description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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This application is a continuation of application Ser. No. 08/277,485 filed Jul. 19, 1994, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of controlling the position of the stage of an exposing apparatus, and more particularly to a method of controlling the position of a stage for use in an exposing apparatus.
2. Description of the Related Art
If a stage for precisely positioning a wafer for use in an exposure apparatus or the like has a multiplicity of axes along which it can move, the influence of forces generated when the wafer is driven along one axis on another axis cannot be prevented even in a case where the stage is driven along a single axis. As a result, precise positioning of the wafer using only mechanisms for moving the stage along the different axes encounters the following problems.
(1) The accuracy of each mechanism must be improved in order to manufacture a positioning apparatus capable of meeting a desired stage moving accuracy. Therefore, the manufacturing cost cannot be reduced and the time required to manufacture the apparatus cannot be shortened.
(2) The environmental conditions with which the desired stage movement accuracy can be met are limited.
In order to reduce the manufacturing cost and shorten the time taken to manufacture the apparatus capable of meeting the required stage movement accuracy while realizing a precise positioning capability not limited by environmental conditions, a stage position correction method has been employed. As a method of correcting the stage position, the following methods have been employed:
(1) The amount of interference with the movement of the stage along another axis that can be generated at the time of a positioning operation along an axis is previously calculated before the operation of positioning the stage along this axis so as to correct the position of the stage along each axis.
(2) After the positioning operation along one axis has been performed, the interference with the movement of the stage along another axis is corrected in such a manner that the generated interference with the movement of the stage along another axis is made to be zero.
In an actual process of the exposure apparatus, the position of the stage along each shaft and the methods for positioning the stage along each shaft are divided into the following two categories.
(1) The position of the stage along one axis must be positioned precisely in such a manner that the influence of the movement of the stage along another axis cannot be disregarded, and a method of positioning the foregoing position (the position accuracy is about ±0.01 micrometer).
In this case, the interference with the movement of the stage along another axis can be prevented by a method in which only an axis the movement along which does not interfere with the movement along another axis is used to position the stage, by a method in which the amount of interference with the movement of the stage along another axis that can be generated at the time of a positioning operation of the stage is previously calculated before the positioning operation is performed and the position of the stage along each axis is corrected, or by a method in which a driving operation for correcting the amount of interference with the movement of the stage along another axis is so performed that the generated amount of interference with the movement of the stage along the another axis is made to be be zero. Therefore, precise positioning of the stage can be achieved. However, the time (hereinafter called a "positioning period") required to complete the positioning operation cannot be shortened.
(2) The stage is positioned at a position at which one is able to disregard the influence of another axis and a positioning method therefor (the position accuracy is about ±1.0 micrometer).
In this case, the amount of interference with the movement of the stage along another axis is not calculated and a drive operation for correcting the amount of the interference with the movement of the stage along the another axis generated after a positioning operation of the stage is performed is not performed. Therefore, the positioning period can significantly be shortened although positioning cannot be achieved precisely.
However, the conventional structure for performing these methods is arranged in such a manner that the correction of the amount of interference with the movement of the stage along another axis is performed and precise positioning of the stage is performed regardless of the functions required for carrying out each command for positioning the stage. Therefore, the positioning operation is performed with excessive accuracy even for a positioning operation in which shortening of the positioning period is given priority over precise positioning. As a result, the positioning time cannot be shortened, and therefore an optimum positioning method satisfying the function required for each location command has not been employed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a stage control method capable of always performing an optimum positioning method while satisfying the functions required for each positioning command.
According to one aspect, the present invention which achieves these objectives relates to a method of controlling a stage comprising the steps of setting a plurality of drive modes according to which the stage is driven, which correspond to a plurality of positioning processes for positioning an element supported by the stage, and driving the stage according to the plurality of drive modes corresponding to the plurality of positioning processes.
The stage can comprise a major-movement stage mechanism and a fine-movement stage mechanism. In this embodiment the setting step comprises the step of setting a plurality of drive modes according to which the stage is driven by the major-movement stage mechanism and the minor movement stage mechanism, and the driving step comprises the step of driving the stage according to the plurality of drive modes with the major-movement stage mechanism and the fine-movement stage mechanism. The setting step can further comprise the steps of setting a drive mode in which the major-movement stage mechanism drives the stage and the fine-movement stage mechanism does not drive the stage, setting a drive mode in which both the major-movement stage mechanism and the fine-movement stage mechanism drive the stage, and setting a drive mode in which the fine-movement stage mechanism drives the stage and the major-movement stage mechanism does not drive the stage.
