outer tube 103 by melting them into the tube wall. The diaphragms 101 are each formed as a cylindrical porous ceramic body.
[0033] At a connection point 107 , the inner tube 106 and the outer tube 103 are fused together. The connection point 107 closes one end of an annular chamber 108 formed between the inner tube 106 and the outer tube 103 . The inner tube 106 is open at its end 109 located in the region of the connection point 107 .
[0034] The connection of the inner tube 106 to the outer tube 103 and the formation of the end region of the glass body, which comprises the connection point, with the opening of the inner tube 106 at its end 109 may, for example, be carried out in an automated manner, in accordance with the method described in EP 1692 080 B1. Subsequently, openings, into each of which the diaphragm body 101 may be inserted and fused into the tube wall, as described based upon FIGS. 2A and 2B , may be created in the wall of the outer tube 103 .
[0035] The introduction of the diaphragms 101 may also be carried out in an automated manner. For this purpose, a glass assembly that is not yet provided with diaphragms and consists of the outer tube 103 and the inner tube 106 that is connected thereto at the connection point 107 and whose end 109 is open, is inserted into a workpiece holder arranged on a rotatable spindle of a lathe. In doing so, the axis of rotation, about which the spindle can be rotated, and the common cylinder axis Z of the inner tube 106 and the outer tube 103 coincide. The annular chamber 108 of the glass assembly, which is arranged between the inner tube 106 and the outer tube 103 , is connected to a gas supply line, via which air, nitrogen, or an inert gas or an inert gas mixture, for example, can be blown into the annular chamber under pressure.
[0036] The lathe further comprises a first tool slide, on which a gas burner arrangement with one or more gas burners is arranged so as to be movable in a direction parallel and/or orthogonal to the axis of rotation of the spindle. In the example described here, all processing steps that comprise the effect of a heat source on the glass workpieces to be processed are carried out by means of gas burners. Alternatively, it is also possible to use a laser beam as the heat source. In this case, lasers are used instead of the gas burners. It is also possible to combine lasers and gas burners. The lathe comprises a second tool slide on which a gripper tool is arranged that is movable relative to the axis of rotation of the spindle and can grasp and transport one or more diaphragm bodies like those shown in FIG. 1 from a diaphragm body supply. The gas burners, the movement of the first and the second tool slides, of the gas burners and of the gripper tool, the rotation of the spindle, and the gas supply line into the annular chamber 108 are controlled by means of an automatic controller in accordance with a defined operating program.
[0037] In order to control the gas burners, the controller on the one hand controls the gas mixture that is supplied to the gas burners, an ignition device, and the position of the burners and their angles with respect to the axis of rotation of the spindle. The temperature of the glass regions to be processed is an essential criterion for the control and/or regulation of the gas burners; it is measured by means of a pyrometer whose measured values are captured and processed by the controller. The processing temperature may, for example, be between 800° C. and 900° C.
[0038] In order to control the introduction of gas into the annular chamber 108 , a pressure sensor may be provided, which detects the pressure in the gas supply line connected to the annular chamber 108 and outputs measured values to the controller, which processes them and uses them to control the gas pressure in the annular chamber. The end of the glass assembly or the annular chamber 108 facing away from the connection point 107 is preferably closed in a pressure-tight manner during the process.
[0039] In order to create an opening in the wall of the outer tube 103 , the wall of the outer tube is heated locally by means of a gas burner. Simultaneously, an overpressure is created in the annular chamber 108 via the gas supply line. This results in the forming of an opening, through-hole, or aperture in the heated region. In the process, the flame of the gas burner and the applied overpressure are controlled in such a way that the diameter of the aperture is between 1 and 2 mm. This may of course be adjusted to other diaphragm sizes, depending upon the requirements of the sensor to be produced. In this way, one or more apertures—in the present example, two apertures—may be created in the wall of the outer tube 103 .
[0040] Subsequently, a diaphragm body that corresponds to the diaphragm body shown in FIG. 1 is taken from a supply by the gripper tool and preheated by means of a gas burner flame. The preheated diaphragm body is then fixed by the action of a burner flame in an aperture created in the glass wall, cf. FIG. 2A . Subsequently, the diaphragm body is fused with the wall of the outer tube by means of a directional oxygen-hydrogen flame of a gas burner moved circularly along the perimeter of the diaphragm body, and, in this way, a diaphragm 101 substance-to-substance and gap-free bonded to the glass wall is created. This is repeated for each additional aperture created in the wall of the outer tube.
[0041] The glass body 100 produced in this way may be further processed in order to produce a potentiometric sensor, such as a pH sensor. The production of a pH sensor with a glass electrode made of the glass body 100 may, for example, be carried out in the following manner. For example, the glass body 100 may be processed further to produce a pH sensor with a glass electrode by blowing a pH-sensitive glass membrane onto the open front end 109 of the inner tube 106 , by introducing a buffer solution and a potential discharger into the inner tube 106 , and by introducing a reference electrolyte and a reference electrode into the chamber 108 formed between the inner tube 106 and the outer tube 103 . The glass body 100 may then be closed on the rear side, wherein the reference electrode and the potential discharger are conducted to a contact point that is arranged outside the chambers that are formed in the glass body 100 and filled with electrolyte. The contact point may be connected to a measuring circuit, which may be arranged in an electronic housing that is connected firmly at the rear side to the glass body 100 and that may be designed, for example, as a plug head.
[0042] FIGS. 4A-4D schematically show the process of a method in which two glass bodies, each with an outer tube and an inner tube and a diaphragm arranged in the wall of the outer tube, may be simultaneously produced in an automated manner.
[0043] In a first step ( FIG. 4A ), a glass assembly 200 is loaded into two tool holders of spindles 213 , 214 of a lathe, which are opposite each other and rotatable about a common axis of rotation Z. The glass assembly 200 comprises an outer tube 203 and a first inner tube 206 , as well as a second inner tube 210 , which are arranged coaxially with respect to a common axis of rotation that coincides with the axis of rotation Z of the spindles 213 , 214 . The inner tubes 206 , 210 respectively comprise at ends facing each other a circular or disk-shaped radial expansion that is fused with the outer tube in a central region—hereafter also called processing center point 209 —at connection points 207 , 211 opposite each other. The first annular chamber 208 formed between the first inner tube 206 and the outer tube 203 and the second annular chamber 212 formed between the second inner tube 210 and the outer tube 203 are respectively connected to a gas supply line (not shown), by means of which a gas pressure in the annular chambers 208 and 212 can be adjusted.
[0044] The lathe comprises a first tool slide 215 and gas burners 216 , 217 , 218 that are arranged thereon and that, by means of the tool slide and/or a burner support possibly arranged on the tool slide, can be moved relative to the axis of rotation Z or to the glass assembly 200 loaded into the spindles 213 , 214 . In this exemplary embodiment, it is also possible to use lasers as an alternative to one or all gas burners 216 , 217 , 218 for the processing of the glass workpieces.
[0045] The lathe further comprises a controller (not shown) that controls drives of the spindles 213 , 214 , a drive of the tool slide 215 , the gas pressure in the annular chambers 208 , 212 , and the burners 216 , 217 , 218 , in order to carry out the method described here in accordance with a defined operating program. In order to control and/or regulate the gas pressure, the controller uses, in the exact same manner as described previously based upon FIG. 3 , measured values of one or more pressure sensors that detect the pressure prevailing in the annular chambers 208 , 212 . In order to control and/or regulate the gas burners, the controller uses measured values of one or more pyrometers that measure the temperature of the regions of the glass assembly heated by means of the gas burners. All steps described in the following are carried out in an automated manner in the present example by means of the controller.
[0046] In order to create apertures in the wall of the outer tube 203 , two gas burners 216 , 218 are respectively approximated to a position on the exterior of the outer tube 203 , which has a distance of about 10 mm to the processing center point 209 . By means of the gas burners 216 , 218 , the outer tube 203 is locally heated at these positions. At the same time, the pressure in the annular chambers 208 , 212 is increased, so that when the tube wall softens in the heated region, apertures 205 that have a diameter of about 1 to 2 mm form in the tube wall.
[0047] In a second step ( FIG. 4B ), two porous diaphragm bodies 201 , which comprise at least in sections a coating of glass, are inserted into the apertures 205 , 219 . For this purpose, the lathe comprises a second tool slide 221 , on which two gripper tools 222 and 223 are arranged, which are arranged so that they can be moved by means of the tool slide 221 relative to the glass assembly 200 arranged in the spindles 213 , 214 . The controller is also designed to control the movement of the second tool slide 221 and/or the gripper tools 222 and 223 .
[0048] The gripper tools 222 , 223 grip two diaphragm bodies 201 , 220 from a supply of diaphragm bodies that are designed in the same manner as the diaphragm body 1 shown in FIG. 1 . The gripped diaphragm bodies 201 , 220 are preheated by means of a gas burner arranged on the first tool slide 215 and inserted into the apertures 205 and 219 in the wall of the outer tube 203 . For this purpose, the glass assembly can be rotated toward the second tool slide 221 by means of the spindles 213 , 214 .
[0049] In a third step ( FIG. 4C ), the diaphragm bodies 201 , 220 inserted into the apertures 205 and 219 are fused with the wall of the outer tube 203 by means of two gas burner flames 216 , 218 that are guided circularly around the respective diaphragm body 201 , 220 .
[0050] In a last step ( FIG. 4D ), the glass assembly 200 is set into rotation by means of the spindles 213 , 214 , and a gas flame is directed toward the processing center point 209 by means of an additional gas burner 217 . By locally heating and pulling apart the two ends of the glass assembly, it is divided into two individual glass bodies corresponding to the glass body 100 shown in FIG. 3 . | One aspect of the present disclosure relates to a method for the automated production of a glass body comprising a diaphragm for a potentiometric sensor. The method includes providing a glass assembly, which includes an outer tube and at least one inner tube running inside the outer tube, wherein the inner tube and the outer tube are arranged coaxially and wherein one end of the inner tube is substance-to-substance bonded to a tube wall of the outer tube; forming at least one aperture through the tube wall of the outer tube; introducing a porous diaphragm body into the aperture, the diaphragm body including a coating of glass in at least one section; and creating a substance-to-substance bond between the tube wall of the outer tube and at least the section of the diaphragm body comprising the coating of glass. | 2 |
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The invention relates to gas turbine engines. More particularly, the invention relates to the mounting of low pressure compressor exit stators to turbine engine intermediate cases.
[0003] (2) Description of the Related Art
[0004] FIG. 1 shows a gas turbine engine 20 having a case assembly 22 containing concentric high and low pressure rotor shafts 24 and 25 . The shafts are mounted within the case for rotation about an axis 500 which is normally coincident with central longitudinal axes of the case and shafts. The high pressure rotor shaft 24 is driven by the blades of a high pressure turbine section 26 to in turn drive the blades of a high pressure compressor 27 . The low pressure rotor shaft 25 is driven by the blades of a low pressure turbine section 28 to in turn drive the blades of a low pressure compressor section 29 and a fan 30 . Air passes through the engine along a core flowpath 502 sequentially compressed by the low and high compressor sections 29 and 27 , then passing through a combustor 32 wherein a portion of the air is combusted along with a fuel, and then passing through the high and low turbine sections 26 and 28 where work is extracted. Additional air is driven by the fan along a bypass flowpath 504 .
[0005] FIG. 2 shows the core flowpath 502 at the downstream end of the low pressure compressor section. A final ring of compressor blades 50 is mounted to an aft compressor disk 52 of the low speed spool. Upstream of the blades 50 is a ring of vanes 54 secured at their outboard ends to a compressor case assembly 56 and at their inboard ends having a seal system for sealing with the low speed spool. Downstream of the vanes 50 is an exit stator 60 having an array of vanes 62 extending between inner (inboard) and outer (outboard) stator shrouds 64 and 66 . The stator shrouds have respective outboard and inboard surfaces 67 and 68 which locally form inboard and outboard boundaries of the core flowpath. At downstream ends, the shrouds 64 and 66 have mounting flanges 70 and 71 bolted to associated flanges 72 and 73 respectively extending inward and outward from respective forward portions of respective inboard and outboard walls 74 and 75 of an intermediate case 76 . The inboard and outboard walls 74 and 75 (although not necessarily inboardmost and outboardmost) are connected by an array of webs or struts 77 . In the exemplary embodiment, a bearing support 80 is also bolted to the flange 72 outboard of a bearing compartment.
[0006] The intermediate case 76 is an important structural element of the engine providing a load path for the engine thrust and providing transverse stiffness. Exemplary intermediate cases are formed essentially as castings with subsequent machining and addition of minor components such as threaded inserts for receiving the bolts. The shrouds 64 and 66 are subject to different loads. Although the shrouds may be of like composition (e.g., titanium alloy) to the intermediate case, they may advantageously be made in different ways (e.g., stamping of sheet stock or forging) to provide the desired strength parameters. In an exemplary method of engine assembly, the stator vanes may be preassembled to the shrouds and the stator then bolted to the intermediate case as a unit. The preassembly may involve inserting the vanes through apertures in the shrouds, with a stablug portion 84 at the tip of the vane airfoil protruding beyond the outboard surface of the outboard shroud and being sealed thereto by an encapsulant such as RTV Silicone™. At the inboard end of the airfoil, a transversely extending foot 86 may have an outboard surface facing the inboard surface of the inboard shroud (e.g., contacting). The foot may be secured to the shroud via fasteners such as rivets (not shown).
SUMMARY OF THE INVENTION
[0007] Accordingly, one aspect of the invention involves a gas turbine engine. A compressor section has a number of rings of blades and vanes. A turbine section is downstream of the compressor section along a core flowpath of the engine. An intermediate case has inboard and outboard portions forming inboard and outboard walls for the core flowpath. At least a first of the rings of the compressor section vanes extends between inboard and outboard stator shrouds. At least a first of the stator shrouds is welded to the intermediate case.
[0008] In various implementations, the compressor section may be a low pressure compressor section and the engine may further include a high pressure compressor section downstream thereof. The first ring may be a downstreammost one of the rings. The inboard and outboard stator shrouds may be respectively welded to the intermediate case inboard and outboard portions. Each of the inboard and outboard stator shrouds may be a full annulus. The first of the inboard and outboard stator shrouds may be a forging or a stamping. The intermediate case may be a casting. Each of the compressor vanes may have an inboard foot with an airfoil extending outboard from the foot. Each foot may be secured to the inboard shroud via fasteners, with an outboard surface of the foot facing an inboard surface of the inboard shroud. Each vane may extend through an associated aperture in the outboard shroud. Each vane may have a stablug and an outboard end of the airfoil protruding beyond an outboard surface of the outboard shroud and sealed relative to the outboard shroud.
[0009] Another aspect of the invention involves a method for remanufacturing such a gas turbine engine. A first of the inboard and outboard stator shrouds is removed. A replacement shroud is welded in place of the first shroud. In various implementations, replacement vanes may individually be installed to the replacement shroud in place of the first ring of the compressor vanes after the welding.
[0010] Another aspect of the invention involves a method for reengineering a gas turbine engine configuration from a first configuration to a reengineered configuration. The first configuration has compressor exit stator inboard and outboard shrouds secured to first and second portions of an intermediate case by first and second groups of fasteners. The first and second groups of fasteners are engaged to first and second groups of fastener-receiving features of the intermediate case. The initial configuration is altered to reengineered configuration having a reengineered intermediate case welded to a reengineered at least one of the exit stator inboard and outboard shrouds.
[0011] Another aspect of the invention involves a method for retrofitting a gas turbine engine. Compressor exit stator inboard and outboard shrouds are initially secured to first and second portions of intermediate case by first and second groups of fasteners engaged to first and second groups of fastener-receiving features of the intermediate case. According to the method, the shrouds are removed. A portion of the intermediate case at least partially containing at least one of the first and second groups of fastener-receiving features is then destructively removed. A replacement stator shroud may then be welded to the intermediate case.
[0012] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a partially schematic longitudinal sectional view of an exemplary prior art gas turbine engine.
[0014] FIG. 2 is a view of a compressor exit of the engine of FIG. 1 .
[0015] FIG. 3 is a view of a compressor exit according to principles of the invention.
[0016] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0017] FIG. 3 shows a similar portion of the flowpath 502 through an engine which may be a remanufacturing of the engine of FIG. 2 or may be of a configuration representing a reengineering of the configuration of the engine FIG.2 . Like components are shown with like numbers to their counterparts of FIG. 2 . An alternate intermediate case 120 has inboard and outboard walls 122 and 124 and struts 126 generally similar to analogous elements of FIG. 2 . Similarly, a flange 128 extends inboard from the inboard wall 122 for connection with the bearing support. The case 120 lacks the FIG. 2 features for mounting stator shrouds. Inboard and outboard stator shrouds 130 and 132 similarly lack the FIG. 2 mounting features. In the exemplary embodiment, the inboard shroud 130 has respective outboard and inboard surfaces 133 and 134 and the outboard shroud has respective inboard and outboard surfaces 135 and 136 . Aft rim portions 140 and 142 of the inboard and outboard shrouds are respectively welded to forward rim portions 144 and 146 of the intermediate case inboard and outboard walls 122 and 124 . The welding saves the weight of the mounting bolts and the associated mating features of the intermediate case. Additionally, the welding potentially reduces costs through simplification of the shrouds and intermediate case and through elimination of various mounting hardware. Additionally, the use of welding may limit the chances of leakage between the shrouds and intermediate case.
[0018] An exemplary assembly method may involve first welding the shrouds to the intermediate case. The vanes may then be installed as in the prior art or otherwise. In repair situations, the vanes may be individually removed and replaced. If necessary to repair or replace one or both of the shrouds, such shroud(s) may be cut off or unwelded and replacement shroud(s) welded in place. To permit such rewelding, advantageously, the forward rim portions of the intermediate case walls may be slightly thickened relative to other portions.
[0019] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the invention may be applied to a variety of existing turbine engine configurations or to configurations yet developed. When applied as a reengineering, the engineering may include additional changes while leaving other aspects of the engine unchanged. In some situations it may be desired that only one of the shrouds be welded in place. Accordingly, other embodiments are within the scope of the following claims. | A gas turbine engine has an intermediate case. At least one compressor exit stator shroud is welded to the intermediate case. | 5 |
FIELD OF THE INVENTION
This application provides a bubble CPAP (Continuous Positive Airway Pressure device). It works, in combination with a CPAP system, to provide respiratory support to newborn infants who have underdeveloped respiratory systems. The bubble CPAP acts as a pressure generator and water bottle pressure relief device which stabilizes the outgoing infant's air pressure to a desired level by maintaining the exhalation tube under a specific depth of water.
BACKGROUND OF THE INVENTION
Most respiratory diseases of the neonate occur as a result of the immaturity of the premature neonate's lungs. Despite stimulation, the normal process involved in the first breath does not occur. The respiratory system is underdeveloped and adequate gas exchange cannot take place. With this, there is a need for respiratory support.
The bubble CPAP with the combined effects of CPAP and pressure oscillations from the bubbles provides a lung protective, safe and effective method of respiratory support to spontaneously breathing neonates.