The stage can be drivable along a plurality of shafts by the major-movement and fine-movement stage mechanisms. The driving of the stage along one shaft by a certain amount changes the position of the stage along another shaft by a predetermined amount. In addition, the driving step can comprise the step of driving the stage according to the plurality of driving modes along the plurality of shafts. Moreover, the setting step can also comprise the steps of setting a mode in which the stage is driven to correct the predetermined amount of change in the position of the stage along the another shaft and setting a drive mode in which the stage is driven without correcting the predetermined amount of change in the position of the stage along the another shaft. The predetermined amount of correction can be a correction in the amount of change in the attitude of the stage, a correction in the amount of abbe error of the stage, or a correction in the amount of movement due to the movement of the stage by the major-movement stage mechanism along the X and Y axes. The setting step can also comprise the step of setting a plurality of drive modes, each of which uses data from different length-measuring means to determine the manner in which the stage is driven. The different length-measuring means can each comprise a length measuring unit and a laser interference meter provided for the major-movement stage mechanism.
According to still another aspect, the present invention which achieves these objectives relates to an exposure apparatus comprising a stage mechanism on which a substance is placed, exposing means for exposing the substrate to light, storage means for storing data representing a plurality of drive modes according to which the stage mechanism is driven for positioning the substrate, driving means for driving the stage mechanism in accordance with the plurality of drive modes, and control means for selecting one of the drive modes stored in the storage means in accordance with a positioning process according to which the substrate is to be positioned, and for controlling the driving means in accordance with the selected drive mode. The stage mechanism can comprise a major-movement stage mechanism and a fine-movement stage mechanism. In this embodiment each of the major-movement stage mechanism and the fine-movement stage mechanism comprises an X axis stage mechanism and a Y axis stage mechanism. Moreover, the apparatus can further comprise measuring means for measuring the position of the stage mechanism.
Other and further objects, features and advantages of the invention will be evident from the following detailed description of preferred embodiments when taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram which illustrates a stage controller in which one embodiment of a stage control method according to the present invention can be embodied;
FIG. 2 is a schematic side view which illustrates a stage portion of an exposure apparatus in which a stage is positioned by the stage controller shown in FIG. 1;
FIG. 3 is a schematic top view which illustrates the position at which the wafer chuck shown in FIG. 2 is positioned;
FIG. 4 is a flow chart of the control operation performed by the stage controller shown in FIG. 1;
FIG. 5 is a block diagram which illustrates a stage controller in which another embodiment of a stage control method according to the present invention can be embodied; and
FIG. 6 is a flow chart of the control operation performed by the stage controller shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
A first embodiment of the present invention will now be described with reference to the drawings.
FIG. 1 is a block diagram which illustrates a stage controller in which a first embodiment of a method of controlling the stage position according to the present invention can be embodied. FIG. 2 is a schematic side view which illustrates a stage portion of an exposing apparatus having the stage which is positioned by the stage controller shown in FIG. 1.
A stage controller 10 processes the results of measurement performed by each of laser interference meters (X-axis laser interference meter 60 X and the like) and controls the operation of each shaft of a stage portion or stage 50 shown in FIG. 2. The stage controller 10 comprises: a drive mode control unit 11, to which control process information I CP and instructed position information I P are transmitted from an instruction unit 20; and a drive control unit 12 for driving the shafts of the stage portion 50 in accordance with drive shaft information I A , drive method information I M and instructed position information I P . The drive mode control unit 11 has a drive mode table 11 1 storing data relating to a plurality of drive modes instructing the control of the stage. The drive control unit 12 is supplied with results of measurements performed by laser interference meters.
The stage portion 50 of the exposing apparatus, as shown in FIG. 2, comprises: an X-directional major-movement shaft 51 provided with a distance-measurement means (not shown) such as an encoder or an optical scale providing a high drive resolution and distance resolution; a Y-directional major-movement shaft 52 provided with a distance-measurement means (not shown) such as an encoder or an optical scale providing a high drive resolution and distance resolution; an X-directional fine-movement shaft 53; a Y-directional fine-movement shaft 54; a Z-directional tilt shaft 55; a wafer chuck 56 for holding a wafer 1; a mask shaft 57 for positioning the mask 2; an X-directional laser interference meter 60 X ; a Y-directional laser interference meter (not shown); an X-directional-rotation laser interference meter (not shown); a Y-directional-rotation laser interference meter (not shown); a Z-directional-rotation laser interference meter (not shown); and a mirror 61 for reflecting light to the various laser interference meters so they can measure various distances from the mirror 61 to the various laser interference meters.