The Bubble CPAP effectively maintains Functional Residual Capacity (FRC). Most lung diseases that lead to respiratory failure are commonly associated with a reduced FRC. Maintaining FRC is very important to premature neonates who have a greater tendency of airway closure when FRC falls below closing volume.
The bubble CPAP helps reduce the infant's Work of Breathing (WOB). In a prospective randomized cross over trial performed by Lee, Dunn et. al. (see Lee K S, Dunn M S, et al, A Comparison of Underwater Bubble Continuous Positive Airway Pressure in Premature Neonates Read for Extubation. Biol. Neonate 73: 69-75.1998 comparing bubble CPAP with ventilator-derived CPAP, results showed that there was a decrease in the infant's minute volume and respiratory rate with bubble CPAP. They observed chest vibrations caused by the pressure oscillations from the bubbling. These pressure oscillations, according to the study, are reverberated back into the infant's airway and may have provided an alternate form of gas exchange through the principle of facilitated diffusion. This physiologic effect of bubble CPAP may help improve gas exchange and reduce the infant's work of breathing. Measurements done in vitro by Pillow and Travadi (see Pillow J J. Travadi J N. Bubble CPAP: is the noise important? An in vitro study. Pediatr. Res 2005; 57: 826-830) as well as in vivo measurements on a baby on bubble CPAP confirmed that the pressure oscillations from the bubbling are transmitted into the neonate's airway and lungs.
The bubble CPAP may reduce the need for intubation and mechanical ventilation. In the multi-center comparative study of Avery, et. al. (see Avery M E, Tooley W H, Keller J B, Hurd S S, Bryan M H, Cotton R B, Epstein M E, Fitzhardinge P M, Hansen C B, Hansen N. Is chronic lung disease in low birth weight infants preventable? A survey of eight centers. Pediatrics 1987; 79:26-30) it was noted that the use of bubble CPAP avoided the need for intubation reducing the possibility of airway injury, aspirations and secondary infection associated with the use of the ET tube. Results also showed significant reduction in the need for mechanical ventilation that may minimize the possible incidence of barotrauma.
A historical control study performed by A M De Klerk and R K De Klerk (see A M de Klerk, R K de Klerk. Nasal continuous positive airway pressure and outcomes of pre-term infants. J. Paediatr. Child Health 2001; 114: 697-702) in the use of bubble CPAP further confirmed earlier results with data showing marked reduction in intubation and ventilation rates. There was also a decline in the number of days on oxygen and there were trends indicating less number of days on any respiratory support and to an earlier postnatal day of life when respiratory support is no longer needed.
The bubble CPAP tends to reduce the incidence of Chronic Lung Disease (CLD). Early treatment with bubble CPAP for infants with respiratory distress showed a change in the severity and duration of the disease. Significant reduction in the incidence of chronic lung disease which was defined as O 2 dependence at 28 days postnatal age or 36 weeks corrected gestation had been noted in some multi-center and comparative studies.
A case-cohort study of Linda Van Marter and colleagues (see Marter L J, Pagano M, et al, Do Clinical Marker of Barotrauma and Oxygen Toxicity Explain Interhospital Variation in Rates of Chronic Lung Disease? Pediatrics, Vol 105 No 6: 1194-1202. June 2000) suggested that barotrauma and oxygen toxicity were linked with CLD and that most of the increased risk of CLD was a result of the initiation of mechanical ventilation. Comparison of different respiratory care in 3 hospitals supported earlier results of reduced incidence of CLD with the use of bubble CPAP. Similar outcomes are being reproduced in hospitals that have used bubble CPAP.
Faster recovery with less lung injury and better respiratory outcomes are possible using a cost-effective respiratory support system such as bubble CPAP.
The Basics of Bubble CPAP systems are really very simple. CPAP systems become confusing when you look at them as multiple hoses, gauges, tubes. To complicate matters more the circuit is connected at one end to a ventilator or blender and at the other end to a baby via a mask or nasal prongs.
Babies in the high humidity environment of an isolate pose unique problems and challenges. Additionally, CPAP therapy does not occur in a vacuum. The bedside nurse and respiratory therapist must understand the system well so that they can deal with the ongoing patient care problems and not spend all their time trying to make the CPAP “work”.
In the CPAP circuit, gas flows from the ventilator, blender or flow driver to the humidifier then to the patient. A drainage bag and pressure gauge are present to catch humidifier “rain out” and measure CPAP pressure. All CPAP humidifiers for neonates must be heated between 36.5 and 37.2 degrees Celsius.
The CPAP Interface connects the patient to the CPAP circuit and pressure. Without a good interface the benefits of the CPAP will not be effectively delivered. Nurses and Respiratory Therapists need to be comfortable, fitting and working with the CPAP interface. The three interface types are mask, tube and nasal prongs. Nasal prongs are the best type to use in neonates as the fit is better and the CPAP delivery can easily be assured. Hudson type nasal prongs are well regarded b many CPA P educators as the best type.
The CPAP pressure generator is a simple device that acts to increase the pressure inside the CPAP circuit. The pressure generator must be able to safely keep the pressure at the desired level and safeguard against high system pressures. The pressure generator for Bubble CPAP is a water bottle in which the expiratory limb of the circuit is immersed to a depth in centimeters that equals the desired CPAP pressure. Bubble CPAP may provide what some experts call “high frequency oscillation” effect. In theory this effect could be responsible for improving gas distribution in the lung.
Numerous innovations for the Continuous Positive Airway Pressure Device have been provided in the prior art that are described as follows. Even though these innovations may be suitable for the specific individual purposes to which they address, they differ from the present design as hereinafter contrasted. The following is a summary of those prior art patents most relevant to this application at hand, as well as a description outlining the difference between the features of the Continuous Positive Airway Pressure Device (CPAP) and the prior art.
U.S. Pat. No. 8,235,042 of Lionel Newman Jr. describes an apparatus for providing pressure into which a patient must exhale is provided. The canister has a canister axis and is disposed to hold liquid. The canister also has indicia of pressure on the canister. The apparatus also includes a substantially rigid lid disposed to substantially cover a mouth of the canister and having a first inlet through the lid. The apparatus also includes an adapter in the first inlet. The apparatus also includes a conduit being retained by the adapter such that the conduit is substantially immovable relative to the canister axis.
This patent describes an apparatus for providing pressure into which a patient must exhale but does not have the over loaded water feature that will remove water into the drainable cavity on the inside surface of the outer vessel to provide better adjustment setting of CPAP pressure. It also does not have a selection of different sized end caps for the hollow control tube to control the size of the bubble that is released by the hollow tube to increase or decrease the pressure swings in the respiratory circuit.
U.S. Pat. No. 8,225,787 of Lionel Newman Jr. describes an adjustable airway pressure system is provided. The system may include a cap and a canister. The cap may include a substantially hollow conduit having indicia indicative of a plurality of airway pressure values and adapted to receive and output exhaled gas. The conduit may have screw threads on an exterior surface of the conduit. The cap may also include an adjust collar circumscribing the conduit and having an interior surface with a second plurality of screw threads. The second plurality of screw threads may couple and be complementary to the first plurality of screw threads such that a rotation of the adjust collar causes the conduit to move in a substantially vertical direction. The conduit may be adapted to be adjusted to heights along a continuum. The canister may contain liquid and receive the conduit such that the received exhaled gas is output from the conduit into the liquid.
This patent describes an adjustable airway pressure system but also does not have the over loaded water feature that will remove water into the drainable cavity on the inside surface of the outer vessel to provide better adjustment setting of CPAP pressure. It also does not have a selection of different sized end caps for the hollow control tube to control the size of the bubble that is released by the hollow tube to increase or decrease the pressure swings in the respiratory circuit. It does not have the fine adjustment, having at least 4 adjustment points within 1 cm H20.
Patent No. 2010/0282256 A1 of Thomas C. Loescher et al. describes an apparatus configured to provide positive airway pressure in a respiratory circuit comprises a container configured to be filled to a preselected level with liquids; a drop tube assembly comprising a hollow gas tube rotatably mounted in said container having an upper end extending a static distance outwardly of the container and connected to a respiratory circuit downstream of a user, and a hollow drop tube reciprocally movable upwardly and downwardly in the liquid in response to rotational movement of the gas tube. The container is provided with a gas vent and a liquid fill port.
This patent describes an apparatus configured to provide positive airway pressure in a respiratory circuit system but also does not have the over loaded water feature that will remove water into the drainable cavity on the inside surface of the outer vessel to provide better adjustment setting of CPAP pressure or the inner pressure control vessel. It also does not have a selection of different sized end caps for the hollow control tube to control the size of the bubble that is released by the hollow tube to increase or decrease the pressure swings in the respiratory circuit. It does not have the fine adjustment means, having at least 4 adjustment points within 1 cm H20 using the dimple engagement mechanism engaging in the side of the rotating cap lower cylinder.
U.S. Pat. No. 7,077,154 of Harris C. Jacobs et al. describes an apparatus for effecting bubble CPAP. The apparatus includes a hollow vessel holding a liquid, a cap, and a positionable tube assembly. The positionable tube assembly comprises a guide tube and a positionable tube. The positionable tube is arranged to have a gas introduced through it and is located within the guide tube. The positionable tube is arranged to be slid to various discrete longitudinal positions with respect to the guide tube and to be held in any one of those discrete positions against accidental displacement so that the lower free end of the positionable tube is held at a desired position below the surface of the liquid.
This patent describes an apparatus for effecting bubble CPAP but has a large positionable tube assembly that does not give the precise control required or the different sized end caps for the hollow control tube to control the size of the bubbles. It does not have the fine adjustment means, having at least 4 adjustment points within 1 cm H20 using the dimple engagement mechanism engaging in the side of the rotating cap lower cylinder. It does not have the unique capabilities of the inner pressure control vessel.
U.S. Pat. No. 6,988,497 of Walter Levine describes a humidifier apparatus for operating at an air pressure is disclosed for use with a respiratory therapy breathing apparatus that provides a breathable gas supply to patients requiring higher concentrations of liquid vapor and gas pressure. The humidifier apparatus includes a feed liquid supply bag in fluid communication with a humidifier cartridge via a conduit. The conduit enables air to flow there through to equalize air pressure between the humidifier cartridge and the feed liquid supply bag in response to liquid being supplied to the humidifier cartridge.
This patent describes a humidifier apparatus for operating at an air pressure but does not offer the unique capabilities of the Continuous Positive Airway Pressure Device.
U.S. Pat. No. 6,805,120 of Craig Robert Jeffrey et al. describes a pressure regulator for regulating the expiratory flow in a CPAP system includes submerging a tube into a column of water. Improvements are included for adjusting the level to which the tube is submerged and for ensuring constant water level.
This patent describes a pressure regulator for regulating the expiratory flow in a CPAP system but still does not offer the unique capabilities of the Continuous Positive Airway Pressure Device.
None of these previous efforts, however, provides the benefits attendant with the Continuous Positive Airway Pressure Device. The present design achieves its intended purposes, objects and advantages over the prior art devices through a new, useful and unobvious combination of method steps and component elements, with the use of a minimum number of functioning parts, at a reasonable cost to manufacture, and by employing readily available materials.
In this respect, before explaining at least one embodiment of the Continuous Positive Airway Pressure Device in detail it is to be understood that the design is not limited in its application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The Continuous Positive Airway Pressure Device is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for designing of other structures, methods and systems for carrying out the several purposes of the present design. It is important, therefore, that the claims be regarded as including such equivalent construction insofar as they do not depart from the spirit and scope of the present application.
SUMMARY OF THE INVENTION
The principal advantage of the Continuous Positive Airway Pressure Device is to aide in the care and treatment of respiratory diseases of the neonate that occur as a result of the immaturity of the premature neonate's lungs.
Another advantage of the Continuous Positive Airway Pressure Device is a large dial for easy adjustment.
Another advantage of the Continuous Positive Airway Pressure Device is having two locations for an adjustment number that can be viewed from top and side.
Another advantage of the Continuous Positive Airway Pressure Device is having a self-drainable air vent ports with a wall in the rotating cap around the hollow control tube orifice.
Another advantage of the Continuous Positive Airway Pressure Device is a higher wall to prevent water from coming out of the bottle due to large bubbles.
Another advantage of the Continuous Positive Airway Pressure Device is the smaller hollow control tube compared with other design makes water level more consistent.
Another advantage of the Continuous Positive Airway Pressure Device is the straight hollow control tube lower end outlet creates larger CPAP pressure amplitude (larger pressure swing)
Another advantage of the Continuous Positive Airway Pressure Device is the fine adjustment, having at least 4 adjustment points within 1 cm H20.
Another advantage of the Continuous Positive Airway Pressure Device is the water level stabilizer hole offset from center for water level measurement in the cavity between the outer vessel and inner vessel.
Another advantage of the Continuous Positive Airway Pressure Device is the over loaded water feature that will remove water into the drainable cavity on the inside surface of the outer vessel to provide better adjustment setting of CPAP pressure.
Another advantage of the Continuous Positive Airway Pressure Device is the bottom drain port for overloaded water in the bottle.
Another advantage of the Continuous Positive Airway Pressure Device is the spring loaded button for added safety for making adjustment to CPAP pressure.
Another advantage of the Continuous Positive Airway Pressure Device is the locking feature on the spring loaded button for added safety during use.
Another advantage of the Continuous Positive Airway Pressure Device is the smaller package design for shipping and storing the unit.
The B&B CPAP system is an expiratory pressure system to create a precise and settable pressure within a respiratory circuit.
The Continuous Positive Airway Pressure device has been designed as a vessel within a vessel. The system consists of a double walled vessel and a rotating cap that moves the hollow control tube up and down. The double walled vessel consists of an inner pressure control vessel and an outer water level reading and overflow vessel. A small orifice at the bottom of the inner control vessel is in communication with the outer vessel to allow equalization of water level between the two vessels and to reduce or eliminate the water level fluctuations caused by the bubbling in the inner vessel with the ability to read the water levels in the outer and inner vessels. The system was designed so that the water level remains constant and the hollow control tube is moved up or down to fixed depths to control the pressure.
To fill the system with water, there is a fill port on the top surface of the rotating cap. The fitting is accomplished with a female Luer fitting that will connect with standard medical syringes or water reservoir bags that allow the vessel to be filled. A plug seals the port when it is not in use.
There is a water level line inscribed on the outer surface of the outer vessel to indicate the correct level of water that should be in the vessel. To assure that too much water is not placed in the inner vessel an overflow well in the outer vessel will prevent the water level from rising above the desired height. To keep the overflow well available for accidental overfilling, a drain port connected to the overflow well with a removable plug enables the water in the well to be removed.
To set and maintain the depth of the hollow control tube with a fine and precise setting, the cap lower cylinder has a spiral set of grooves that engage with protrusions on the outer vessel retaining ring. The spiral design allows for small vertical movement in response to large rotational movement. Therefore it is easy for the clinician to control the depth of the hollow control tube. Markers on the top of the rotating cap indicate the depth of the tip of the hollow control tube relative to the depth of the water in the inner vessel.
Parallel to the rotational spiral grooves are a set of spiral dimples in the cylinder of the cap. A mating dimple engaging mechanism is pressed against the dimples by a spring loaded button. To release the latch, the spring loaded button is depressed so that the latch can be moved away from the dimples. When the button is released, a spring under the button lifts the button up and forces the latch back into the dimple at the set height. This prevents accidental movement of the rotating cap that could change the depth of the hollow control tube and therefore the pressure in the respiratory circuit.
Air flows into the top orifice of the hollow control tube that has been designed for securing tubing from a conventional expiratory pressure system. Once the pressure exceeds the depth of the water in cm H20, the air bubbles up through the water and flows out the vents in the rotating cap. Therefore, controlling the depth of the hollow control tube in the water controls the pressure in the respiratory circuit. The wall in the rotating cap around the hollow control tube orifice and the vent ports keeps water from coming out of the bottle due to large bubbles.
To ease mounting for clinical use, a bracket bar is molded into the outer vessel. This bracket bar fits standard respiratory device brackets that mount to poles or rails. Molded into the outer vessel, it assures that the weight of the water is supported by the outer vessel.
To prevent the rotation of the cap from exerting torqueing force on the respiratory circuit tubing, the hollow control tube rotates freely. When the hollow control tube is first inserted into the rotating cap it stays permanently fixed by the means of a barbed attachment to the rotating cap but will still rotate within the orifice in the center of the rotating cap freely.
The small hole in the bottom of the inner vessels allows water to flow from the inner vessel into the outer vessel. The hole is small enough to dampen the oscillation of the water that occurs in the inner vessel from the bubbling of the gas from being transmitted to the outer vessel. This causes the water in the outer vessel to be stable and ease the reading of the water level against the water level marker on the outer vessel.
There is a desire in some situations to increase the amplitude of the pressure swings in the airway by controlling the amplitude of the water oscillations. This is determined by the size of the bubble as gas flows out the hollow tube. To control the size of the bubble that is released by the hollow tube, several optional hollow tip designs can be used to increase or decrease the size of the bubble by accumulating more gas and releasing it as a bolus and therefore increase or decrease the pressure swings in the respiratory circuit.
The foregoing has outlined rather broadly the more pertinent and important features of the present Continuous Positive Airway Pressure Device in order that the detailed description of the application that follows may be better understood so that the present contribution to the art may be more fully appreciated. Additional features of the design will be described hereinafter which form the subject of the claims of this disclosure. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment may be readily utilized as a basis for modifying or designing other structures and methods for carrying out the same purposes of the present design. It should also be realized by those skilled in the art that such equivalent constructions and methods do not depart from the spirit and scope of this application as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the Continuous Positive Airway Pressure Device and together with the description, serve to explain the principles of this application.
FIG. 1 depicts a Perspective illustration of the assembled Continuous Positive Airway Pressure Device
FIG. 2 depicts a perspective view of an exploded Continuous Positive Airway Pressure Device.
FIG. 3 depicts a top view of the Continuous Positive Airway Pressure Device.
FIG. 4 depicts a cross section through the Continuous Positive Airway Pressure Device.
FIG. 5A depicts a cross section through the Continuous Positive Airway Pressure Device.
FIG. 5B depicts an enlarged cross section view through the Continuous Positive Airway Pressure Device, illustrating detail in the overflow vessel, overflow well and drain plug location.
FIG. 6 depicts a top view of the rotating cap having the cap lower cylinder permanently attached.
FIG. 7 depicts a side view of the rotating cap having the cap lower cylinder permanently attached.
FIG. 8 depicts a bottom view illustrating the inside of the rotating cap.
FIG. 9 depicts a cross section through the rotating cap having the cap lower cylinder permanently attached.
FIG. 10 depicts a side view of the outer water level reading and overflow vessel.
FIG. 11 depicts a top view of the outer water level reading and overflow vessel.
FIG. 12 depicts a cross section through the outer water level reading and overflow vessel.
FIG. 13 depicts a perspective view of the top surface of the outer vessel retaining ring.
FIG. 14 depicts a top view of the outer vessel retaining ring.
FIG. 15 depicts a side view of the outer vessel retaining ring.
FIG. 16 depicts a bottom view of the outer vessel retaining ring.
FIG. 17 depicts a perspective view of the spring loaded locking button.