The Z-directional tilt shaft 55 is composed of three piezo stacks (not shown) for moving the wafer chuck 56 in a Z direction with respect to the Y-directional fine-movement shaft 54. The piezo stacks are, on the XY plane, equally spaced on the circumference around the center of the wafer chuck 56. Thus, by varying the driving amount of the piezo stacks, the surface of the wafer chuck 56, which holds the wafer 1, can be tilted with respect to the XY plane, the wafer chuck 56 being capable of moving in the Z direction.
The position at which the wafer chuck 56 is positioned will now be described with reference to FIG. 3.
First to fourth exposing shot positions Q S1 to Q S4 respectively indicate exposing shot positions on the wafer 1. An exposure pattern P is a pattern exposed to light through the mask 2. Wafer replacement position Q U is a position at which the center of the wafer chuck 56 is positioned when the wafer 1 is replaced by moving a wafer from a wafer hand 70 to the wafer chuck 56. Pre-alignment position Q PA is a position at which the center of the wafer chuck 56 is positioned when the wafer 1 is previously aligned. Fine alignment position Q FA is a position at which one of the first to fourth exposing shot positions Q S1 to Q S4 is precisely positioned with respect to the exposure pattern P of the mask 2. An exposure shot region A is a region in which the center of the wafer chuck 56 is positioned when one of the first to fourth exposing shot positions Q S1 to Q S4 is positioned at the fine alignment position Q FA . A wafer chuck retracting position Q E is a position at which the center of the wafer chuck 56 is positioned when the wafer chuck 56 is retracted at the time of replacing the mask 2. Mask alignment position Q MA is a position at which the center of the wafer chuck 56 is positioned when a reference mark (not shown) on the mask 2 is precisely positioned with respect to a mask-axis stage reference 99 on the mirror 61 with which a laser interference meter measures the distance from the mirror 61 to the laser interference meter.
A process of controlling the drive of the stage portion 50 of the exposing apparatus will now be described.
(1) Wafer Receipt Process
In this process, the wafer 1 is moved from the wafer hand 70 to the wafer chuck 56. The wafer 1 received by the wafer chuck 56 is positioned at the pre-alignment position Q PA in its Z-directional rotational direction. Then, the wafer 1 is precisely aligned with respect to the mask 2 for each exposure shot at the fine alignment position in the exposure shot region A. Therefore, it is preferable that shortening of the time required to perform positioning of the stage be given priority over precise positioning of the stage when the center of the wafer chuck 56 is positioned at the wafer replacement position Q U .
(2) Pre-Alignment Process
In this process, the wafer 1 is positioned along a direction in which it rotates around the Z axis. The operation of positioning the wafer 1 in the direction in which it rotates around the Z axis is performed by positioning a reference mark (not shown) on the wafer 1 with respect to a reference position (not shown) for positioning the wafer chuck 56 in the direction of rotation around the Z axis. Therefore, when the center of the wafer chuck 56 is positioned to the pre-alignment position Q PA , it is preferable that precise positioning of the stage be given priority in the Y direction and shortening of time required to complete positioning of the stage be given priority in the X direction by employing a method of detecting the amount of deviation between the reference position for positioning the wafer chuck 56 in a direction of rotation around the Z axis and the reference mark on the wafer 1.
(3) Mask Replacement Process
In this process, the mask 2 is replaced. When the mask 2 is replaced, the wafer chuck 56 is positioned at the wafer chuck retracting position Q E at which the wafer chuck 56 is positioned during the replacement operation. As a result, a mask conveyance apparatus (not shown) and the wafer chuck 56 are protected safely. Therefore, when the center of the wafer chuck 56 is positioned at the wafer chuck retracting position Q E , it is preferable that shortening of the time required to complete positioning of the stage be given priority over precise positioning of the stage.
(4) Mask Alignment Process
The reference mark (not shown) on the mask 2 is precisely aligned with the mask-axis stage reference 99 on the mirror 61 with which the laser interference meter measures the distance from the mirror 61 to the laser interference meter. Therefore, when the center of the wafer chuck 56 is positioned at the mask alignment position Q MA , it is preferable that precise positioning of the stage be given priority. When the center of the wafer chuck 56 is moved from the wafer chuck retracting position Q E , at which the wafer chuck 56 is retracted during the replacement of the mask 2, to the mask alignment position Q MA , the movement is performed by using the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 because of the drive stroke needed for such movement. The foregoing case, in which the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven, involves interference with the movement of the wafer chuck 56 along another shaft. In other words, the driving of the wafer chuck 56 along the shafts 51 and 52 by a certain amount changes the position of the wafer chuck 56 along another shaft by a predetermined amount. As will be discussed in more detail below, the present invention provides devices to drive the stage and the wafer chuck 56 to correct this predetermined amount of change in the position of the stage and the wafer chuck 56 along the another shaft. Thus, correction of the interference with the movement of the wafer chuck 56 along another shaft enables precise positioning to be performed.