FIG. 18 depicts a side view of the spring loaded locking button.
FIG. 19 depicts a top view of the spring loaded locking button.
FIG. 20 depicts a cross section through the spring loaded locking button.
FIG. 21 depicts a side view of the hollow control tube.
FIG. 22 depicts a cross section through the hollow control tube.
FIG. 23 depicts cross section of an end cap with a bulbous shape having a small sized orifice.
FIG. 24 depicts cross section of an end cap with a bulbous shape having a medium sized orifice.
FIG. 25 depicts cross section of an end cap with a bulbous shape having a large sized orifice.
FIG. 26 depicts cross section of an end cap with bell mouth opening.
FIG. 27 depicts a top view of the drain plug.
FIG. 28 depicts a side view of the drain plug.
FIG. 29 depicts an end view of the drain plug.
FIG. 30 depicts a perspective view of the dimple engaging mechanism.
FIG. 31 depicts a side view of the dimple engaging mechanism.
FIG. 32 depicts a top view of the dimple engaging mechanism.
FIG. 33 depicts a cross section of the dimple engaging mechanism.
FIG. 34 depicts a cross section operational diagram of the Continuous Positive Airway Pressure Device.
For a fuller understanding of the nature and advantages of the Continuous Positive Airway Pressure Device, reference should be had to the following detailed description taken in conjunction with the accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the design and together with the description, serve to explain the principles of this application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein similar parts of the Continuous Positive Airway Pressure Device 10 are identified by like reference numerals, there is seen in FIG. 1 a perspective illustration of the assembled Continuous Positive Airway Pressure Device 10 incorporating a rotating cap 12 having the rotating cap lower cylinder 14 permanently attached. The elevated wall 16 on the top of the rotating cap 12 around the hollow control tube 18 orifice 20 keeps water from coming out due to large bubbles. Indicia 22 on the top surface of the rotating cap 12 indicate its relative elevated position. Stop tabs 24 are located around the orifice in the outer vessel retaining ring 26 to maintain the lowest position of the rotating cap 12 . The outer vessel retaining ring 26 is fixably attached by the means of barbed connectors 28 on the transparent outer water level reading and overflow vessel 30 . The transparent outer water level reading and overflow vessel 30 has an overflow drain plug 32 on the bottom with a water level fill line 34 inscribed on the outer surface and a bracket bar 36 on the side that fits standard respiratory device brackets that mount to poles or rails. A spring loaded locking button 38 on the upper surface of the outer vessel retaining ring 26 couples with the dimple engaging mechanism 40 for precise rotational adjustments.
FIG. 2 depicts a perspective view of an exploded Continuous Positive Airway Pressure Device 10 exposing the hollow control tube 18 and the rotating cap 12 having the rotating cap lower cylinder 14 permanently attached. The elevated wall 16 around the orifice 20 for the hollow control tube 18 exposes one of the vent ports 46 into the central cavity. On the top surface of the rotating cap 12 are the indicia 22 and the fill port 48 with the plug 50 . Spiral grooves 52 along with a spiral ring of dimples 54 are on the outer surface of the rotating cap lower cylinder 14 . The spiral row of dimples 54 engage with the dimple engaging mechanism 40 when the spring loaded button 38 is pressed. Around the central orifice of the outer vessel retaining ring 26 are four nibs 56 that engage with the spiral grooves 52 when the rotating cap 12 is turned. The spiral row of dimples 54 provide minuscule adjustments while securing the rotating cap 12 with the rotating cap lower cylinder 14 securely in position. Around the periphery of the outer vessel retaining ring 26 are three cavities 58 where the barbed connectors 28 attach on the outer water level reading and overflow vessel 30 . An arrow 60 on surface of the outer vessel retaining ring 26 works in conjunction with the indicia 22 on the top surface of the rotating cap 12 indicating its relative elevated position. The inner pressure control vessel 66 seats into a groove 68 (as seen in FIG. 4 ) on the underside of outer vessel retaining ring 26 shown in FIG. 4 . The transparent outer water level reading and overflow vessel 30 has an overflow drain plug 32 on the bottom with a water level fill line 34 inscribed on the outer surface and a bracket bar 36 on the side that fits standard respiratory device brackets that mount to poles or rails. A portion of the overflow well 70 is exposed with its top edge 72 at the same elevation as the water level fill line 34 on the outside of the transparent outer water level reading and overflow vessel 30 .
FIG. 3 depicts a top view of the Continuous Positive Airway Pressure Device 10 indicating the locations of the fill port 48 and the indicia 22 on the surface of the rotating cap 12 . The arrow 60 , the spring loaded button 38 and the dimple engagement mechanism are located on the upper surface of the outer vessel retaining ring 26 . The cross section arrows 4 - 4 and 5 - 5 indicate the view taken for FIG. 4 and FIG. 5 .
FIG. 4 depicts a cross section through the Continuous Positive Airway Pressure Device 10 where the location where the hollow control tube 18 is inserted through the orifice 20 (as seen in FIG. 2 ) in the outer vessel retaining ring 26 . A barbed segment 78 engages with the lower sleeve 80 of the outer vessel retaining ring 26 allowing it to rotate freely but not easily removed.
FIG. 5A depicts a cross section through the Continuous Positive Airway Pressure Device 10 illustrating the location of the overflow well 70 and the overflow drain plug 32 . The small hole 82 in the bottom of the inner pressure control vessel 66 allows water to flow to the outer water level reading and overflow vessel 30 . The small hole 82 is small enough to dampen the oscillation of the water that occurs in the inner pressure control vessels 66 from the bubbling of the gas from being transmitted to the outer water level reading and overflow vessel 30 . This causes the water in the outer vessel to be stabilized and ease the reading of the water level against the water level fill line 34 on the outer vessel 30 .
FIG. 5B depicts an enlarged cross section view through the Continuous Positive Airway Pressure Device, illustrating detail in the overflow well and plug location, showing the relationship of the overflow vessel 30 , the overflow well 70 and the bottom of the inner pressure control vessel 66 . There is no drain in the inner vessel other than the small hole in the bottom portion. The shape in the inner vessel 66 is formed to create space for the outer vessel drain plug 32 (as seen in FIG. 5A ). The drain plug 32 only connects with the outer vessel and is directly in line with the pull lines from the tool.
FIG. 6 depicts a top view of the rotating cap 12 illustrating the locations of the three vent ports 46 in the orifice 20 along with the indicia 22 and the fill port 48 .
FIG. 7 depicts a side view of the rotating cap 12 having the rotating cap lower cylinder 14 permanently attached illustrating the set of four spiral grooves 52 and the single spiral row of dimples 54 .
FIG. 8 depicts a bottom view illustrating the inside of the rotating cap 12 having the cap lower cylinder 14 permanently attached illustrating the three vent ports 46 in the orifice 20 and the location of the fill port 48 .
FIG. 9 depicts a cross section through the rotating cap 12 having the rotating cap lower cylinder 14 permanently attached illustrating the elevated wall 16 and the orifice 20 with the vent ports 46 . The slots 76 in the lower sleeve 80 allow for the flexibility required for expansion when the hollow control tube 18 (as seen in FIGS. 4 and 5 , but not shown in FIG. 9 ) is inserted into secured position but also allow it to rotate freely and still be removed for cleaning.
FIG. 10 depicts a side view of the outer water level reading and overflow vessel 30 illustrating the location of the bracket bar 36 and the barbed connectors 28 . Cross section arrows 12 - 12 indicate the view at which FIG. 12 is taken.
FIG. 11 depicts a top view of the outer water level reading and overflow vessel 30 illustrating the location of the overflow well 70 and the bracket bar 36 .
FIG. 12 depicts a cross section through the outer water level reading and overflow vessel 30 illustrating the bracket bar 36 and the overflow well 70 having the top edge 72 .
FIG. 13 depicts a perspective view of the top surface of the outer vessel retaining ring 26 indicating the location of the four stop tabs 24 and the nibs 56 that go into the spiral grooves 52 in the rotating cap lower cylinder 14 . The arrow 60 on top surface of the outer vessel retaining ring 26 is shown that works in conjunction with the indicia 22 on the top surface of the rotating cap 12 indicating its relative elevated position.
FIG. 14 depicts a top view of the outer vessel retaining ring 26 with the four stop tabs 24 and the nibs 56 along with the cavities 58 where the barbed connectors 28 of the outer water level reading and overflow vessel 30 make contact.
FIG. 15 depicts a side view of the outer vessel retaining ring 26 showing the upright positions of the stop tabs 24 where they will restrain the downward movement of the rotating cap 12 and rotating cap lower cylinder 14 .
FIG. 16 depicts a bottom view of the outer vessel retaining ring 26 illustrating the groove 68 that mates with the top edge of the inner pressure control vessel 66 .
FIG. 17 depicts a perspective view of the spring loaded locking button 38 with the ramped surface 86 .
FIG. 18 depicts a side view of the spring loaded locking button 38 with the ramped surface 86 .
FIG. 19 depicts a top view of the spring loaded locking button 38 .
FIG. 20 depicts a cross section through the spring loaded locking button 38 with the ramped surface 86 .
FIG. 21 depicts a side view of the hollow control tube 18 with the barbed segment 78 that engages with the lower sleeve 80 of the rotating cap 12 . At the lower distal end of the hollow control tube 18 is a ring 88 for securing different end tips 90 .
FIG. 22 depicts a cross section through the hollow control tube 18 with the barbed segment 78 that engages with the lower sleeve 80 of the rotating cap 12 . At the lower distal end of the hollow control tube 18 is a retaining ring 88 for securing different end tips 90 .
FIG. 23 depicts cross section of an end tip 90 with a bulbous shape 92 having a small sized orifice 94 with an internal groove 97 that will mate with the retaining ring 88 on the hollow control tube 18 .
FIG. 24 depicts cross section of an end tip 90 with a bulbous shape 92 having a medium sized orifice 96 with an internal groove 97 that will mate with the retaining ring 88 on the hollow control tube 18 .
FIG. 25 depicts cross section of an end tip 90 with a bulbous shape 92 having a large sized orifice 98 with an internal groove 97 that will mate with the retaining ring 88 on the hollow control tube 18 .
FIG. 26 depicts cross section of an end tip 90 with bell mouth opening 100 with an internal groove 97 that will mate with the retaining ring 88 on the hollow control tube 18 .
FIG. 27 depicts a top view of the drain plug 32 .
FIG. 28 depicts a side view of the drain plug 32 .
FIG. 29 depicts an end view of the drain plug 32 .
FIG. 30 depicts a perspective view of the dimple engaging mechanism 40 with a round protrusion 106 that will mate with any one of the row of dimples 54 on the outer surface of the rotating cap lower cylinder 14 . Ramped ribs 108 on the opposite side of the dimple engaging mechanism 40 engage with the ramped surface 86 to lock or release the rotational up and down movement of the rotating cap lower cylinder 14 when the spring loaded locking button 38 is pressed or released.
FIG. 31 depicts a side view of the dimple engaging mechanism 40 showing the position of the ramped ribs 108 .
FIG. 32 depicts a side view of the dimple engaging mechanism 40 illustrating the locations of the round protrusion 106 and the ramped ribs 108 . The cross section arrows 33 - 33 indicate the view taken for FIG. 33 .
FIG. 33 depicts a cross section of the dimple engaging mechanism 40 .
FIG. 34 depicts a cross section operational diagram of the Continuous Positive Airway Pressure Device 10 depicting the exhaled air 112 traveling down through the center of the hollow control tube 18 to below the surface of the water 114 to bubble up to the surface and travel out through the vent port 46 in the rotating cap 12 . When the turbulence in the water from the bubbles or the water has been over filled, it spills over each end of the top edge 72 of the over flow overflow well 70 . The overflow well outer surface 116 is tight against the outer surface of the inner pressure control vessel 66 forcing the water 114 to the outer edges of the overflow well 70 . The small hole 82 in the bottom of the inner pressure control vessels 66 allows water to flow to the outer water level reading and overflow vessel 30 . The small hole 82 is small enough to dampen the oscillation of the water that occurs in the inner pressure control vessels 66 from the bubbling of the gas from being transmitted to the outer water level reading and overflow vessel 30 . This causes the water in the outer vessel to be stabilized and ease the reading of the water level against the water level fill line 34 (not shown in FIG. 34 ) on the outer vessel.
The Continuous Positive Airway Pressure Device 10 shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present application. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed for providing a Continuous Positive Airway Pressure Device 10 in accordance with the spirit of this disclosure, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this design as broadly defined in the appended claims.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. | The present invention is directed to a Continuous Positive Airway Pressure Device as an apparatus configured to provide positive airway pressure in a respiratory circuit that comprises a container configured to be filled to a preselected level with liquids; a drop tube assembly comprising a hollow gas tube rotatably mounted in said container having an upper end extending a static distance outwardly of the container and connected to a respiratory circuit downstream of a user, and a hollow drop tube reciprocally movable upwardly and downwardly in the liquid in response to rotational movement of the gas tube. The container is provided with a gas vent and a liquid fill port. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. Utility Application No. 12/245,239, entitled METHOD AND PROCESS FOR COLLECTING AND PROCESSING RECYCLABLE WASTE, filed on Oct. 3, 2008 now abandoned, which is a divisional of U.S. Utility Application No. 11/299,442, now abandoned, entitled METHOD AND PROCESS OF COLLECTING AND PROCESSING RECYCLABLE WASTE, filed on Dec. 12, 2005, which is a continuation of United States Utility Application No. 11/166,516, now abandoned, entitled: “METHOD AND PROCESS OF COLLECTING AND PROCESSING RECYCLABLE WASTE,” filed on Jun. 24, 2005, and which claims the benefit of U.S. Provisional Application No. 60/617,971, filed Oct. 11, 2004. This application claims the benefit and priority of all of the foregoing applications which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to the field of recycling. More particularly, the present invention relates to methods of collecting and processing recyclable plastic film waste through the formation of bales including both plastic and cardboard.
2. The Relevant Technology
The field of plastic recycling is increasingly important as the use of plastic wrap and plastic film bags permeate more and more aspects of retail sales as well as the shipping and packaging industry. For example, plastic shopping bags are well known to the general public as they are the predominant method for consumers to carry groceries and other purchased goods from a store. An even greater volume of plastic film, however, is generated for product packaging and distribution. For example, pallets of goods are frequently wrapped with large sheets of shrink wrap plastic to keep the content of the pallet from shifting or falling during transit. Another example is clothing distribution, wherein each garment is typically transported wrapped in its own plastic sleeve. Some estimates are that plastic bags on apparel account for over 60% of plastic waste at retail department stores.
With this proliferation of plastic wrap and plastic bags into the shipping and packaging industry, there is a need to recover this material out of the waste stream in an efficient and effective manner. Stores that aggressively collect and recycle waste plastic wrap and plastic bags separate from other garbage frequently save hundreds of dollars per month in the cost of trash hauling. Still, the storage, baling, shipping, and processing of the plastic is extremely inefficient under current methods.
At stores and distribution centers, for example, one conventional method of collecting plastic waste film for recycling is to stuff plastic into other large plastic bags and toss them somewhere in the facility in a haphazard fashion, for example on top of other bales or bins. For transportation, the bags are thrown into the back of a truck for transportation. Both of these methods are extremely inefficient uses of space.
Because of these challenges, the majority of plastic wrap and plastic bags are disposed of as waste. Not only does this add to pollution and more quickly fill landfills, but the plastic film fills on-site trash receptacles very quickly. Because waste is typically paid for by volume, i.e. the number of waste containers hauled off, the large volume of plastic film that is disposed of in on-site trash receptacles represent a significant cost. In addition, waste plastic film has a recycling value that is unrealized when the plastic film is disposed of in garbage.
Despite the challenges in collecting recyclable plastic film, uses for recyclable plastic are quickly expanding. For example, recycled plastic is now used in plastic garbage can liners, landfill liners, agricultural film, and composite lumber products for picnic tables, park benches, porches, and walkways where rot-resistant wood-like products are desired. Shipping containers, carpet materials, and hard plastic containers are also more and more frequently made with recycled plastic film. This increased demand for products made from recycled plastic is fueling an increased demand for the collection of recyclable plastic.
In addition, recent increases in the cost of raw petroleum have led to a dramatic increase in the cost of plastics for plastic products. As a result, the per pound value of collected recyclable plastic has also increased dramatically. This adds to the demand for the collection of recyclable plastic.
Nevertheless, the volume of plastic that is collected for recycling remains considerably lower than is feasible. One key imitation on the use of recyclable plastic is that plastic film is difficult and costly to collect. For example, consumers using small plastic bags rarely return them to a source whereby they can be recycled. In addition, shrink wrapped plastic and garment bags at department stores are often discarded rather than collected. In particular, garment bags and shrink wrapped plastic at department stores and warehouse stores are often discarded because the volume of space required to store all the plastic accumulated within the store becomes too expensive to dedicate to that purpose. Although there are feasible methods for collecting plastic film, such as dedicated plastic compactors and balers, these devices are too expensive and the volume of space that must be dedicated to storing precompacted plastic is usually impractical for most businesses.
By analogy, efforts at recycling cardboard have been much more successful. Cardboard recycling is performed at retailers, for example, by using large cardboard balers to compact waste cardboard and form the waste cardboard into bales for storage and transportation to cardboard recycling facilities. Cardboard balers are generally not used for plastic recycling, however, because they are much too large for the volume of plastic that is dealt with. Cardboard balers are typically designed to form forty-eight inch tall bales. The amount of loose plastic it would take to form a forty-eight inch tall bale simply cannot be stored by most, if not all, retailers. As a result, unlike cardboard, for which there is an efficient recycling infrastructure, there is currently no effective method for collecting large volumes of recyclable plastic.
In addition, plastic and cardboard cannot be mixed for recycling. This is because they are completely different materials that are recycled by very different processes. There are also no efficient methods to separate plastic and cardboard since the value of either material does not justify the labor. For this reason, it is well known that the presence of plastic film in a cardboard bale leads to rejection of the entire bale such that it is discarded rather than recycled.
Accordingly, it would represent an advance in the art to provide systems and methods to more efficiently and less expensively collect and process recyclable plastic for use in downstream recycling processes.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to the collection of recyclable plastic film in bulk form. As noted above, the disposal or collection of plastic film from large retail stores, discount warehouses, and distribution centers has heretofore presented a significant cost to companies that made it inefficient or impractical. This difficulty in recovering recyclable plastic film results in the waste of a significant amount of otherwise recyclable plastic and reduces profits for those that do collect and recycle the plastic film.
These problems are overcome by the herein disclosed methods for the collection of plastic film within plastic/cardboard bales formed through novel methods of using balers such as conventional cardboard balers. In general, a plastic/cardboard bale is formed of layers of cardboard encompassing one or more layers of plastic. Thus, an amount of plastic insufficient to form a bale by itself is combined with one or more cardboard layers and compacted in a plastic/cardboard bale. As a result of these improved methods, a locale can use a cardboard baler not only to form cardboard bales, but also to form plastic/cardboard bales.
Accordingly, a first example embodiment of the invention is a method for collecting recyclable plastic. The method generally includes: providing a cardboard baler; placing a first layer of cardboard in the baler; placing a layer of recyclable plastic film in the baler on top of the first layer of cardboard, wherein the layer of recyclable plastic film has a thickness of at least about three inches; and operating the cardboard baler to form a bale formed of plastic and cardboard.
Another example embodiment of the invention is also a method for collecting recyclable plastic. This method generally includes: providing a cardboard baler; compacting a first layer of cardboard in the baler; compacting a layer of recyclable plastic film in the baler on top of the first layer of cardboard, wherein the layer of recyclable plastic film comprises a plurality of used plastic bags and/or plastic sheets and has a thickness of at least about three inches to about thirty-six inches; and compacting a second layer of cardboard over the plastic layer, whereby a bale is formed of plastic and cardboard, wherein the bale has a thickness of from about twenty-four inches to about sixty inches.
Yet another example embodiment of the invention is a bale formed of cardboard and recyclable plastic. The bale generally includes: a layer of recyclable plastic film, the layer of recyclable plastic film comprising first and second opposing surfaces, wherein the layer of recyclable plastic film comprises a plurality of used plastic bags and plastic sheets and has a thickness of at least about three inches; and a first layer of cardboard in contact with the first surface of the layer of recyclable plastic film, wherein the layer of recyclable plastic film and the first layer of cardboard are compactly bound together to facilitate transportation and storage. A second layer of cardboard can formed on and in contact with the second surface of the recyclable plastic film layer. Other cardboard and plastic film layers can also optionally be included in the bale.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 illustrates a cardboard bale according to the prior art;
FIG. 2 illustrates a plastic/cardboard bale according to one embodiment of the invention;
FIG. 3 illustrates a plastic/cardboard bale according to another embodiment of the invention;
FIG. 4 illustrates the insertion of recyclable plastic film into a cardboard baler for forming a plastic/cardboard bale according to embodiments of the invention;
FIG. 5 illustrates a plastic/cardboard bale formed in a cardboard baler according to embodiments of the invention;
FIG. 6 illustrates a series of plastic/cardboard bale stacked for storage according to another embodiment of the invention;
FIG. 7 illustrates a bin for storing recyclable plastic prior to its compacting in a plastic/cardboard bale according to another embodiment of the invention; and
FIG. 8 illustrates another bin for storing recyclable plastic prior to its compacting in a plastic/cardboard bale according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made to the figures wherein like structures will be provided with like reference designations. It is understood that the drawings are diagrammatic and schematic representations of presently preferred embodiments of the invention, and are not limiting of the present invention nor are they necessarily drawn to scale.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known aspects of cardboard balers and recyclable plastics have not been described in particular detail in order to avoid unnecessarily obscuring the present invention.
Referring now to FIG. 1 , a conventionally formed cardboard bale 100 includes a compacted single layer 102 of cardboard. As depicted, the compacted cardboard bale 100 is bound together by bands 104 to keep the cardboard bale 100 in a compacted state. Cardboard bale 100 can be formed by a cardboard baler as generally depicted in FIG. 4 or any other suitable baler or device used to compact cardboard. Typically, the majority of the individual pieces of cardboard that form cardboard bale 100 come from the same product distribution activities that generate most recyclable plastic film.
As previously noted, it has been conventionally held that cardboard cannot be mixed with plastic film in collecting materials for recycling. More particularly, the chemical and mechanical processes for recycling cardboard and plastic film cannot work if both are present. It has therefore been axiomatic that cardboard bales, such as bale 100 , cannot contain any plastic film or the whole bale must be discarded. This is because not only can the materials not be mixed in recycling processes, but the cost of separating plastic film from cardboard is too high for cost-effective recycling. As a result, mixed cardboard and plastic bales have heretofore been discarded as waste.
Contrary to this conventional thinking, however, it has been surprisingly found that plastic film can be effectively combined with cardboard in forming a combined cardboard and plastic film bale. As generally depicted in FIG. 2 , one embodiment of such a combined cardboard and plastic film bale 200 incorporates a first layer 204 of cardboard, a layer 202 of plastic film, and a second layer 206 of cardboard. The plastic film layer 202 is in effect sandwiched between the two cardboard layers 204 , 206 . The compacted plastic/cardboard bale is bound together by bands 208 .
It can be readily seen in FIG. 2 how a significant amount of plastic film has been compacted to a very small space in the plastic/cardboard bale. In addition, it is also apparent that a significantly less amount of plastic is used in this plastic/cardboard bale than if the entire bale were formed of only plastic film. Thus, because a smaller amount of plastic film can be compacted in a single bale, the plastic can be disposed of in a timely fashion from a single location. In contrast, if the plastic were required to fill the entire bale, it would require many days, weeks, or even months to fill a single bale, requiring great expense to store a significant amount of uncompacted plastic.
Although it is preferred to have cardboard layers both above and below the plastic film layer, other embodiments of the invention may use only a single cardboard layer on one side of a plastic film layer. Alternatively, a plastic/cardboard bale may have numerous layers. For example, FIG. 3 illustrates several plastic film layers 256 , 260 , 264 sandwiched between several cardboard layers 254 , 258 , 262 , 266 to form a plastic/cardboard bale having a thickness 252 . Of course, one skilled in the art, in view of the disclosure herein, could configure a plastic/cardboard bale with any number of layers of plastic and cardboard. The limiting factor is that the thickness of each plastic layer and the number of such plastic layers must be cost effective. This use of numerous plastic film layers may be preferable in locations where there is little storage space for loose plastic or cardboard and so it is desirable to frequently compact the on hand loose plastic and cardboard in multiple layers.
With reference now to FIG. 4 , a conventional cardboard baler 400 is used to form plastic/cardboard bales according to embodiments of the invention. Using conventional cardboard balers greatly reduces the cost to retailers and distributors that already have the balers on-site in that they do not have to acquire another machine nor do they have to store two machines, one for cardboard and one for plastic. The construction and operation of conventional cardboard balers, such as for example cardboard baler 400 , is well known in the art and will not be described in great detail herein. Most conventional balers are designed to form 48 inch, 60 inch, or 72 inch bales.
Generally, it can be seen that cardboard and plastic can each be inserted through a top opening 402 while a gate 404 is in the open position. In the illustration, a series of bags 302 containing plastic film have been inserted into the baler. Although not visible in the illustration, a layer of compacted cardboard of preferably twelve to eighteen inches is already formed below the uncompacted plastic bags 302 . After the gate 404 is closed, the baler 400 can then be operated to compact the plastic bags 302 into a compacted plastic film layer over the previously compacted cardboard layer. It is preferably to load and compact several cycles of plastic bags, for example eight to twelve, to form an ideally sized plastic film layer. For example, a preferred plastic film layer will be from about nine inches to about eighteen inches in thickness.
After the plastic film layer is formed, an operator preferably inserts a cycle of cardboard and then operates baler 400 to compress a layer of cardboard over the plastic film layer. This top layer may be formed over several load cycles and preferably has a thickness of twelve to eighteen inches. Finally, the finished bale is bound, preferably with wire in contrast to conventional plastic bands, to keep it compacted and then ejected from the baler 400 . Preferably the bales have two wires at each end to further bind the bales. FIG. 5 illustrates a completed and bound bale 200 seated within the bottom portion of baler 400 . Alternatively, as illustrated in FIG. 3 and previously discussed, multiple layers of plastic film can be formed within a single bale and top or bottom cardboard bales can be omitted. These embodiments are less preferred, however.
Referring now to FIG. 6 , forming stacks of plastic/cardboard bales 200 A-C is important in the recycling industry because it allows for economy of storage and transport efficiency. Completed plastic/cardboard bales 200 A-C are typically stored for a time at distribution and recycling centers, as seen in FIG. 6 , stacked on top of one another to conserve space. During transport to these locations, bales are typically stacked on top of one another on a flat-bed trailer. As the trailers travel, turn corners, bounce, etc., the need for increased stability is important as bales shift and tend to lose their structural integrity. The weight of these bales is often over one thousand pounds, accentuating the tendency of the bales to shift and lose structural integrity.
The structure of the inventive bales is particularly beneficial in that having cardboard layers 204 A-C, 206 A-C sandwich plastic layers 202 A-C forms structural bookends that allow the bales to maintain form and be transported safely and effectively. In other words, whereas the plastic layers are not strong enough to effectively stack perpendicularly on their own, the cardboard end layers provide excellent structural integrity so the bales can be stacked perpendicular to gravity without collapsing. The top and bottom cardboard layers 204 A-C, 206 A-C therefore preferably each have a thickness of at least about twelve inches to provide good support, but as few as six inches or even three inches may also be used in some embodiments.
In addition, the cardboard ends of the plastic/cardboard bales allow the bales to be tightly secured by straps tightened by a winch on a flat-bed trailer without the force of the straps breaking the bales part.
Accordingly, one embodiment of the invention is a method of transporting or storing plastic/cardboard bales by stacking two or more plastic/cardboard bales, wherein each of the bales has a cardboard layer, perpendicular to the stack, on each end of each bale such that the bales do not lose structural integrity and do not collapse. Such cardboard layers preferably have a thickness of least about three inches, more preferable at least about six inches, still more preferably at least about twelve inches.
In addition to providing structural support, the top and bottom cardboard layers 204 A-C, 206 A-C also help contain loss of debris when the bales 200 A-C are transported on an open flat-bed trailer. Cardboard is less likely to pull loose in the wind than plastic and so having cardboard at the end pieces reduces the likelihood of plastic being pulled loose. The cardboard layers are also beneficial when the bales are stored on the ground in that the cardboard absorbs water, reducing the amount of water entering the plastic.
One example process of implementing the invention involves first gathering recyclable plastic film to a single location. Such plastic may include plastic generated on-site, for example plastic shrink wrap or plastic garment bags removed from clothing prior to sale. Plastic may also be gathered from other locations. For example, a collection location may have a plastic bag collection program wherein consumers can return their small plastic grocery or shopping bags for recycling. In addition, plastic bags can be collected throughout a community, such as at local schools, to promote recycling and thereby provide the double effect of providing a revenue stream for the store (sales of recyclable plastic) and by generating community goodwill.
The gathered plastic film must then be stored for a brief period of time. Storing recyclable plastic according to one embodiment of the invention includes providing a specially designed collection area. As seen in FIGS. 7 and 8 , such a collection area may be for example a tall narrow ball bin 280 , 300 similar to those currently used to store large rubber balls and the like. Within a ball bin 280 , 300 a plurality of single plastic bags 302 , such as a garbage bags, are filled with shrink wrap and other accumulated plastic. The plastic bags 302 are preferably themselves recyclable plastic film bags having other recyclable plastic film therein.
A ball bin 280 , 300 can be conveniently located near a cardboard baler so that bags 302 of plastic film can be stored vertically to minimize occupied floor space. The ball bins can also be formed or placed on a pallet 288 or wheeled dolly so it can be moved as desired. In the embodiment of FIG. 7 , the ball bin 280 can have a lightweight frame 282 , for example formed of PVC. The depicted ball bin has a funneled top opening 290 and plurality of bungee cords or ropes 286 that keep bags 302 from falling out. For storage, the plastic bags can be either tossed in through the funneled top opening or pushed between the movable bungee retainer cords 286 . The bags can then be removed for compacting by pulling them through the movable bungee retainer cords 286 . In the depicted embodiment of FIG. 8 , in another example the ball bin also be a metal cage having top and bottom openings where the plastic bags 302 can be tossed in and removed.
The bags of plastic are preferably stored in a ball bin until it is completely full. That volume of plastic is then loaded into the baler over a series of compacting cycles to make a plastic/cardboard bale. It has been determined that one bin of approximately 4 feet in width, 4 feet in depth, and ten feet in height can hold the plastic generated over two to three days by a typical large retail store or discount warehouse.
It is preferable to make each plastic layer as thick as possible to reduce the number of plastic/cardboard bales. Fewer plastic/cardboard bales is preferable since it reduces the number of bales that need to be specially handled. It is estimated that large retail stores using a ball bin as describe herein to store plastic film will generate approximately one plastic/cardboard bale for every eight or nine cardboard bales.
Upon formation of a plastic/cardboard bale, such as for example plastic/cardboard bale 200 or plastic/cardboard bale 250 . The plastic/cardboard bale can then be stored on-site until it is shipped to a plastic and cardboard processing center, optionally via other distribution locales such as returns centers. Because, the plastic film has been compacted in the plastic/cardboard bales, it takes up the less space in a trailer or other transportation vehicle as a similar weight of loosely gathered plastic film.
At the downstream plastic and cardboard processing center the bale is separated into its constituent parts, for example first cardboard layer 204 , plastic layer 202 , and second cardboard layer 206 . Because the plastic film in the plastic/cardboard bale is contiguous, the compact plastic layer can be easily and readily removed and isolated for recycling. Thus, neither the plastic nor the cardboard is contaminated by the other.
Cardboard balers typically form bales that are about forty-eight inches tall, about sixty to seventy-two inches wide, and about thirty inches deep. A single plastic layer, in turn, may comprise from about three inches to about thirty-six inches or more in height. Alternatively, the layer of plastic film can be described as being at least about 5% of the bale thickness, more preferably from about 10% to about 70% of the bale thickness. While less than about 3 inches, or less than about 5%, can z be used in embodiments of the invention, unless the price per pound for recyclable plastic film becomes very high it is significantly less financially feasible to process a bale to collect such a relatively small volume of plastic. In addition, having at least about 30% cardboard in each bale helps ensure sufficient rigidity for bale stability and containment or plastic.
A lower cardboard layer will preferably be from about 5% to about 95% of the bale thickness, more preferably about 75% of the bale thickness. The optional top cardboard layer is preferably thinner than the bottom cardboard layer such that it can be more easily removed when the bale is disassembled. A top cardboard layer thickness of about three to twelve inches, more preferably about six inches to about nine inches, is therefore preferred. Although not necessary, the use of the top cardboard layer is preferred as it helps keep the bale more compact and intact than it would be if plastic film were on the top of the bale.
Of course, the denotations of top and bottom are interchangeable and the bales can be formed in an inverse manner to that described hereinabove.
Various approaches can be used to track the weight of plastic film that is pressed into each plastic/cardboard bale. One efficient manner of keeping track of the volume of plastic that is compacted in each bale is simply to measure the thickness of each plastic layer and multiply that thickness times other known constants such as the dimensions of the bale to determine an approximate plastic volume. This number is particularly helpful for use in determining the value of the plastic that has been recovered.
For example, it is currently known that every three inches of compacted plastic film in a 60″ by 48″ by 30″ bale weights about 50 pounds. A 72″ by 48″ by 30″ bale, in turn weights about 65 pounds. Thus, upon the formation of the bale the thickness of the plastic film layer can be approximately measured in inches and a weight estimate can be made.
Alternatively, the thickness of the plastic film layer can be estimated as a fraction of the bale thickness. Regardless, the entire bale can also be weighed so that the correct fractional portion of the load is assigned to the plastic film layer. Past measurements of separated bales as well as the known densities of plastic and cardboard can be used to create tables that indicate any adjustments to these estimates if more precise estimates are desired.
At the plastic and cardboard processing center, the whole bales can be again weighed. After the bales are broken open and the plastic is separated from cardboard the plastic can once more be weighed to get a final accurate measurement of the recovered plastic film. Of course, not all of these measurements may be necessary depending upon the accuracy and tracking that is desired.
After sorting the cardboard and plastic, each of the cardboard and plastic can be baled separately and shipped either on truck or rail car to paper and plastic consuming manufacturers throughout the country.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Recyclable plastic film is efficiently collected for recycling at stores or other locations by compacting the plastic film as layers in plastic/cardboard bales. The plastic/cardboard bales can be formed using existing cardboard balers that stores typically already have for baling recyclable cardboard. In one embodiment, the plastic/cardboard bales are preferably formed with a bottom layer of cardboard, a middle layer of the recyclable plastic film, and a top layer of cardboard. The layered structure can be modified to omit one of the cardboard layers or to add additional plastic film and cardboard layers. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to method and apparatus for controlling time base in a system for reading information recorded on a record medium such as a record disc or recording tape, and more specifically to time base control method and apparatus for use in a system for playing back video and/or audio signal recorded on the recording medium.
2. Description of Background Information
In a video disc player for example, a time base control method is adopted in which time base is coarsely adjusted by controlling the rotational speed of a spindle motor for rotating the recording disc, so as to control a relative speed between the recording disc and an information reading point of a pickup operating as a signal reading means. At the same time a fine adjustment of the time base is effected by supplying a playback signal obtained by the pickup to a variable delay element. Owing to the fall in price of memory devices, it has become increasingly frequent to adopt a method in which a memory is employed as the variable delay element for the fine control, a pulse train signal is generated in synchronism with the time base variation of the playback signal, and the playback signal is written in the memory device by using this pulse train signal, and subsequently read out from the memory device by means of a reference pulse signal which has a stable frequency.
With conventional time base control systems, however, if the jump operation is executed with a CLV (constant linear velocity) disc, a disturbance is generated in the phase difference between write and read reset pulses since the reproduced video signal becomes discontinuous. As result, there arises a shortcoming that the values in write and read address counters of the memory device approach to each other, so that the time base correction is not performed properly.
OBJECT AND SUMMARY OF THE INVENTION
An object of the present invention is therefore to provide a time base control method by which the time base correction is effected properly even immediately after jumping a plurality of tracks in a CLV disc.
Another object of the present invention is to provide a time base control apparatus by which the time base correction is effected properly even immediately after jumping a plurality of tracks in the CLV disc.
A time base control method according to the present invention is characterized by changing phases of generation of the read-out reset signal of the memory for the fine control of the time base before and after a starting of the track jump operation.
A time base control apparatus according to the present invention is characterized by a provision of device for changing phases of generation of the read-out reset signal of the memory for the fine control of the time base before and after a starting of the track jump operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of the present invention,
FIGS. 2 and 3 are waveform diagrams showing operations of each part of the system of FIG. 1,
FIG. 4 is a diagram showing the changes in the addresses of the line memory in the system of FIG. 1,
FIG. 5 is a block diagram showing another embodiment of the present invention,
FIG. 6 is a block diagram showing a system according to a conventional method,
FIGS. 7 through 9 are diagrams showing the changes in the addresses of the line memory in the system of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before entering into the description of the preferred embodiments, an example of the conventional time base correction system will be explained with reference to the accompanying drawings.
A video disc player in which a conventional time base control method is adopted is shown in FIG. 6. In FIG. 6, a recording disc is driven to rotate by means of a spindle motor 2. From the recording disc 1, an RF (Radio Frequency) signal carrying video information and others is read out by means of a pickup 3. A read spot of the pickup 3 is positioned in a radial direction of the recording disc 1 by means of a tracking servo mechanism 4 so as to trace a track formed on the recording disc 1. In a special playback mode requiring a jump operation (an operation of jumping a track) such as a scanning playback mode, the tracking servo mechanism 4 operates to cause a jump movement of the read spot of the pickup 3 in response to a jump command a supplied from a control circuit (not shown).