(5) Exposing Shot Locating Process
In this process, one of the first to fourth exposing shot positions Q S1 to Q S4 is precisely positioned at the fine alignment position Q FA . Therefore, it is preferable in this case that precise positioning be given priority. Since the X-directional distance and the Y-directional distance between the exposure shots is longer than the stroke of the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, positioning is performed by using the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54. Therefore, the foregoing case, in which the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven, involves interference with the movement of the stage along another shaft. However, correction of the interference with another shaft enables precise positioning to be performed.
(6) Fine Alignment Process
One of the first to fourth exposing shot positions Q S1 to Q S4 is precisely aligned with the exposure pattern P on the mask 2. Therefore, when each of the first to fourth exposing shot positions Q S1 to Q S4 is aligned with the exposure pattern P, it is preferable that precise positioning be given priority. In this case, positioning is performed in such a manner that the wafer chuck 56 is previously positioned at the fine alignment position Q FA and the amount of deviation of the present exposure shot position from the exposure pattern P of the mask 2 measured by an external measuring means (not shown) is used to determine the distance the wafer chuck 56 needs to move to eliminate the deviation and the wafer chuck 56 is then driven to correct the deviation so it is zero. That is, the previous positioning of one of the exposing shot positions at the fine alignment position Q FA causes the distance the wafer chuck 56 needs to move to correct the deviation to be within the stroke of the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54. Therefore, by driving the wafer chuck 56 by using only the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, positioning can be performed without interfering with the movement of the stage 50 or the wafer chuck 56 along another shaft.
(7) Wafer Receipt Process
In this process, the wafer 1 held by the wafer chuck 56 is received by the wafer hand 70. When the wafer chuck 56 is positioned at the wafer replacement position Q U , it is preferable that shortening of the time required to complete positioning of the wafer chuck 56 be given priority to precise positioning of the wafer chuck 56.
The foregoing process of controlling the drive of the stage 50 includes the first to fourth drive modes below.
(1) First Drive Mode
When X-directional positioning and Y-directional positioning operations are performed, shortening of the time required to complete the positioning of the wafer chuck 56 be given priority.
That is, only the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven, and the interference with the movement of the wafer chuck 56 along another shaft involved when the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven is not corrected. Thus, the time taken to complete positioning in the X and Y directions is shortened. In this case, a drive method is employed in which measuring data from length measuring means, each provided for the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, are used to perform positioning of the wafer chuck 56 by means of the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52. Before the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are positioned at intermediate positions of their strokes. The X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven simultaneously. The foregoing method is called an "XY-directional major-movement drive method".
The foregoing drive mode (a first drive mode) is employed when the center of the wafer chuck 56 is positioned at the wafer replacement position Q U and when the center of the wafer chuck 56 is positioned at the wafer chuck retracting position Q E at the time of replacing the mask 2. The first drive mode is employed to drive the X-directional major-movement shaft 51 or the Y-directional major-movement shaft 52 or when the Z-directional tilt shaft 55 is driven without abbe error quantity correction driving.
(2) Second Drive Mode
In this mode X-directional positioning and Y-directional positioning are performed, but only positioning along the Y axis is precisely performed.
That is, the X-directional drive is performed by only the X-directional major-movement shaft 51 and the interference with the driving of the wafer chuck 56 by shafts 53 and 54 and 55 that arises due to driving of the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 is corrected in only the Y direction so that positioning of the wafer chuck 56 only in the Y direction is precisely performed. In this case, the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55 for correcting the interference with the movement of the wafer chuck 56 along another shaft are used as the drive shafts.
In this case, a drive method arranged as follows is performed: initially, measuring data from length measuring means, provided for the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, are used to perform the positioning operation by using the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52. Moreover, data from the laser interference meter is used to perform the positioning operation by means of the Y-directional major-movement shaft 52. Then, data from the laser interference meter is used to perform the positioning operation by means of the Y-directional fine-movement shaft 54. Before the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are positioned at the intermediate positions of their stroke. The X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are simultaneously driven. The interference with the positioning of the wafer chuck 56 along another shaft is corrected by a method in which the interference is previously calculated (i.e. the distance the wafer chuck 56 moves along the another shaft is previously calculated) and thus the positioning position for each shaft is corrected before the positioning drive is performed and/or a method in which a driving of the wafer chuck 56 for correcting the interference is performed to make the generated interference zero. The correcting of the interference is performed by a drive device for correcting the amount of change in the attitude of the wafer chuck 56, a drive device for correcting the amount of abbe error of the wafer chuck 56 and a drive device for correcting the interference arising from the driving of the wafer chuck 56 along the X and Y axes with another axis. The drive method above is called a "major movement along the X-axis and major and fine movements along the Y-axis drive method".
The second drive mode is employed in a case where the center of the wafer chuck 56 is positioned at the pre-alignment position Q PA . The driving operation to be performed in the second drive mode comprises driving operations using the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52 and the Y-directional fine-movement shaft 54.
(3) Third Drive Mode
When positioning of the wafer chuck 56 in the directions of the X and Y axes is performed, precise positioning in both directions of the X-axis and Y-axis is given priority.
That is, an interference with the movement of the wafer chuck 56 along another axis, generated when the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven, is corrected so that positioning of the wafer chuck 56 in the directions of the X-axis and Y-axis is performed precisely. In this case, the following drive shafts are driven to correct the interference with the movement of the wafer chuck 56 along another shaft: the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55.
In this mode, the following drive method is employed: data from the distance measuring means provided for the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, are used to position the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52. Then, the laser interference meter is used to position the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52. Then, the laser interference meter is used to position the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54. Before the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are positioned at the intermediate positions of their stroke. The X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are simultaneously driven, and the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are simultaneously driven. The interference with the movement of the wafer chuck 56 along another shaft is corrected by a method in which the interference is previously calculated and thus, the positioning position for each shaft is corrected before the positioning drive is performed and/or a method in which a driving operation of the wafer chuck 56 for correcting the interference is performed to make the generated interference zero. The correcting of the interference is performed by a drive device for correcting the amount of change in the attitude of the wafer chuck 56, by a drive device for correcting the amount of abbe error of the wafer chuck 56 and a drive device for correcting the interference of the driving of the wafer chuck 56 along the X and Y axes with another axis. The drive method above is called a "major and fine movements along the X and Y axes drive method".
The third drive mode is employed in a case where the exposure shot position is positioned at the fine alignment position Q FA and in a case where the center of the wafer chuck 56 is positioned at the mask alignment position Q MA . The following shafts are driven in the third drive mode: the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55 which is driven to correct the amount of abbe error.
(4) Fourth Drive Mode
In this mode positioning of the wafer chuck 56 in the direction of X-axis and Y-axis is performed in such a manner that positioning of the wafer chuck 56 is given priority for both the X-axis and the Y-axis.
That is, only the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are driven so that interference with movement of the wafer chuck 56 along another axis is prevented, positioning in the directions of the X and Y axes is performed precisely, and the time required to complete positioning is shortened. In this mode, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are driven.
The driving operation is performed in this case in such a manner that data from the laser interference meter is used to position the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, respectively. The X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are simultaneously driven. The foregoing drive method is called a "fine-movement XY-axes drive method".
The fourth drive mode is performed in a case where the pattern of the mask 2 and the exposure shot are precisely positioned at the fine alignment position Q FA . The X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are driven in the fourth drive mode.
Although only the drive modes to be employed when positioning is performed in the direction X and the direction Y have been described, a drive mode in a direction of another axis is also performed (using for example, the Z-directional tilt shaft 55). However, a description of the driving of this type is omitted here.
The correspondence between the control processes and the drive modes from the viewpoint of their function is as shown in Table 1.
TABLE 1______________________________________Correspondence between Control Processes and Drive ModesControl Process Drive Mode______________________________________wafer receipt process first drive modepre-alignment process second drive modemask replacement process first drive modemask alignment process third drive modeexposure shot positioning process third drive modefine alignment process fourth drive modewafer receipt process first drive mode______________________________________
The flow of information that occurs when a command is issued from the instruction unit 20 to the stage controller 10 shown in FIG. 1 will now be described.
Control process information I CP is transmitted from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode corresponding to the supplied control process information I CP is selected from the Table 1 showing the correspondence between the control process and the drive mode. As a result, the drive mode is set. Moreover, drive shaft information I A and drive method information I M corresponding to the set drive mode are read from the drive mode table 11 1 . Then, all positioning drive operations are performed in accordance with the set drive mode as long as the drive mode is not changed. Then, instructed position information I P is supplied from the instruction unit 20 to the drive mode control unit 11. Drive shaft information I A , drive method information I M and instructed position information I P corresponding to the set drive mode are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning drive operation is performed.
The method of the present invention will now be described with reference to a flow chart shown in FIG. 4 in accordance with an actual exposure sequence.