The RF signal read out from the recording disc 1 by means of the pickup 3 is supplied to a demodulation circuit 5 which comprises an FM demodulator for example. In the demodulation circuit 5, a video signal is reproduced and supplied to an A/D (Analog to Digital) converter 6 and a sync detection circuit 7. By the sync detection circuit 7, a horizontal synchronizing signal contained in the video signal is detected. The reproduced horizontal synchronizing signal h outputted from this sync detection circuit 7 is supplied to a phase comparator circuit 8 and a write pulse signal generating circuit 9. In the phase comparator circuit 8, phase comparison between the reproduced horizontal synchronizing signal h and a reference signal r of a predetermined frequency is effected to generate a phase difference detection signal corresponding to the phase difference between these two signals. As a spindle error signal, the phase difference detection signal is supplied to the spindle motor 2 which drives the disc through a servo amplifier 10. Thus, the speed of rotation of the recording disc 1 is controlled.
The reference signal r is outputted from a reference signal generating circuit 11. The reference signal generating circuit 11 comprises a crystal oscillator 12 which oscillates at a frequency N-times (N is a natural number) the frequency fH of the horizontal synchronizing signal, and a frequency divider 13 which divides an oscillation output signal of the crystal oscillator 12 by N, to generate the reference signal r.
In the write pulse signal generating circuit 9, the reproduced horizontal synchronizing signal h is supplied to a phase comparator circuit 14 in which it is compared in phase with an output signal of a frequency divider 15, and a phase difference detection signal corresponding to a phase difference between these two signals is generated. This phase difference detection signal is supplied to a VCO (Voltage Controlled Oscillator) 16. The voltage controlled oscillator 16 is designed so that its free-running frequency is substantially equal to a frequency N times the frequency fH of the horizontal synchronizing signal. An output signal of this VCO 16 is supplied to the frequency divider 15 in which it is divided by N. A PLL (Phase Locked Loop) is formed by the phase comparator circuit 14, the divider 15, and a signal which is synchronized in phase with the reproduced horizontal synchronizing signal h is outputted from the frequency divider 15. The output signal of the VCO 16 is supplied, as a sampling pulse signal, to the A/D converter 6 and, as a write clock signal, to a line memory 18. The output signal of the frequency divider 15 is supplied, as a write reset pulse signal e which is generated substantially at the same timing as the reproduced horizontal synchronizing signal h, to the line memory 18.
In the A/D converter 6, the video signal is sampled by means of the output signal of the VCO 16, and a digital signal representing sampled values obtained by the sampling is generated. Output data of this A/D converter 6 is supplied to the line memory 18. To the line memory 18, a reference signal r outputted from the frequency divider 13 in the reference signal generating circuit 11 is supplied, as a read-out reset pulse f along with the write clock signal and the write reset pulse e, and the output signal of the crystal oscillator 12 is supplied as a read-out clock signal. The line memory 18 includes for example a write address counter which is reset by the write reset pulse e and whose count value is varied in sequence by means of the write clock signal, and a read address counter which is reset by means of the read-out reset pulse f and whose count value is varied in sequence by means of the read-out clock signal, and constructed so that data is written into an address corresponding to output data of the write address counter every time the write clock signal is generated, and that data in an address corresponding to the output data of the read address counter is read-out every time the readout clock signal is generated.
Data read-out from the line memory 18 is supplied to a picture memory 21. The picture memory 21 has a memory capacity capable of storing data corresponding to 1 field of video information. Write and read-out operations into and from this picture memory 21 are controlled by means of a memory controller 22. The memory controller 22 performs a control such that writing is performed in sequence every time data is read-out from the line memory 18 by means of the read-out reset pulse f and the readout clock signal of the line memory 18, and data is readout in the same order as the writing by means of a command from a control circuit (not shown).
Data read out from the picture memory 21 is supplied to a D/A converter 23 in which the data is converted to an analog signal. A playback video signal is outputted from this D/A converter 23.
With the above construction, the rotation of the spindle motor 2 becomes unstable due to a disturbance of the continuity of the reproduced horizontal synchronizing signal h supplied to the phase comparator circuit 8 which is caused as a result of the jump operation during a scanning playback of a CLV disc, that is, a mode of operation in which the jump operation of the information reading point of the pickup 1 and the operation for following the recording track are performed alternately. On the other hand, in the event that the continuity of the reproduced horizontal synchronizing signal h is lost in the write pulse generating circuit 9 which controls the writing of data in the line memory 18 operating as the means for the fine control of the time base control, a disturbance occurs in the phase locked loop circuit generating the write clock signal, which in turn results in a shortcoming such that the writing and reading of data into and from the line memory occurs in a memory cell at the same time, and consequently the time base correction operation is disabled.
The operation of the line memory 18 will be explained with reference to FIGS. 7 through 9. in FIGS. 7 through 9, with the axis of ordinates being an axis of co-ordinates for values in the write and read address counters of the line memory 18, and the axis of abscissas being an axis of co-ordinates for time, the manner of variation of the value in the read address counter is shown by the solid line, and the manner of variation of the value in the write address counter is shown by the dashed line. The read address is shown by a perfect straight line because it is varied by the reference clock signal including no jitter. When the reading of data of 1H (one horizontal period) is completed, the read address counter is reset and the data is read from the head of address. Therefore, video data free of jitter is read out from the line memory 19.
On the other hand, the value of the write address counter shows a non-linear variation. Since the write clock is synchronized with the video signal including jitter, it will not change linearly with respect to time, and has a slight rolling.
The line memory 18 is constructed so that the read and write address counters are operated by independent clock signals, and the reading and writing take place at memory cells of designated addresses. Therefore, as shown in FIG. 7, the time base control is effected properly unless the values of the write and read address counters become identical with each other.
However, as shown in FIG. 8, in the event that the values of the write and read address counters become identical with each other so that there arises a state where accesses to a memory cell of the same address take place, or that an overtake of the address occurs, a time jump will appear in read out video data, and the time base control will not be effected properly.
Therefore, as shown in FIG. 7, in order that the values in the write and read address counters will not approach to each other during the playback, it is only necessary to control the speed of the spindle motor 2 so that the phase difference between the write and read-out reset pulses e and f becomes equal to H/2 in average. Since the write reset pulse e is generated from the reproduced horizontal synchronizing signal h, the speed control of the spindle motor 2 is effected by the phase comparison between the reproduced horizontal synchronizing signal h and the read-out reset pulse f in the conventional system shown in FIG. 6.
However, as mentioned before, with the conventional system even if the phase difference between the write and read reset pulses e and f is maintained at H/2 during the normal playback operation, when the jump operation is executed with a CLV disc, a disturbance is generated in the phase difference between the write and read reset pulses e and f since the playback video signal becomes discontinuous. Therefore, as shown in FIG. 9, there arises a shortcoming that the values of the write and read address counters approach to each other, so that the time base correction is not performed properly.
Embodiments of the present invention will be explained in detail with reference to FIGS. 1 through 5. In FIG. 1, the recording disc 1, the spindle motor 2, the pickup 3, the tracking servo mechanism 4, the demodulation circuit 5, the A/D converter 6, the sync detection circuit 7, the phase comparator circuit 8, the write pulse signal generating circuit 9, the servo amplifier 10, the reference signal generating circuit 11, the lime memory 18, the picture memory 21, the remote controller 22, the D/A converter 23 are mutually connected in the same manner as in the system of FIG. 6. Since the operations of the above circuit elements are similar to those which have been explained before, the explanation thereof will not be repeated.
In this embodiment, the frequency divider 13 in the reference signal generating circuit 11 is made up of a presettable counter. To a presetting input terminal of this frequency divider 13, there is supplied output data of a data generation circuit 25. The count value of the write address counter of the line memory 18 is supplied, through a bus line A for example, to this data generation circuit 25. The data generation circuit 25 comprises, for example, an operation circuit which is adapted to add a value of N/2 when the count value is equal to or smaller than N/2, and to subtract the value N/2 when the count value is larger than N/2.
A jump command a is supplied as a trigger input of a monostable multivibrator (referred to as MMV hereinafter) 26. The inversion period of the MMV 26 is set to be longer than the period of a track jump operation. A Q output b of the MMV 26 is supplied to a D input of a D flip-flop 27. To the D flip-flop 27 there supplied is the reproduced horizontal sync signal h as a clock signal. A Q output signal d of this D flip-flop 27 is supplied to a presetting command pulse generation circuit 28 which for example comprises a differentiation circuit. When the D flip-flop 27 is set, a presetting command pulse c is outputted from the presetting command pulse generating circuit 28 and supplied to a presetting command input terminal of the frequency divider 13. By means of this presetting command pulse signal c, output data of the data generation circuit 25 is preset in the frequency divider 13 as a counting data.
With the above described arrangement, the jump command a is periodically generated during the scanning playback as shown in FIG. 2 (A), so that the jump operation is executed. Under this condition, the tracking error signal becomes as shown in FIG. 2 (B).
Referring to FIG. 3, operations of various parts of the system during a period of one of a plurality of jump operations in the scanning playback and periods immediately before and after that period will be explained. In the figure, (A) is a waveform diagram of the jump command a, (B) is a waveform diagram of the Q output b of the MMV 26, (C) is a waveform diagram of the presetting command pulse c, (D) is a waveform diagram of the Q output signal d of the D flip-flop 27, (F) is a waveform diagram of the read reset pulse f.
If a jump command a is generated at a time t 1 , the track jump operation is started and the MMV is triggered to start the inversion operation. The period of inversion of this MMV 26 is set to be a time period T which is longer than the period of track jump operation, its Q output b has a low level for the time period T. Since this Q output signal b is latched by the D flip-flop 27 every time the reproduced horizontal synchronizing signal h is generated, the Q output signal d of the D flip-flop 27 forms pulses whose leading edge is synchronized with the reproduced horizontal synchronizing signal h after the completion of the track jump operation. The presetting command pulse c is outputted from the presetting command pulse generator 28 at the time of every leading edge of the Q output signal d. Then a predetermined value is set in the frequency divider 13.
In the embodiment described above, the presetting command pulse is generated upon reception of the first reproduced horizontal synchronizing signal h immediately after the turn over of the output signal of the MMV 26. At this time, the write reset pulse e is also generated, so that the count value of the write address counter is equal to 0. Therefore, the data generation circuit 25 outputs a value obtained by addition of N/2, and the value N/2 is preset in the frequency divider 13 which is made up of a presettable counter. As a result, the frequency divider 13 generates the read reset pulse f after the elapse of time period of H/2. Thus, such a condition that the read and write addresses become identical with each other in the line memory 18 is surely prevented as illustrated in FIG. 4. Also, even if the jitter on the writing side is considered, it is possible to preset so that there remains a sufficient phase difference.
Therefore, the values of the write and read address counters are varied as shown in FIG. 4, to prevent the generation of the overtake phenomenon of the address values, so that a good time base control operation will be performed.
In the above embodiment, the arrangement is shown in which the presetting is effected upon receipt of the reproduced horizontal synchronizing signal h. However, the arrangement is not limited to this. Even if the presetting occurs at an arbitrary timing, the data generation circuit 25 outputs a preset value which is always shifted from the count value of the write address counter by N/2. Therefore, the write and read addresses are prevented from become identical with each other.
In the foregoing, a case in which a memory which has a storage capacity for storing data of the amount of 1 line is used as the line memory 18 has been explained. FIG. 5 on the other hand shows an example of the system in which a memory having a memory capacity for storing data of the amount of M lines is used as the line memory 18. In the figure, each part of the system is constructed in the same manner as the system of FIG. 1 except that a frequency divider 29 for dividing the output signal of the frequency divider 15 by M is connected, and an output of this frequency divider 29 is supplied to the line memory 18 as the write reset pulse, and at the same time supplied to the phase comparator circuit 8 and the D flip-flop circuit 27 instead of the reproduced horizontal synchronizing signal h, and the frequency divider 13 is constructed to divide the input signal by M×N. In this construction, the supply of the write and read reset pulses e and f of the line memory 18 to the line memory 18 is effected every M lines so that the data is written into the whole memory area of the line memory.
On the other hand, the output signal of the frequency divider 29 and the reproduced horizontal synchronizing signal h are synchronized with each other by means of the PLL loop, the same action as in the system of FIG. 1 is effected although the output signal of the frequency divider 29 is supplied to the phase comparing circuit 8 and the D flip-flop 27.
In the above described embodiments the frequency divider 13 is preset in synchronism with the reproduced horizontal synchronizing signal h after the track jump operation. However, other methods are conceivable to set predetermined phases of the write and read reset pulses e and f on the line memory 18. For example, it is also possible to effect the presetting at timings which are not identical with the reproduced horizontal synchronizing signal h. Furthermore, it is possible to employ a method in which the presetting operation is executed at the same time as the start of the track jump operation or precedently to it, and the value is held while the preset state is maintained, and the preset state is released after the track jump operation so as to restart the count operation.
Moreover, in the above embodiments, the value preset in the frequency divider 13 is determined to be constant. However, it is possible to arrange the system such that the count value of the frequency divider 13 immediately before a track jump operation is memorized and the memorized value is preset in the frequency divider 13 after the track jump operation. This operation is equivalent to hold a previous value of the count value of the frequency divider 13. Therefore, as a simplest method, it is sufficient to stop the count operation of the frequency divider 13 during the output period (during the presence of the output signal d) of the flip-flop circuit 27.
Also, it is possible to change the preset value depending on the direction of the track jump operation. Specifically, when the number of jumped track is large and the linear velocity before and after the jump operation is changes greatly, the speed of the advancement of the write address becomes slower than the speed of the advancement of the read address in the case that the jump operation is directed to the inner periphery, and faster than it in the case that the jump operation is directed to the outer periphery. Taking this into account, it is conceivable to change the preset value, and the generation of the phenomenon of overtaking after the presetting can be prevented by such a provision.
In addition, the construction of the data generation circuit 25 is not limited to the operational circuit explained in the above description. For example, it is also possible to use a circuit which generates a predetermined value (such as N/2) at the same time as the generation of the reproduced horizontal synchronizing signal or the write reset pulse.
A described specifically in the above, the time base control method or apparatus according to the present invention is arranged so that the phase of the read reset pulse is reset so that the phase difference between the read and write reset pulses which respectively reset the values of the read and write address counters of the memory for the fine adjustment of the time base immediately after the completion of the jump operation. Therefore, the generation of a time gap of output signal due to the phenomenon of overtaking of address value after the jump operation is prevented even if a discontinuous part is generated in the read signal by the jump operation. Thus, a good time base control operation is performed. | Method and apparatus of controlling time base for use in an information reading system in which information recorded on a recording medium is read by a pickup, write a read signal obtained by the pickup into a memory device and read-out the signal stored in the memory device by using a read-out reset signal so as to perform the time base control. Upon starting of a track jump operation of the information reading system, phases of generation of the read-out reset signal before and after the starting of the track jump operation is changed with each other. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to valve actuation in internal combustion engines that include compression release-type engine retarders. In particular, it relates to methods and apparatus for controlling valve lift and duration for compression release valve events and main exhaust valve events.
BACKGROUND OF THE INVENTION
Engine retarders of the compression release-type are well-known in the art. Engine retarders are designed to convert, at least temporarily, an internal combustion engine of compression-ignition type into an air compressor. In doing so, the engine develops retarding horsepower to help slow the vehicle down. This can provide the operator increased control over the vehicle and substantially reduce wear on the service brakes of the vehicle. A properly designed and adjusted compression release-type engine retarder can develop retarding horsepower that is a substantial portion of the operating horsepower developed by the engine in positive power.
Safety, reliability and environmental demands have pushed the technology of compression release engine retarding significantly over the past 30 years. Compression release retarding systems are typically adapted to a particular engine in order to maximize the retarding horsepower that could be developed, consistent with the mechanical limitations of the engine system. In addition, over the decades during which these improvements were made, compression release-type engine retarders garnered substantial commercial success. Engine manufacturers have become more willing to embrace compression release retarding technology. Compression release-type retarders have continued to enjoy substantial and continuing commercial success in the marketplace. Accordingly, engine manufacturers have been more willing to make engine design modifications, in order to accommodate the compression release-type engine retarder, as well as to improve its performance and efficiency.
In addition to these pressures, environmental restrictions have forced engine manufacturers to explore a variety of new ways to improve the efficiency of their engines. These changes have forced a number of engine modifications. Engines have become smaller and more fuel efficient. Yet, the demands on retarder performance have often increased, requiring the compression release-type engine retarder to generate greater amounts of retarding horsepower under more limiting conditions.
As the market for compression release-type engine retarders has developed and matured, the aforementioned factors have pushed the direction of technological development toward a number of goals: securing higher retarding horsepower from the compression release retarder; working with, in some cases, lower masses of air deliverable to the cylinders through the intake system; and the inter-relation of various collateral or ancillary equipment, such as: silencers; turbochargers; and exhaust brakes. In addition, the market for compression release engine retarders has moved from the after-market, to original equipment manufacturers. Engine manufacturers have shown an increased willingness to make design modifications to their engines that would increase the performance and reliability and broaden the operating parameters of the compression release-type engine retarder.
Functionally, compression release-type retarders supplement the braking capacity of the primary vehicle wheel braking system. In so doing, it extends substantially the life of the primary (or wheel) braking system of the vehicle. The basic design for a compression release engine retarding system of the type involved with this invention is disclosed in Cummins, U.S. Pat. No. 3,220,392, issued November 1965.
The compression release-type engine retarder disclosed in the Cummins '392 patent employs a hydraulic system or linkage. The hydraulic linkage of a typical compression release-type engine retarder may be linked to the valve train of the engine. When the engine is under positive power, the hydraulic linkage may be disabled from providing valve actuation. When compression release-type retarding is desired, the hydraulic linkage is enabled such that valve actuation is provided by the hydraulic linkage responsive to an input from the valve train.
Among the hydraulic linkages that have been employed to control valve actuation (both in braking and positive power), are so-called "lost-motion" systems. Lost-motion, per se, is not new. It has been known that lost-motion systems are useful for variable valve control for internal combustion engines for decades. In general, lost-motion systems work by modifying the hydraulic or mechanical circuit connecting the actuator (typically the cam shaft) and the valve stem to change the length of that circuit and lose a portion or all of the cam actuated motion that would otherwise be delivered to the valve stem to actuate a valve opening event. In this way lost-motion systems may be used to vary valve event timing, duration, and the valve lift.
Compression release-type engine retarders may employ a lost motion system in which a master piston engages the valve train (e.g. a push tube, cam, or rocker arm) of the engine. When the retarder is engaged, the valve train actuates the master piston, which is hydraulically connected to a slave piston. The motion of the master piston controls the motion of the slave piston, which in turn may open the exhaust valve of the internal combustion engine at a point near the end of a piston's compression stroke. In doing so, the work that is done in compressing the intake air cannot be recovered during the subsequent expansion (or power) stroke of the engine. Instead, it is dissipated through the exhaust and radiator systems of the engine. By dissipating energy developed from the work done in compressing the cylinder gases, the compression release-type retarder dissipates the kinetic energy of the vehicle, which may be used to slow the vehicle down.