Initially, the control process is set to the wafer receipt process by supplying control process information I CP , denoting the wafer receipt process, from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode is set to the first drive mode (see Table 1) corresponding to the wafer receipt process (step S11). All positioning drive operations are performed in the first drive mode until a next drive mode is set.
Then, the wafer chuck 56 is positioned at the wafer replacement position Q U (see FIG. 3) to receive the wafer 1 from the wafer hand 70 in accordance with instructed position information I P , denoting the wafer replacement position Q U , supplied from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the first drive mode in this state, drive shaft information I A denoting the "X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52", drive method information I M denoting the "XY-directional major-movement drive method", and instructed position information I P , denoting the wafer replacement position Q U , are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning drive operation is performed in accordance therewith. When the wafer chuck 56 is positioned at the wafer replacement position Q U , the wafer 1 held by the wafer hand 70 is received by the wafer chuck 56 (step S12).
Then, in order to set the control process to the pre-alignment process, control process information I CP , denoting the pre-alignment process, is supplied from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode is set to the second drive mode (see Table 1) corresponding to the pre-alignment process (step S13). All positioning drive operations are performed in the second drive mode until a next drive mode is set.
Then, the wafer chuck 56 is positioned at the pre-alignment position Q PA (see FIG. 3) and thus the wafer 1 is positioned along the direction of rotation around the Z axis by supplying instructed position information I P , denoting the pre-alignment position Q PA , from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the second drive mode, drive shaft information I A , denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the "major movement along the X-axis and major and fine movements along the Y-axis drive method", and instructed position information I P denoting the pre-alignment position Q PA , are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning drive operation is performed in accordance therewith. When the wafer chuck 56 is positioned at the pre-alignment position Q PA , the wafer 1 is positioned along the direction of rotation around Z axis in a pre-alignment step (step S14).
Then, whether or not the mask 2 must be replaced is discriminated (step S15). If a discrimination has been made that the replacement of the mask 2 is not required, the method proceeds to step S20 (for setting the exposure shot position positioning process).
If a discrimination is made in step S15 that the mask 2 must be replaced, the control process is set to the mask replacement process (step S16) in accordance with the control process information I CP , denoting the mask alignment process, which is supplied from the instruction unit 20 to the drive mode control unit 11. The mask 2 is then replaced (step S17) and in the drive mode control unit 11, the drive mode is set to the third drive mode (see Table 1) corresponding to the mask alignment process (step S18). All positioning drive operations are performed in accordance with the third drive mode until a next drive mode is set.
Then, the center of the wafer chuck 56 is positioned at the mask alignment position Q MA and thus the reference mark on the mask 2 is precisely positioned with respect to the mask-axis stage reference 99 on the mirror 61 with which the laser interference meter measures the distance from the interference meter to the mirror 61 in accordance with instructed position information I P , denoting the mask alignment position Q MA (see FIG. 1), supplied from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the third drive mode, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, drive method information I M denoting the "major and fine movements along the X and Y axes drive method", and instructed position information I P denoting the mask alignment position Q MA , are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning drive operation is performed in accordance therewith. When the center of the wafer chuck 56 is positioned at the mask alignment position Q MA , mask alignment is performed (step S19).
In order to set the control process to the exposure shot positioning process, control process information I CP denoting the exposure shot positioning process is supplied from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode is set to the third drive mode (see Table 1), corresponding to the exposure shot position positioning process (step S20). All positioning drive operations are performed in the third drive mode until a next drive mode is set.
Then, the present exposure shot position (for example, the first exposure shot position Q S1 shown in FIG. 3) is positioned at the fine alignment position Q FA in accordance with the instructed position information I P (see Table 1) denoting the position of the center of the wafer chuck 56 when the first exposure shot position Q S1 is positioned at the fine alignment position Q FA and supplied from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the third drive mode, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the "major and fine movements along the X and Y axes drive method", and instructed position information I P denoting the center of the wafer chuck 56 are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning drive operation is performed in accordance therewith (step S21).
In order to set the control process to the fine alignment process, control process information I CP denoting the fine alignment process is supplied from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode is set to the fourth drive mode (see Table 1) corresponding to the fine alignment process (step S22). All positioning drive operations are performed in the fourth drive mode until a next drive mode is set.