Regardless of the specific actuation means chosen, inherent limits were imposed on operation of the compression release-type retarder based on engine parameters. One such engine parameter is the physical relationship of an engine cylinder valve used for compression release braking and the piston in the same cylinder. If the extension of the valve into the cylinder was unconstrained during compression release braking, the valve could extend so far down into the cylinder that it impacts with the piston in the cylinder.
There may be a significant risk of valve-to-piston contact when a unitary cam lobe is used to impart the valve motion for both the compression release valve event and the main exhaust valve event. Use of a unitary cam lobe for both events means that the relatively large main exhaust lobe motion will be imparted to the hydraulic linkage, or more particularly to the slave piston. Because there is typically little or no lash between the slave piston and the exhaust valve, input of the main exhaust event motion to the slave piston may produce a greater than desired main exhaust event.
Accordingly, there is a need for a system and method for avoiding the occurrence of valve-to-piston contact when a unitary cam lobe is used to impart the valve motion for both a compression release event and a main exhaust valve event. More particularly, there is a need for a system and method of limiting the stroke or displacement of a slave piston when a lost motion system is imparted with the motion from a main exhaust cam lobe.
One way of avoiding valve-to-piston contact as a result of using a unitary cam lobe for both compression release valve events and main exhaust valve events is to limit the motion of the slave piston which is responsible for pushing the valve into the cylinder during compression release braking. A device that may be used to limit slave piston motion is disclosed in Cavanagh, U.S. Pat. No. 4,399,787 (Aug. 23, 1983) for an Engine Retarder Hydraulic Reset Mechanism, which is incorporated herein by reference. Another device that may be used to limit slave piston motion is disclosed in Hu, U.S. Pat. No. 5,201,290 (Apr. 13, 1993) for a Compression Relief Engine Retarder Clip Valve, which is also incorporated herein by reference. Both of these (reset valves and clip valves) may comprise means for blocking a passage in a slave piston during the downward movement of the slave piston (such as the passage 344 of the slave piston 340 of FIG. 6). After the slave piston reaches a threshold downward displacement, the reset valve or clip valve may unblock the passage through the slave piston and allow the oil displacing the slave piston to drain there through, causing the slave piston to return to its upper position under the influence of a return spring.
A reset valve, such as the one disclosed in Cavanagh, may be provided as part of a lash adjuster or a slave piston. A reset valve may comprise a hydraulically actuated means for unblocking a passage through the slave piston to limit the displacement of the slave piston. In Cavanagh, compression release retarding is carried out by opening one of two valves connected by a crosshead member or bridge. A purpose of the reset valve used in Cavanagh is to reseat the exhaust valve used for the compression release event before a subsequent main exhaust valve event so that the rocker arm will not push down on an unbalanced crosshead during the main exhaust event and transmit a bending force to the crosshead guide pin or to the non-braking valve stem.
A clip valve, such as the one disclosed in Hu, may comprise a mechanically actuated means for unblocking the passage through the slave piston to limit the displacement of the slave piston. A purpose of the Hu clip valve is to enable a sharp hydraulic pulse to be applied to the slave piston to rapidly open an exhaust valve while maintaining an accurate limit on the extension of the slave piston.
FIG. 1 illustrates a system in which a cam section 110 is connected to valves 200 by both a hydraulic linkage 300 and a mechanical linkage 400. With reference to FIG. 1, the actuation provided by the hydraulic linkage 300, which may include a slave piston, during the main exhaust valve event may be further limited by providing the mechanical linkage 400 with a greater actuation ratio than that of the hydraulic linkage. For example, for each unit of linear motion input to the hydraulic and mechanical linkages, the hydraulic linkage may transfer 1.3 units of linear motion to the valve 200 while the mechanical linkage may transfer 1.5 units of linear motion. By differing the actuation ratios of the hydraulic and mechanical linkages, the mechanical linkage 400 may be able to make up the lash distance 410 and thereby dominate the actuation of the valve 200 during the main exhaust portion 114 of the cam lobe.
Use of a unitary cam lobe for both the compression release event and the main exhaust event may also result in excessive overlap between the opening of the exhaust valve for the main exhaust valve event and the opening of the intake valve for the main intake event. With reference to FIG. 3, when the main exhaust event is input to the slave piston, the exhaust valve motion may be represented by curve 520-620 and the overlap of the main exhaust event with the main intake event may be illustrated by the combined shaded areas 650 and 652. The overlap represented by areas 650 and 652 may dramatically reduce brake effectiveness because intake charge (mass) used for the subsequent compression release event may pass right through the cylinder and out the exhaust port.
Accordingly, there is a need for a system and method for limiting and controlling the overlap between the main exhaust event and the main intake event when a unitary cam lobe is used to provide both a compression release event and the main exhaust event.
There also remains a significant need for a system and method for controlling the actuation of the exhaust valve in order to increase the effectiveness of and optimize the compression release retarding event. Further, there remains a significant need for a system that is able to perform that function over a wide range of engine operating parameters and conditions. In particular, there remains a need to "tune" the compression release-type retarder system in order to optimize its performance Whereas, exhaust valve actuation for retarding that can be provided by the existing cam profiles (valve or injector) may not produce this result.
OBJECTS OF THE INVENTION
It is therefore an object of the present invention to provide an actuation means for retarding that optimizes engine retarding performance.
It is another object to provide a system and method of providing compression release and main exhaust valve actuation with a unitary cam lobe.
It is another object of the present invention to provide a system and method for avoiding valve-to-piston contact during a main exhaust valve event.
It is a further object of the present invention to provide a system and method for limiting the stroke of a lost motion system slave piston during a main exhaust event.
It is yet another object of the present invention to provide a system and method for resetting a lost motion system slave piston following a compression release valve event.
It is still another object of the present invention to provide a system and method for clipping the motion of a lost motion system slave piston during a main exhaust valve event.
It is still a further object of the present invention to provide a system and method for ensuring that the motion input from a mechanical linkage to an exhaust valve during a main exhaust event exceeds the motion input from a hydraulic linkage to the exhaust valve.
It is still yet another object of the present invention to provide a system and method for controlling the overlap between a main intake valve event and the main exhaust valve event.
SUMMARY OF THE INVENTION
In response to this challenge, Applicants have developed innovative and reliable systems and apparatus to achieve control of the engine valves in a compression release-type engine retarder using lost-motion. In accordance with the teachings of the present invention, the present invention is an engine braking system, for providing a main exhaust valve event and a compression release valve event in an internal combustion engine, comprising: means for imparting motion to an engine valve; first means for transferring motion from said imparting means to the engine valve; hydraulic means for transferring motion from said imparting means to the engine valve; and means for controlling the amount of motion transferred by said hydraulic means to the engine valve such that the motion transferred by said hydraulic means is less than the motion transferred by said first means during the main exhaust valve event.
An alternate embodiment invention comprises a method of providing a compression release valve event and a main exhaust valve event from a unitary cam lobe and in which said compression release valve event is provided by a hydraulic linkage between said valve and said cam lobe and said main exhaust event is provided by a mechanical linkage between said valve and said cam lobe, and wherein the method of limiting the stroke of the exhaust valve during the main exhaust valve event comprises the step of selectively reducing the hydraulic pressure in the hydraulic linkage at the conclusion of the compression release valve event and prior to the main exhaust valve event.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated herein by reference, and which constitute a part of this specification, illustrate certain embodiments of the invention and, together with the detailed description, serve to explain the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing illustrating fundamental elements of the lost motion fixed timed system embodiment of the invention.
FIG. 2 is a graph of exhaust valve events, including mechanical and hydraulic actuation resulting from the cam profile, which illustrates the functioning of an embodiment of the invention.
FIG. 3 is a graph of exhaust valve and intake valve events, including mechanical and hydraulic actuation, and which illustrates an embodiment of the invention.
FIG. 4 is a graph of exhaust valve events, including engine braking, main exhaust, and exhaust gas recirculation (EGR) events, using a reset valve.
FIG. 5 is a graph of exhaust valve events, including engine braking, main exhaust, and EGR events, using a clip valve.
FIG. 6 is a cross-sectional view in elevation of an embodiment of the invention utilizing a reset or clip valve, a master-slave piston circuit, and a low pressure, normally closed, on/off solenoid valve.
FIG. 7 is a cross-sectional view in elevation of an embodiment of the invention utilizing a hydraulic tappet and a low pressure, normally closed, on/off solenoid valve.
FIG. 8 is a cross-sectional view in elevation of an embodiment of the invention utilizing a hydraulic tappet and a high pressure, normally open, on/off solenoid valve.
FIG. 9 is a cross-sectional view in elevation of an embodiment of the invention utilizing a master-slave piston circuit and a high pressure, normally open, on/off solenoid valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to a preferred embodiment of the present invention, an example of which is illustrated in the accompanying drawings. A preferred embodiment of the present invention is shown in FIG. 1 as engine braking system 10. The engine braking system 10 shown in FIG. 1 may include a means for imparting motion 100 to an engine valve 200, a hydraulic linkage 300, and a mechanical linkage 400 connecting the motion imparting means and the engine valve. The hydraulic linkage 300 and the mechanical linkage 400 may each independently link the motion imparting means 100 to the valve 200 such that linear motion imparted from the motion imparting means 100 to the hydraulic linkage 300 and the mechanical linkage 400 may be transferred by these linkages to the valve 200. In this manner the motion imparting means 100 provides motion to open the valve 200 for various engine valve events, e.g. compression release valve events and main exhaust valve events.
The motion imparting means 100 may be provided by a cam section 110 having fixed compression release, main exhaust, and EGR lobes 114 (or a unitary cam). The lift of the main exhaust portion of the lobe 114 provides a linear input to both the hydraulic linkage 300 and the mechanical linkage 400. By building a lash space 410 into the mechanical linkage, the linear input of the beginning and end of lobe 114 may be absorbed by the mechanical linkage 400 and thereby not transferred by the mechanical linkage to the valve 200.
The hydraulic linkage 300 may be provided as a lost motion system so that the linear input of the lobe 114 may be selectively "lost" or absorbed by the hydraulic linkage 300 and thereby not transferred by the hydraulic linkage to the valve 200. When the engine braking system 10 is turned "off", the hydraulic linkage 300 may lose all, or a predetermined portion, of the linear motion imparted to it by the lobe 114. When the engine braking system 10 is turned "on", the hydraulic linkage 300 may lose only a selective portion, or none, of the linear motion imparted to it by the lobe.
When the hydraulic linkage 300 is turned "on," the hydraulic linkage could completely control the actuation of the valve 200 for the main exhaust, compression release, and EGR portions of the cam 110. Each event (main exhaust, compression release, etc.) may be dictated by a lobe on the unitary cam. If the hydraulic linkage were permitted to impart the full displacement provided by the main exhaust portion of the cam lobe 114 to the valve 200, the valve may be displaced far enough into the engine cylinder at top dead center intake that it impacts with the piston. Therefore, the actuation provided by the hydraulic linkage 300 may be selectively reduced following the compression release and EGR portions of the cam 110, and particularly before the main exhaust portion of the cam lobe.
FIG. 4 illustrates the lift verses crank angle for an exhaust valve employing a reset valve (curve 520-620). The main exhaust event 620 is produced by a mechanical linkage (e.g. a rocker arm), while the engine brake events 520 and 820 are produced by the hydraulic linkage.
FIG. 5 illustrates the lift versus crank angle for an exhaust valve employing a clip valve (curve 520-620). Given the same cam lobe input, the valve lift resulting from the combined hydraulic and mechanical linkage (without a clip valve) can exceed the valve lift resulting from the combined linkage (with a clip valve).
With reference to FIG. 4, the compression release valve event the main exhaust valve event, and the EGR event, may be governed by the curves 520, 620 and 820, respectively. As illustrated by the curves, after the compression release event 520 the valve may be reset to base circle; i.e. the hydraulic linkage is reset and the mechanical linkage has no influence yet because of the lash distance. By resetting the hydraulic linkage after the compression release event 520 the main exhaust event is governed solely by the mechanical linkage and therefore the lift corresponding to the main exhaust event during braking 620 is the same lift as for the main exhaust event 630 provided during positive power. The main exhaust event is solely governed by the mechanical linkage because the available lift from the hydraulic linkage, represented by curve 640, is less than the lift provided by mechanical linkage. The lift available from the hydraulic linkage may be less than that of the mechanical linkage because the hydraulic ratio is less than the rocker ration, and because a reset or clip valve may lose a portion of the motion of the hydraulic linkage.
In FIG. 5, in which like numerals refer to like elements of FIG. 4, rather than resetting the hydraulic linkage after the compression release event 520, the hydraulic linkage may be clipped at the beginning 622 of the main exhaust event 620. Because the hydraulic linkage is clipped, the main exhaust event may be solely governed by the actuation of the mechanical linkage.
Selective reduction of the actuation provided by the hydraulic linkage is useful in a second context. With reference to FIGS. 2 and 3, in which like reference numerals refer to like elements, the main exhaust valve event 620 would be prolonged during engine braking absent reduction of the hydraulic linkage actuation. The main exhaust valve event provided with reduction of the hydraulic linkage is illustrated by curve 620 in FIGS. 4 and 5. With reference to FIG. 3, the unreduced main exhaust valve event 620 in FIGS. 2 and 3 may produce overlap between the intake valve event 700 and the main exhaust valve event 620, illustrated by the combined light shaded area 650 and dark shaded area 652. The overlap represented by combined areas 650 and 652 may produce excessive exhaust gas recirculation in the gas exchange process occurring near top dead center (360°) of the piston cycle. Excessive overlap may detrimentally affect brake performance because the early intake charge passes out through the open exhaust valve rather than being trapped in the cylinder for use in the subsequent braking event. In contrast, when the main exhaust valve event is provided solely by the mechanical linkage, as illustrated by curve 630, the overlap between the intake valve event and the main exhaust valve event is limited to dark shaded area 652. By reducing the overlap, excessive gas exchange may be avoided.
A preferred embodiment of the invention is further illustrated with reference to FIG. 6, in which like elements are referred to with like reference numerals. In FIG. 6, the hydraulic linkage 300 may be turned on by applying a voltage to a solenoid valve 310 to open the solenoid valve and permit oil to be provided from a sump (not shown) by a low pressure pump (not shown) through a check valve 302 and through the open solenoid valve 310. The low pressure oil may flow into a passage 304 and push open a control valve 320 against the bias of a control valve return spring 322. After the control valve 320 is opened, the low pressure oil may pass through a check valve 324 in the control valve 320 and into a passage 306 which provides communication between a master piston 330 and a slave piston 340. After the passage 306 is filled with low pressure oil, which cannot escape back past the check valve 324, the system is ready to provide valve actuation via the hydraulically linked master piston 330 and slave piston 340.
The master piston 330 may be slidably retained in a bore 332 by a retaining spring 334. As the master piston 330 is forced upward in the bore 332 by the movement of the valve train element 120, the oil displaced by the master piston 330 may cause the slave piston 340 to be downwardly displaced in its associated bore 342. Downward displacement of the slave piston 340, in turn opens the valves 200.
The downward displacement of the slave piston 340 may be limited by providing a passage 344 in the slave piston connecting the top of the slave piston with an annular groove 346 in the side of the slave piston. The slave piston 340 may be displaced downward to a predetermined extent, at which point communication is established between the high pressure oil passage 306 and the low pressure oil passage 304 via the slave piston passage 344 and the annular groove 346. Communication between the high pressure and low pressure oil passages causes the high pressure passage 306 to drain and the slave piston 340 to be upwardly displaced under the influence of a slave piston return spring 348. Oil which flows to the low pressure passages may be temporarily stored in accumulator 360.
The upper position of the slave piston 340 may be limited by a lash adjuster 350, which provides a mechanical stop against which the slave piston may be biased by the return spring 348. The extension of the lash adjuster into the high pressure passage may be adjusted by screwing the lash adjuster in or out of the hydraulic linkage 300 housing 308.
When no compression release retarding and/or exhaust gas recirculation is desired, the solenoid valve 310 may be closed and the low pressure oil passage 304 may drain through a solenoid exhaust port passage 312 back to the sump. The draining of the low pressure oil from the low pressure passage 304 may cause the control valve 320 to return to a lower position under the influence of the return spring 322. Once the control valve 320 assumes a lower position, the high pressure oil may drain from the passage 306 over the control valve 320, effectively turning off the brake.
As is apparent from the explanation of the hydraulic linkage 300 shown in FIG. 6, limitation of the downward displacement of the slave piston may be fixed by the position of the annular groove 346 on the slave piston and the location of the intersection of the low pressure oil passage 304 and the slave piston bore 342. The limitation of the downward displacement of the slave piston may alternatively be achieved through the use of a reset valve or clip valve 350.
With reference to FIG. 7, in which like elements are referred to with like reference numerals, the hydraulic linkage 300 may be turned on for braking by energizing the normally closed solenoid valve 310. Upon opening, the solenoid valve 310 may permit low pressure oil to enter passage 304. The low pressure oil is provided from a sump (not shown) by a low pressure pump (not shown) through a check valve 302. Low pressure oil is also provided directly to passages 309 and 311 without passing through the soleniod valve. From passages 309 and 311 the oil may pass through a check valve 324. The shuttle valve 323 connects passages 305 and 306 when the solenoid is off and in a down position (positive power). The shuttle valve 323 blocks the flow of oil to the accumulator 360 from a tappet 333 when it is in the "up" position.
During braking, oil may fill the high pressure circuit and the interior chamber 331 of the tappet 333 through the check valve 324. As the rocker 120 pushes on the tappet 333, oil pressure seals the check valve 324 and the engine valves 200 are opened according to FIGS. 4 or 5. At a pre-set stroke, the tappet oil port 335 reaches the spill passages 309 and 311 and the trapped oil is drained to the accumulator 360. The tappet 333 then goes solid and further valve lift follows the standard cam profile. This truncation of motion prevents over stroking of the valve 200 and valve-to-piston contact at the next TDC. Also, normal exhaust-intake valve lift overlap is maintained. The tappet 333 is refilled for the next cycle with the oil that is stored in the accumulator 360, along with any make-up oil from passages 309 and 311.
For positive power operation, the solenoid 310 prevents oil from entering the high pressure circuit through the high pressure check valve 324. The oil passage 304 to the shuttle valve 323 is drained through the solenoid exhaust port 312 and the spool valve 323 moves to the off position. Any remaining tappet oil is directed to the accumulator 360 via the spool passage 325. The braking motion on the cam is lost as the tappet 333 collapses. Normal exhaust valve motion ensues as the oil passes to the accumulator 360 and back, and through the shuttle valve 323, at the top of each stroke. This also provides a hydraulic cushion as the tappet assembly goes solid.
With reference to FIG. 8, in which like elements are referred to with like reference numerals, the hydraulic linkage 300 may be turned on for braking by energizing the normally open solenoid valve 310. Once the solenoid valve 310 is closed, it isolates the oil in the high pressure circuit in the housing 308. Low pressure oil is provided from a sump (not shown) by a low pressure pump (not shown) through a check valve 302 and into a passage 304. From the passage 304 the oil may pass through a check valve 324 and into a passage 306. The low pressure oil may flow through passage 306 past the closed solenoid valve 310 and into a passage 307. From passage 307 the low pressure oil may be provided into the interior chamber 331 of a tappet 333 formed from the combination of a master piston 330 and a slave piston 340.