Then, the present exposure shot position (for example, the first exposure shot position Q S1 shown in FIG. 3) and the exposure pattern P of the mask 2 are precisely aligned with each other as follows: the amount of deviation of the first exposure shot position Q S1 from the exposure pattern P of the mask 2 is measured by an external measuring means (not shown); and instructed position information I P (see Table 1) denoting the positioning position of the center of the wafer chuck 56, corrected in accordance with the measured amount of deviation, is supplied from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the fourth drive mode at this time, drive shaft information I A denoting the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, drive method information I M denoting the "fine-movement XY-axes drive method", and instructed position information I P denoting the center of the wafer chuck 56, are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning drive operation is performed in accordance therewith in a fine alignment step (step S23).
Then, the exposure of the mask 2 to radiation is performed (step S24), and a discrimination is made whether or not residual exposure shot is present (step S25). If a discrimination is made that residual exposure shot is present, the method proceeds to step S15 (for discrimination whether or not the mask 2 must be replaced).
If a discrimination is made in step S25 that no residual exposure shot is present, the control process is set to the wafer receipt process in accordance with control process information I CP denoting the wafer receipt process, which is supplied from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode is set to the first drive mode (see Table 1) corresponding to the wafer receipt process (step S26). All positioning drive operations are performed in the first drive mode until a next drive mode is set.
Then, the wafer chuck 56 is positioned at the wafer replacement position Q U (see FIG. 3) and thus the wafer 1 is sent to the wafer hand 70 in accordance with instructed position information I P (see FIG. 1) denoting the wafer replacement position Q U and supplied from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the first drive mode at this time, drive shaft information I A denoting the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, drive method information I M denoting the XY-directional major-movement drive method and instructed position information I P denoting the wafer replacement position Q U , are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning drive operation is performed in accordance therewith. When the wafer chuck 56 is positioned at the wafer replacement position Q U , the wafer 1 is sent from the wafer chuck 56 to the wafer hand 70 (step S27).
Then, whether or not a next wafer (a wafer to be then exposed to light) is present is discriminated (step S28). If a discrimination is made that a next wafer is present, the method proceeds to step S12 (for receiving the wafer). If a discrimination is made that no next wafer is present, the operation is completed here.
Second Embodiment
A second embodiment of the method of controlling a stage according to the present invention will now be described. The stage control method according to this embodiment is adapted to a proximity exposure apparatus for exposing the wafer to light in a state where the mask and the wafer are near (that is, the distance from the mask to the wafer is of the order of tens of micrometers). Since the structure of the stage portion 50 and the position to which the wafer chuck is positioned are the same as those shown in FIGS. 2 and 3, this embodiment will now be described with reference to FIGS. 2 and 3.
In a case where positioning of the wafer 1 is performed by using the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 in the exposure shot region A of the proximity exposure apparatus, interference of the mask 2 and the wafer 1 with each other is prevented by retracting the Z-directional tilt shaft 55 to a non-interference region when the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven. Thus, the mask 2 and the wafer 1 can be maintained safely. Therefore, the following fifth drive mode is provided in the case where a positioning operation between exposing shots in the exposure region A is performed in the proximity exposure apparatus.
The Z-directional tilt shaft 55 is retracted from an original position to a non-interference region before the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven and the Z-directional tilt shaft 55 is restored to its original position after the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 have been driven so that securing of the mask 2 and the wafer 1 is given priority. Moreover, interference with the movement of the wafer chuck 56 along another shaft which arises when the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven is corrected so that the positioning operation in both the X direction and the Y direction is performed precisely. In this case, the following drive shafts are driven: the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55.
The two following drive methods are employed in this case.
First Drive Method
In this method the Z-directional tilt shaft 55 is retracted to a non-interference region, data from the distance measuring means each provided for the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are used to position the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, and then data from the laser interference meter is used to position the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52. Then, the laser interference meter is used to position the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54. Finally, the Z-directional tilt shaft 55 is restored to its original position.
Second Drive Method:
In this method the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are positioned, and then the Z-directional tilt shaft 55 is restored to its original position. Finally, data from the laser interference meter is used to position the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54.
With either the first drive method or the second drive method, the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are positioned at the intermediate positions of their strokes before the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven. The X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven simultaneously. Also the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54 are driven simultaneously. Interference with the movement of the wafer chuck 56 along another shaft is corrected by a method in which interference with the movement of the wafer chuck 56 along another axis is previously calculated before positioning the wafer chuck 56 in the X and Y directions is performed and thus the positioning position for each shaft is corrected and/or by a method in which a drive operation for correcting the interference with the movement of the wafer chuck 56 along another axis is performed to make the interference zero.
The drive operation for correcting the interference with the movement of the wafer chuck 56 along another shaft is performed by a drive device for correcting the amount of change in the attitude of the wafer chuck 56, a drive device for correcting the amount of abbe error of the wafer chuck 56 and a drive device for correcting the interference of the driving of the wafer chuck 56 along the X and Y axes with another axis. The drive method above is called a "Z-directional tilt shaft retraction drive performed via major and fine movements along the X and Y axes drive method".