As the valve train element 120 displaces the tappet 333 downward, the oil in the interior chamber becomes pressurized and is forced back through passage 306 against check valve 324. Because check valve 324 is a one way valve, the oil is trapped in the interior chamber 331 until the access port 335 in the tappet 333 is displaced sufficiently downward to communicate with the passage 304. Upon communication between the access port 335 and the passage 304, the oil in the interior chamber 331 may flow rapidly, under the force of the valve springs 200, into the passage and may displace an accumulator 360 which communicates with the passage 304. As the interior chamber 331 is drained of oil, the tappet 333 may collapse and go solid, thereby limiting the downward motion which is transferred from the valve train element 120 to the valves 200. The system may be designed that some additional downward displacement of the valves 200 occurs after the tappet 333 goes solid. The system may thus be designed to provide the valve lift related to the standard cam profile (e.g. exhaust events) with a solid tappet 333 and to provide compression release and exhaust gas recirculation events with a tappet 333 containing oil in its interior chamber 331.
After the valve train element 120 reaches its maximum downward displacement, the tappet may resume its upper position. At its upper position, the access port 335 in the tappet 333 may again communicate with the passage 307 and the tappet may refill with low pressure oil for the next cycle of valve actuation.
With continued reference to FIG. 8, during positive power operation of the engine (non-braking mode), the solenoid valve 310 may be maintained in an open position. When in an open position, oil may flow freely through passage 309, through the open solenoid valve 310 and through passage 307. As the valve train element 120 displaces the tappet 333 downward, the oil in the interior chamber becomes pressurized and is forced back through passage 307, through the open solenoid valve 310, through passage 309 and against the accumulator 360. Since there is no check valve to stop the flow of oil out of the interior chamber 331, the tappet 333 collapses until the accumulator 360 goes solid or until the tappet goes solid. After the accumulator 360 or the tappet 333 go solid, any further downward movement of the valve train element 120 may be transferred to the valves 200. In this manner the extension of the tappet required for braking may be limited and the valve train motion relating to engine braking events truncated.
Hydraulic fill and spill during repeated collapsing of the tappet 333 during positive power may also benefit the overall operation of the system by providing a lubricating cycle for the tappet 333. As the oil is squeezed out of the tappet with each actuation of the valves 200 the interior walls of the master piston 330 are lubricated for the reception of the slave piston 340. In one embodiment of the invention, the accumulator 360 may be provided with a small bleed passage (not shown) for slowly bleeding the oil out of the housing during operation of the system. This slow bleeding of the oil results in circulation of the oil which is in the system, thereby allowing fresh cool oil to be introduced to the system at a constant rate. An additional benefit of using a collapsing tappet is that the interior oil creates a hydraulic cushion during tappet collapse which results in quiet operation.
An alternative embodiment of the invention is shown in FIG. 9. With respect to FIG. 9, in which like elements are referred to with like reference numerals, the hydraulic linkage 300 may be turned on for braking by closing the normally open solenoid valve 310. Once the solenoid valve 310 is closed, it permits oil to be provided to the high pressure circuit in the housing 308. Low pressure oil is provided from a sump (not shown) by a low pressure pump (not shown) through a check valve 302 and into a passage 304. From the passage 304 the oil may pass through a check valve 324 and into a passage 306. The low pressure oil may flow through passage 306 past the closed solenoid valve 310 and into a passage 307. From passage 307 the low pressure oil may be provided into the circuit connecting a slave piston 340 with a master piston 330.
As the valve train element 120 displaces the master piston 330 upward, the oil in the circuit connecting the master and slave pistons becomes pressurized and is forced back through passages 307 and 309 against check valve 324. Because check valve 324 is a one way valve, the oil is trapped in the high pressure circuit and the slave piston 340 is displaced downwards as the master piston is displaced upwards. The slave piston 340 may continue downwards, thereby opening valves 200, until an annular groove 346 in the slave piston communicates with the passage 304. When the annular groove 346 communicates with the passage 304, oil in the high pressure circuit may flow rapidly through the passage 344 in the slave piston under the force of the valve springs and into the passage 304. In one embodiment of the invention, oil may not flow through the passage 344 until the passage is opened by a reset or clip valve 350. The oil may pass through passage 304 and may displace an accumulator 360 which communicates with the passage 304. As the high pressure circuit is drained of oil, the downward motion of the slave piston 340 may stop. Thereafter, the back pressure from the valves 200 may cause the slave piston 340 to be returned to its upper most position where it abuts against a lash adjuster, reset valve, or clip valve 350. In this manner, the relative placement of the annular groove 346 and the passage 304 may be used to limit the downward motion which is transferred from the valve train element 120 to the valves 200. When the slave piston 340 resumes its upper position, the high pressure circuit may refill with low pressure oil for the next cycle of valve actuation.
Similarly to the system shown in FIG. 8, the accumulator 360 may be designed to go solid, i.e. to accumulate a maximum amount of oil, before all of the oil is drained from the high pressure circuit. In this manner, the system 300 may be designed to provide further valve lift which follows the standard cam profile. This arrangement may simulate the valve actuation that is achieved using a tappet which goes solid or is partially collapsed when oil is drained to an accumulator.
During positive power operation of the engine (non-braking mode), the solenoid valve 310 may be maintained in an open position. When in an open position, oil may flow freely through passage 309, through the open solenoid valve 310 and through passage 307. As the valve train element 120 displaces the master piston 330 upward, the oil in the high pressure circuit becomes pressurized and is forced back through passage 307, the open solenoid valve 310, passage 309 and against the accumulator 360. Since there is no check valve to stop the flow of oil out of the high pressure circuit, the slave piston 340 is not displaced until the accumulator 360 goes solid (if the accumulator is designed to go solid). If and when the accumulator goes solid, the discharge of oil from the high pressure circuit may cease and the additional displacement of the master piston 330 may be transferred to the slave piston 340 via the high pressure circuit. In this manner the downward displacement of the slave piston 340 resulting from movement of the valve train element 120 may be limited.
In one embodiment of the invention, the accumulator 360 may be provided with a small bleed passage (not shown) for slowly bleeding the oil out of the housing during positive power operation of the system. This slow bleeding of the oil may result in circulation of the oil which is in the system when the solenoid is in an open position, thereby allowing fresh cool oil to introduced to the system at a constant rate.
It will be apparent to those skilled in the art that variations and modifications of the present invention can be made without departing from the scope or spirit of the invention. For example, the slave pistons, master pistons, and a tappets, contemplated as being within the scope of the invention include pistons and tappets of any shape or size so long as the elements in combination provide the function of selectively discharging hydraulic fluid from a high pressure circuit or passage to a low pressure circuit or passage responsive to the displacement of one of the elements in the combination. Furthermore, it is contemplated that the scope of the invention may extend to variations on the arrangement of the system elements in the housing, as well as variations in the choice of valve train elements (cams, rocker arms, push tubes, etc.) that may be connected to the hydraulic linkage. It is further contemplated that any hydraulic fluid may be used in the system of the invention.
Thus, it is intended that the present invention cover the modifications and variations of the invention, provided they come within the scope of the appended claims and their equivalents. | An internal combustion engine may include a hydraulic linkage used to transfer motion from a valve train element, such as a cam, to an engine valve. Method and apparatus for selectively limiting the motion transferred by the hydraulic linkage from the valve train element to the engine valve are disclosed. The hydraulic linkage may comprise means for resetting or clipping the displacement of the engine valves into the engine cylinder following a compression release event. The hydraulic linkage may also limit the displacement of the engine valves into the engine cylinder for main exhaust and/or other valve events, as well as limit the overlap between a main exhaust valve event and an intake valve event. | 5 |
This application is a continuation of application Ser. No. 08/244,949, filed as PCT/DK92/00397, Dec. 23, 1992, published as WO93/13023, Jul. 8, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a process for the biological purification of polluted water, such as waste water, wherein the polluted water is successively subjected to an anaerobic, an anoxic and an aerobic treatment in the presence of micro-organisms in order to reduce the nitrogen and phosphorus contents of the water.
2. The Prior Art
The ever increasing eutrophication of rivers, lakes and seas has resulted in more and more countries making requirements for the purification of waste water, in particular for the removal of nitrogen and phosphorus, and in the existing requirements becoming more and more strict.
Various processes for the biological purification of waste water are known wherein at least a partial removal of nitrogen and phosphorus from the waste water is effected. Such known processes for the purification of waste water using bacteria are disclosed in i.a. DK patents Nos. 149,767 and 153,832.
In the known processes for the biological removal of nitrogen and phosphorus from waste water, the amount of easily decomposable organic matter contained in the waste water is often a limiting factor in the effectiveness of the processes, and where the waste water content of easily decomposable organic matter is insufficient, it is often necessary to add organic matter in order to obtain a desired degree of purification.
The biological removal of phosphorus from waste water is a result of the presence of phosphorus-accumulating bacteria which, in anaerobic conditions, absorb easily decomposable organic matter from the untreated waste water, which organic matter is stored in the form of, e.g., polyhydroxy butyrate (PHB). The bacteria acquire the energy to perform such storing by decomposing polyphosphate from an intracellular storage. Hereby orthophosphate ions are produced which are released to the liquid phase.
When the phosphorus-accumulating bacteria are subsequently subjected to aerobic conditions, the storage of organic matter is consumed as oxygen works as an oxidant. The bacteria use the energy thus produced partly for the absorption of orthophosphate ions from the liquid phase and for the accumulation thereof in the form of polyphosphate and partly for the basic metabolism and growth of the phosphorus-accumulating bacteria.
The removal of phosphorus from the waste water is subsequently achieved by removing the excess production of phosphorus-accumulating bacteria at a point in the process when their polyphosphate storages are full.
The removal of nitrogen is based on a nitrification followed by a denitrification. The nitrification which is effected in aerobic conditions consists in oxidiation of ammonia nitrogen into nitrate simultaneously with a decomposition of available organic matter, if any, whereas the denitrification which is effected in anoxic conditions consists in the consumption of organic matter using nitrate ions as oxidants. In this oxidation nitrate nitrogen is reduced to free nitrogen (N 2 ) which is released in its gaseous form.
Part of the phosphorus-accumulating bacteria are also capable of consuming stored organic matter in anoxic conditions as nitrate acts as an oxidant. As it is the case when the consumption of organic matter is effected with the use of oxygen as an oxidant, the energy produced in anoxic conditions is used partly for the absorption and for the accumulation of phosphate in the form of polyphosphate and partly for the growth of the phosphorus-accumulating bacteria.
When nitrate acts as an oxidant as it is the case in the anoxic conditions described above, a reduction of nitrate into free nitrogen takes place as disclosed above, the free nitrogen being released in gaseous form. This means that the organic matter absorbed by the phosphorus-accumulating bacteria using nitrate as an oxidant is used for phosphorus absorption and accumulation as well as for denitrification.
Tests have shown that in an active-sludge method, such as the ones described above wherein a mixture of micro-organisms are successively subjected to anaerobic, anoxic and aerobic conditions, only about half of the phosphorus-accumulating bacteria are capable of absorbing and accumulating phosphate ions in anoxic conditions and thus of using nitrate as an oxidant. Thus, only half of the total amount of organic matter absorbed by the phosphorus-accumulating bacteria is used for denitrification.
If all of the phosphorus-accumulating bacteria were capable of using nitrate as an oxidant, it would be possible to obtain an improved nitrogen removal without the addition of organic matter to waste water which is comparatively poor in organic matter as, in that case, there would be more organic matter available for the nitrogen removal, i.e., the denitrification.
SUMMARY OF THE INVENTION
The present invention is based on the discovery that by giving the phosphorus-accumulating micro-organisms such growth conditions that mainly micro-organisms capable of using nitrate as an oxidant and thus capable of absorbing phosphorus in anoxic condition and storing it in the form of polyphosphate are developed, a substantially improved exploitation of organic matter contained in the polluted water is obtained, thereby avoiding altogether or reducing the addition of organic matter to polluted water which is poor in organic matter.
The process according to the invention is characterized in that, on the one hand, the anaerobic and the anoxic treatment, and on the other hand, the aerobic treatment, are carried out in the presence of separate micro-organism cultures.
The term "separate micro-organism cultures" denotes that the major part of the micro-organism culture(s) used in the anaerobic and anoxic treatments is kept apart from the micro-organism culture(s) used in the aerobic treatment. In practice the liquid which has been subjected to an anaerobic/anoxic treatment and which is subsequently to undergo an aerobic treatment, will unavoidably contain small amounts of micro-organisms originating from the anaerobic/anoxic treatments, and minor amounts of micro-organisms may also be transported from the aerobic treatment step to the anaerobic/anoxic treatment steps along with recycled water.
In the known methods of the kind described above, a mixture containing i.a. phosphorus-accumulating heterotrophic bacteria, phosphorus-accumulating denitrificating heterotrophic bacteria, non-phosphorus-accumulating denitrificating heterotrophic bacteria and nitrificating bacteria will successively be subjected to anaerobic, anoxic and aerobic conditions and consequently they are sometimes exposed to conditions in which they are not active. In other words, part of the bacteria are inactive for a part of the time and in some process steps they will take up space for active bacteria.
By using separate micro-organism cultures in the anaerobic/anoxic and aerobic treatments, respectively, of the polluted water in accordance with the present invention, principally propagation of micro-organisms adapted to live in anaerobic/anoxic and aerobic conditions, respectively, is effected. Thereby a larger part of the micro-organisms becomes active in the treatment steps mentioned, which i.a. results in that the ratio of phosphorus-accumulating micro-organisms capable of using nitrate as an oxidant to phosphorus-accumulating micro-organisms capable of using only oxygen as an oxidant, is shifted in favour of the former whereby, as explained above, improved exploitation of the organic matter contained in the polluted water is obtained.
In addition to an improved exploitation of organic matter, the process according to the invention presents the advantage that the reaction rate per unit mass of biomass is increased, thereby allowing the amount of biomass to be reduced or the total reaction rate of the plant to be increased.
The process according to the invention may by used either in a suspension method or in a fixed-bed method or in a combination of the two methods.
In the former method a mixture of polluted water, such as waste water which may optionally have been subjected to a preclarification treatment, and a micro-organism culture, are successively subjected to an anaerobic and an anoxic treatment in one or more treatment zones following which the micro-organism culture is separated from the water and then another micro-organism culture is added to the water and subsequently the mixture thus formed is subjected to treatment in an aerobic treatment zone, and wherein the micro-organism culture is separated from the water thus treated and a part of the water is recycled to the anoxic treatment zone.
In the method described above recycling is preferably carried out of the micro-organism culture which is separated off after the anoxic treatment and the separated culture or a part thefor is recycled to the anaerobic zone.
In a corresponding manner the micro-organism culture separated from the aerobically treated water may be recycled to the aerobic treatment zone.
Such separation is carried out, e.g., in a precipitation tank.
According to a particular embodiment of the process described above, the anaerobic and the anoxic treatments are carried out in two separate treatment zones wherein anaerobic and anoxic conditions are alternatingly established and wherein polluted water is always conducted to the zone where anaerobic conditions are maintained.
The excess micro-organisms used in connection with the anaerobic/anoxic treatments are preferably removed at such times when the phosphorus content of the micro-organisms is high.
In the fixed-bed method at least two immobilised micro-organism cultures which are kept in anaerobic or anoxic and aerobic conditions, respectively, are used and, wherein a part of the water which leaves the micro-organism culture kept in aerobic conditions is recycled to the micro-organism culture which is kept in anoxic conditions.
In this method the first immobilised micro-organism culture is preferably kept in alternatingly anaerobic and anoxic conditions and the polluted water is conducted to the immobilised micro-organism culture which is kept in anaerobic conditions.
According to a preferred embodiment of the above process three immobilised micro-organism cultures are used and the two first immobilised micro-organism cultures of the three are alternatingly kept in anaerobic and anoxic conditions and polluted water is alternatingly conducted to the first and the second of the two first immobilised micro-organism cultures, polluted water, however, always being conducted to the immobilised micro-organism culture which is kept in anaerobic conditions whereas the discharge from the immobilised micro-organism culture which is kept in anaerobic conditions is conducted to the second of the two first immobilised micro-organism cultures together with nitrate-containing water recycled from the immobilised micro-organism culture which is kept in aerobic conditions.
As mentioned the two methods described above may be combined. The aerobic treatment in the former method may for example be carried out using an immobilised micro-organism culture, viz. by conducting the water which has been subjected to successive anaerobic and anoxic treatments through an immobilised aerobic micro-organism culture and by recycling a part of the water thus aerobically treated to the anoxic treatment zone.
In a corresponding manner the anaerobic and the anoxic treatments may be carried out using one or more immobilised micro-organism cultures following which the water thus treated may be subjected to an aerobic treatment in the presence of micro-organisms suspended in the water.
A particularly preferred embodiment of the process according to the invention is characterized in successively subjecting the polluted water to an anaerobic and an anoxic treatment in two zones using a suspended micro-organism culture, separating the micro-organism culture from the water thus treated, the micro-organism culture being recycled to the anaerobic treatment zone, and subjecting the water relieved of the micro-organism culture to an aerobic treatment with an immobilised micro-organism culture following which a part of the aerobically treated water is recycled to the anoxic treatment step.
The excess micro-organisms used in connection with the anaerobic/anoxic treatments are preferably removed at such times when the phosphorus content of the micro-organisms is high.
The invention also relates to a plant for carrying out the process described above.
The plant according to the invention is characterized in that it comprises means for successively subjecting polluted water to an anaerobic and an anoxic treatment using a first micro-organism culture, means for subjecting the anaerobically and anoxically treated water to an aerobic treatment using a second micro-organism culture which is different from the first micro-organism culture, means for recycling aerobically treated water to the means for treating the water in anoxic conditions and optionally means for removing the excess sludge from the plant.
A preferred embodiment of the plant described above is characterized in that the means for anaerobic and anoxic treatment of the water using the first micro-organism culture comprise an anaerobic and an anoxic tank, means for separating off sludge from the anoxically treated water and means for recycling the sludge thus separated to the anaerobic tank.
A second preferred embodiment of the plant described above is characterized in that the means for anaerobic and anoxic treatment of the water using the first micro-organism culture comprise at least one biological filter comprising a carrier material to which the micro-organism culture is attached.
A further preferred embodiment of the plant described above is characterized in that the means for aerobic treatment of the anaerobically and anoxically treated water using the second micro-organism culture comprise an aerobic tank, means for separating sludge from the aerobically treated water and means for recycling the sludge thus separated to the aerobic tank.
Yet another preferred embodiment of the plant described above is characterized in that the means for aerobic treatment of the anaerobically and anoxically treated water using the second micro-organism culture comprise a biological filter comprising a carrier material to which the micro-organism culture is attached.
The biological filters used are preferably constructed such that they retain suspended matter contained in the water.
Preferably, the plant comprises further means for periodical backwashing of the filters for removal of excess micro-organism containing material from the filters.
Alternatively, there may also be a separate separation means, e.g., in the form of an additional filter, a precipitation tank or a flotation plant for the separation of suspended matter, including micro-organisms from water leaving the filters.
The plant may further comprise means for periodically providing an increased hydraulic load on the filters. Such means serve to achieve increased removal of micro-organisms from the filters at desired points in time.
A particularly preferred embodiment of the plant according to the invention comprises three biological filters connected in series wherein anaerobic, anoxic and aerobic conditions, respectively, may be maintained, and where it further comprises means for alternatingly conducting polluted water to the two first filters and for alternatingly changing the treatment conditions in the filters from anaerobic to anoxic treatment and vice versa thereby establishing anaerobic conditions in the filter to which the polluted water is first conducted.
To maintain a sufficiently heavy flow of water through the filters it may be convenient to recycle a part of the water which leaves a filter to the inlet of that filter.
Finally, it should be noted that the anaerobic treatment may be effected in more successive hydraulically separated treatment zones or tanks and that the same applies to the anoxic and aerobic treatments.
In this connection it should be noted that the polluted water may be supplied to one or more of the anaerobic zones.
In a corresponding manner and where filters are used, several successive filters may be used wherein the same treatment conditions are maintained and in such instances the polluted waste water may also be fed to one or more anaerobically operating filters.
In the same manner the anaerobically treated water may be distributed to several anoxic filters.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail with reference to the drawings, wherein
FIG. 1 is a flow diagram illustrating phase 1 of the operation of a preferred embodiment of a water purification plant according to the invention,
FIG. 2 is a flow diagram illustrating phase 2 of the operation of the purification plant described in connection with FIG. 1,
FIG. 3 is a flow diagram illustrating an alternative aerobic treatment of waste water which has been subjected to an anaerobic and an anoxic treatment in a plant as shown in FIGS. 1 and 2,
FIG. 4 is a flow diagram illustrating a further embodiment of a purification plant according to the invention, and
FIG. 5 is a flow diagram illustrating yet a preferred embodiment of a water purification plant according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The purification plant shown in FIG. 1 comprises three filters 1,2,3 connected in series, each comprising a carrier material and an (immobilised) bacteria culture attached thereto. The filter 1 is connected to a feed conduit 4 for the supply of untreated waste water. In the feed conduit 4 a precipitation tank 5 may be positioned for the removal of a part of the suspended solid matter contained in the untreated waste water. The plant further comprises a conduit 6 which connects the filter 1 to the filter 2, and a conduit 7 which connects the filter 2 to the filter 3. Lastly the plant shown comprises a conduit 8 for the discharge of purified waste water from the filter 3 and a recycling conduit 9, wherein a pump 10 is located. The conduit 9 connecting the conduit 8 to the conduit 6 serves to conduct a part of the purified waste water leaving the filter 3 through the conduit 8 back to the filter 2.
As will appear from FIG. 2, the plant shown therein corresponds to the one shown in FIG. 1 except that the feed conduit 4 and the precipitation tank 5 located therein are connected to the filter 2 and that the conduit 7 connecting filters 2 and 3 has been replaced by a conduit 11 connecting filters 1 and 3.
In phase 1 anaerobic conditions are maintained in the filter 1 which results in the phosphorus-accumulating bacteria attached to the carrier material absorbing easily decomposable organic matter contained in the untreated waste water and simultaneously releasing phosphate ions. The water flowing through the conduit 6 from the filter 1 to the filter 2 and which contains relatively large amounts of phosphate ions is mixed with nitrate-containing water which is supplied through the conduit 9 from the filter 3.
In the filter 2 there prevails anoxic conditions and the phosphorus-accumulating bacteria present therein consume their storages of organic matter using nitrate as an oxidant. Hereby nitrate is reduced to free nitrogen, which leaves in its gaseous form. The bacteria use the energy thus produced partly for basic metabolism and growth and partly for storaging phosphate in the form of polyphosphate. The partially treated water from the filter 2 flows through the conduit 7 to the filter 3 wherein aerobic conditions are maintained. This means that a biological conversion of ammonia nitrogen into nitrate is effected therein simultaneously with any organic matter present being decomposed. Hereby nitrate-containing waste water is produced of which a part is recycled to the filter 2 through the recycling conduit 9.
After a suitable period the plant is changed over by supplying the untreated waste water to the filter 2 as shown in FIG. 2 and the water leaving the filter 2 is conducted to the filter 1 through the conduit 6 from where, following treatment, it is conducted to the filter 3 through the conduit 11.
In phase 2 anaerobic conditions are maintained in the filter 2 and anoxic conditions in the filter 1, whereas aerobic conditions are maintained in the filter 3 like in phase 1.
After a suitable period of time, the plant is again changed over and a new phase 1 is initiated.
In the described embodiment of the process according to the invention an accumulation of phosphorus-accumulating bacteria is effected in filters 1 and 2 and part of the bacteria are removed from the filters at intervals by backwashing when the phosphorus storages of the bacteria are full.
FIG. 3 shows a conduit 12 for anaerobically and anoxically-treated waste water wherein a filter 13 is located which contains a carrier (filter) medium which effectively retains suspended matter, and a bacteria culture. A recycling conduit 14 wherein an additional filter 15 and a recycling pump 16 for nitrate-containing water are located is on the one hand connected to the conduit 12 on the upstream side of the filter 13 and on the other to the conduit 6 in FIGS. 1 and 2.
As opposed to the filter 13 and in addition to a micro-organism culture, the filter 15 comprises a comparatively coarse carrier (filter) medium. By using such coarse filter medium the pressure loss in the recycling conduit 14 is reduced. Aerobic conditions are maintained in the filter 13 as well as in the filter 15.
Excess biomass from the filters 1, 2, 3 and 13 and 15 may be removed by backwashing of the filters with water. The excess biomass is removed together with the washing water through the conduits 17.
The water purification plant shown in FIG. 4 comprises a tank 20 with a feed conduit 21 for untreated waste water and a communication conduit 22 connected to an additional tank 23. The latter is connected to an additional tank 26 through a conduit 24 wherein a precipitation tank 25 is located, the tank 26 having a discharge conduit 27 wherein a precipitation tank 28 is located. The bottom of the precipitation tank 25 is connected to the feed conduit 21 through a sludge recycling conduit 29 wherein a pump 30 is located and the bottom of the precipitation tank 28 is connected to the conduit 24 through a sludge recycling conduit 31 wherein a sludge pump 32 is located. Lastly the plant comprises a water recycling conduit 33, wherein a pump 34 is located and which is connected to the discharge conduit 27 on the downstream side of the precipitation tank 28 and the communication conduit
In the plant shown the untreated waste water supplied through the supply conduit 21 is mixed with recycled sludge supplied through the sludge recycling conduit 29 and the mixture is introduced into the tank 20 wherein anaerobic conditions are maintained. The anaerobically treated water and sludge are introduced into the tank 23 following admixture with nitrate-containing water supplied through the water recycling conduit 33. In the tank 23 anoxic conditions are maintained. After leaving the tank 23 the water flows through the conduit 24 to the precipitation tank 25 wherein sludge is separated off and further to the tank 26 wherein aerobic conditions are maintained. From the bottom of the precipitation tank 25 active sludge is removed and conducted through the sludge recycling conduit 29 to the feed conduit 21.
The aerobically treated water flows from the tank 26 to the precipitation tank 28 and further through the discharge conduit 27 from where a part of the nitrate-containing water is removed and recycled to the communication conduit 22 through the water recycling conduit 33. Lastly active sludge removed through the bottom of the precipitation tank 28 is conducted back to the conduit 24.
In the tanks 20, 23 and 26 processes identical to the ones explained in connection with the disclosures of FIGS. 1 and 2 are carried out.
Excess biomass can be removed from the plant through the conduits 35 and 36 from the precipitation tanks 25 and 28, respectively.
The water purification plant shown in FIG. 5 comprises a tank 20 with an feed conduit 21 for untreated waste water and a communication conduit 22 connected to an additional tank 23.
The latter is connected to a filter 3 through a conduit 24 wherein a precipitation tank 25 is located, the filter 3 having a discharge conduit 39. The bottom of the precipitation tank 25 is connected to the feed conduit 21 through a sludge recycling conduit 29 wherein a pump 30 is located. Lastly the plant comprises a water recycling conduit 33 wherein a pump 34 is located and which is connected to the discharge conduit 39 and the communication conduit 22.
In the plant shown the polluted water supplied through the supply conduit 21 is mixed with recycled sludge supplied through the sludge recycling conduit 29 and the mixture is introduced into the tank 20 wherein anaerobic conditions are maintained. The anaerobically treated water and sludge are introduced into the tank 23 following admixture with nitrate-containing water supplied through the water recycling conduit 33. In the tank 23 anoxic conditions are maintained. After leaving the tank 23 the water flows through the conduit 24 to the precipitation tank 25 wherein sludge is separated off and further to the filter 3 wherein aerobic conditions are maintained. From the bottom of the precipitation tank 25 active sludge is removed and a part thereof is conducted through the sludge recycling conduit 29 to the feed conduit 21.
The aerobically treated water flows from the filter 3 through the discharge conduit 39 from where a part of the nitrate-containing water is removed and recycled to the communication conduit 22 through the water recycling conduit 33.
In the filter 3 and the tanks 20 and 23 the same processes as explained in connection with FIGS. 1 and 2 are effected. | Process and plant for biological purification of polluted water wherein the polluted water is successively subjected to an anaerobic, anoxic and aerobic treatment in the presence of microorganisms, and wherein the anaerobic and the anoxic treatment are carried out in the presence of one or more microorganism cultures which are different from the microorganism culture used in the aerobic treatment. Hereby better exploitation of organic matter in the water is obtained thus improving the removal of nitrogen, and an increased reaction rate per unit mass of biomass is obtained thereby allowing the amount of biomass to be reduced or the total reaction rate of the plant to be increased. | 2 |
This application is a continuation, of application Ser. No. 06/471/355 filed on March 2, 1983, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an electronic game apparatus, for example, a game calculator and the like, that enables the user to enjoy games.
A number of original games utilizing microcomputers have recently been developed and applied to a variety of video games, game machines and educational aids, with the trend being to incorporate these devices into calculators and watches.
OBJECT AND SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide an improved electronic game apparatus for selectively shifting display digits.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
According to one embodiment of the present invention, an electronic game calculator comprises a display means having multiple digits, and means for shifting to the right and to the left a chain or row of randomly arranged numerals or symbols on the abovementioned display means, and a means for interchanging specific digits of the now including numerals or symbols arranged randomly on the abovementioned display means.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein:
FIG. 1 is a perspectine view of one embodiment of an electronic game calculator according to the present invention;
FIG. 2 is shows display contents during the course of a game according to the present invention;
FIG. 3 (1) to FIG. 3 (4) show the relationship between the display and the action of each displacement key;
FIG. 4 is a block diagram showing the system configuration of the abovementioned embodiments of the electronic game calculator;
FIG. 5 is a flowchart explaining the operation of that system.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is an exterior view of one embodiment of an electronic game calculator according to the present invention.
This electronic game calculator comprises a display section 3, for example, an 8-digit display, and a keyboard 2 including a number of keys.
The keyboard 2 is provided with numeral keys (0 to 9), a decimal point key, some function keys, and some keys actuated to play a game.
In this embodiment of the present invention, a game course set key 2a can be operated to select among three step courses, A, B, and C.
This key 2a is actuated to select a particular arrangement of random numerals or symbols.
For example, in this embodiment of the present invention, A course is a game in which the object is to select a particular arrangement of 11223344. By the selection of B course, the game should end up with the particular arrangement of 12341234, and by the selection of C course, the game should end up with a further arrangement of 1122334455667788.
A game start key 2b, is depressed to start a game in conformance with the above courses, and displacement keys, which are discussed later, can be operated as game keys.
In the calculation mode, a key 2c is the "0" key, while in the game mode it operates as a left shift key.
A key 2d is the decimal point key in the calculation mode, while in the game mode it operates as a right shift key.
A key 2e is the plus (+) key in the calculation mode, while in the game mode, in the case where the C course is selected by the course set key 2a, this key 2e is acturated to select an alternate display which appears only during the period when the key 2e is continuously depressed.
In the C course, 16 digits must be displayed. However, the 8 digit display cannot display them simultaneously. Therefore, the initial 8 digits are displayed in the 8 digit display and the last 8 digits are reserved in a memory.
The alternate display is a display the latter 8 digits in the 8 digits display of in place of the first eight digits.
A key 2f is an equal (=) key in the calculation mode while in the game mode it acts as the exchange key.
A portion 3a is a seven segment which displays numerals or symbols.
A course indicator 3b displays a human figure and a staircase, and represents, with the position of the human figure, A course where the human figure is positioned at the first step, B course where the human figure is positioned at the second step, and C course the human figure is positioned at the third step.
However, in the calculation mode, the human figure and the staircase disappear.
An alternate display indicator 3c light up in C course only during the period when the alternate display key 3e is being depressed.
A symbol 3d, activated by the exchange key 2f, indicates interchanged digits, and, during the game, is continually illuminated, but is turned off in the calculation mode.
A symbol 3e is the decimal point while the calculator is operated in the calculation mode, but during a game, counts the time before any key is actuated. Approximately every 2 seconds the decimal shifts one space from the right end in the manner of 1,2,3, . . . 8. During this interval, if none of the left shift key, the right shift key or the exchange key is acturated, the index (number of key inputs) is automatically incremented by a count. In other words, after about a 16 second interval, if there is not one key input, the index is incremented by a count, and this action is repeated every 16 seconds. If there is an effective key input, the timer is cleared, and the decimal point moves back to only one display point from the right end.
FIG. 2 shows the display during the course of a game in which the C course has been selected, and the arrow mark of the symbol 3d indicates two digits which can be exchanged with each other. Thus an 8 digit row of random numerals is prepared.
Here, if the alternate display key 2e is depressed, the second 8 digits are displayed.
FIG. 3 (1) to FIG. 3 (4) show the relationship between the display and the action of each displacement of key.
(1) Right shift key 2d (See FIG. 3 (1))
If the right shift key 2d is operated, the entire row of numerals shifts to the right, and the first number from the right is moved to the left end of the row.
(2) Left shift key 2c (See FIG. 3 (2))
On the operation of the left shift key 2c, the entire row of figures is moved to the left, and the first digit from the left is moved to the right end of the row.
(3) Exchange key 2f (See FIG. 3 (3))
On the operation of the exchange key 2f, the first digit and in the second digit from the left end are exchanged each other, and the seventh and the eighth digits are exchanged.
(4) Alternate display key 2e
While the device is set for the course C, on depressing the alternate display key 2e, the first half of the 16 figures 12357881, and the later half 66442357 are exchanged with each other and displayed.
The above explanation gives the basic action of the game, and the following is a concrete example of the progression of the game.
First of all, the course key 2a is operated to designate which configuration of figures will be displayed. In this example, the game is to end up with 11223344, and the progress of the game is as follows.
Game start key 2b is activated . . . (game start) ##STR1##
The display or light is turned on and off at the designated last configuration, and after that the index (the number of key inputs) is displayed, and the game is over. Furthermore, even with 16 digits, the game will progress with the same actions. In addition, the an interesting element of game is that after the game begins, after, about a 16 second interval, if none of the left shift, right shift, or exchange key is operated, the dispslay or index (the number of key inputs) is incremented by one.
The symbols 3e light up successively about every 2 seconds, indicating the passage of time.
EXAMPLE ##STR2##
In this way, it is possible to offer an electronic game calculator in which the parts which act as the key input section and the display section during calculation, serve as the display and the game key input section, including displacement deys, during the game mode.
FIG. 4 schematically shows the system configuration of one embodiment of an electronic game calculator according to the present invention.
In the diagram, a one-chip microcomputer 4 includes a CPU (central processing unit), a ROM (read only memory), and a RAM (random access memory).
the ROM contains the programs for the electronic calculator function and for the game function.
The RAM is used as the calculator registers, the memory, and flip-flops in the calculation mode, and as the problem memory and index counter for counting the number of the key operations in the game mode.
FIG. 5 is a flowchart explaining the operation of the present invention. In step n 1 , initialization and register clearance are carried out in the calculation mode. In step n 2 , key input takes place.
Here, if there is no key input in the interval of about 7 minutes, an automatic off function is enabled and the power is automatically switched off.
When the keys relating to electronic calculations are depressed, the sequence of operation goes from step n 2 →n 3 →n 4 →n 5 , to perform calculations. The step n 2 is reselected after the calculation result is displayed.
In the case where the game course key is operated, the sequence selects step n 2 →n 3 →n 6 , and one of the courses is selected. In addition, at step n 21 , the X-register is cleared, but in the case where the contents of the X-register are relevant to the A and B course quizzes of the game (11223344 arrangement), then clearance does not take place.
On pushing the game start key 2b, the sequence n 2 →n 3 →n 4 →n 7 takes place, and the decision is made as to whether the quiz, or sequence of numbers, is already set.
If, in the A and B courses, an appropriate quiz or sequence is entered by keys, that quiz is adopted for the game.
However, if any quiz is not set with A and B course, or if the game is set in the C course, step n 8 is executed, then a quiz is prepared using relevant random numbers.
Step n 9 is for key input in the game mode, and in the period when there is no key input, the loop n 9 →n 14 →n 9 is executed. By this loop, the time count is performed, and about every 2 seconds an additional decimal point appears in sequence from the right end to the left end of the display. If the display shows up 8 decimal points and there is no input, the index (the number of key inputs) is incremented by 1. In other words, even if there is no key input, the index is automatically incremented about every 16 seconds.
During the game the self power-off function does not operate.
On depressing the left shift key, the sequence n 9 →n 10 →n 15 progresses, resulting in the left shift. When the right shift key is operated, the right shift results from the sequence n 9 →n 10 →n 11 →n 16 .
Depression of the exchange key selects the sequence n 9 →n 10 →n 11 →n 12 →n 13 →n 17 , and numerals or symbols are exchanged with each other.
By each operation of the left shift, right shift, and exchange keys, the timer is cleared, the decimal point display returns to the right end lamp only, and the index is incremented by 1.
In step n 18 the decision is made as to whether or not the correct answer (final form) has resulted. If not, the program returns to step n 9 , and the game continues. If the correct answer has been obtained, the program proceeds to step n 20 , the index (the number of key inputs) is displayed, and the program returns to step n 2 .
In this event, because the course set has not been cleared, if the game start key 2b is operated immediately after step n 2 , the game can proceed on the same course.
However, if the game is over, everything in the electronic calculator registers is cleared, with the exception of memory.
When the alternate display key 2e is depressed, steps n 9 →n 10 →n 11 →n 12 →n 19 proceed in sequence, and, in the case of the C course only, the usual display does not appear, but, instead the later 8 digits are displayed.
The reverse display key is effective only when this key is continuously depressed. When it is released, the initial display returns.
The alternate display key is ineffective in any course but the C course, and the time remains counted.
The invention thus being described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims. | An electronic game apparatus effects a right shift or a left shift of an entire display of multiple randomly arranged numerals or symbols, and exchange of specified displayed digits of numerals or symbols. The electronic game apparatus can arrange and shift the rows of numerals or symbols displayed on the display means into a prescribed order. | 0 |
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