The fifth drive mode is employed in the case where the exposure shot is positioned at the fine alignment position Q FA and in the case where the center of the wafer chuck 56 is positioned at the mask alignment position Q MA (see FIG. 3). The following drive operations are performed in the fifth drive mode: the Z-directional tilt shaft retraction drive performed via major and fine movements along the X and Y axes drive method, and an abbe error correction drive operation performed via the driving of the Z-directional tilt shaft.
The correspondence between the control processes and the drive modes from the viewpoint of their function in the proximity exposure apparatus is as shown in Table 2.
TABLE 2______________________________________Correspondence between Control Processes and Drive ModesControl Process Drive Mode______________________________________wafer receipt process first drive modepre-alignment process second drive modemask replacement process first drive modemask alignment process fifth drive modeexposure shot positioning process fifth drive modefine alignment process fourth drive modewafer receipt process first drive mode______________________________________
Then, the steps of the stage control method according to this embodiment will now be described with reference to an actual exposure sequence.
Since the method is the same as that of the stage control method according to the first embodiment of the present invention except the steps of: "setting of the mask alignment process"; "mask alignment"; "setting of the process for positioning the exposure shot position"; and "positioning of the exposure shot position", a description will be provided of only these differences.
(1) Setting of Mask Alignment Process
In order to set the control process to the mask alignment process, control process information I CP denoting the mask alignment process is supplied from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode is set to the fifth drive mode (see Table 2) corresponding to the mask alignment process (corresponding to step S18 shown in FIG. 4). All positioning drive operations are performed in the fifth drive mode until a next drive mode is set.
(2) Mask Alignment
The center of the wafer chuck 56 is positioned at the mask alignment position Q MA and the reference mark on the mask 2 is precisely positioned at the mask-axis stage reference 99 on the mirror 61 with which the laser interference meter measures the distance from the mirror 61 to the laser interference meter, in accordance with instructed position information I P (see FIG. 1) denoting the mask alignment position Q MA supplied from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the fifth drive mode at this time, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the Z-directional tilt shaft retraction drive operation performed via the major and fine movements along the X and Y axes drive method, and instructed position information I P denoting the mask alignment position Q MA are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning operation is performed in accordance therewith. When the center of the wafer chuck 56 is positioned at the mask alignment position Q MA , mask alignment is performed (corresponding to step S19 shown in FIG. 4).
(3) Setting of Process of Locating Exposure Shot Position
In order to set the control process to the process of positioning the exposure shot position, control process information I CP denoting the process of positioning the exposure shot position is supplied from the instruction unit 20 to the drive mode control unit 11. In the drive mode control unit 11, the drive mode is set to the fifth mode (see Table 2) corresponding to the process of positioning the exposure shot position (corresponding to step S20 shown in FIG. 4). All positioning operations are performed in the fifth drive mode until a next drive mode is set.
(4) Locating of Exposure Shot Position
In order to position the exposure shot position (for example, the first exposure shot position Q S1 shown in FIG. 3) at the fine alignment position Q FA , instructed position information I P (see FIG. 1) denoting the position of the center of the wafer chuck 56 when the first exposure shot position Q S1 is positioned at the fine alignment position Q FA is supplied from the instruction unit 20 to the drive mode control unit 11. Since the drive mode is set to the fifth drive mode, drive shaft information IA denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the Z-directional tilt shaft retraction drive operation performed via major and fine movements along the X and Y axes drive method, and the instructed position information I P denoting the center of the wafer chuck 56 are supplied from the drive mode control unit 11 to the drive control unit 12 so that the positioning operation is performed in accordance therewith (corresponding to step S21 shown in FIG. 4).
With the stage control method according to the first and second embodiments of the present invention, an error recovery process, an assembly adjustment process and a maintenance process are further provided using the first drive mode as shown in Table 3. As a result, even if precise positioning of the wafer chuck 56 cannot be performed due to occurrence of an error or the like in the laser interference meter, setting of the control method to the error recovery process causes the corresponding first drive mode to be set and thus the wafer chuck 56 can be positioned. Therefore, the wafer 1 and the mask 2 can be recovered. Even if the laser interference meter cannot be used in the assembly adjustment stage in the exposure apparatus, the wafer chuck 56 can be positioned similarly. Therefore, the assembly adjustment can easily be performed. Also the maintenance can easily be performed.
TABLE 3______________________________________Correspondence between Control Process and Drive ModeControl Process Drive Mode______________________________________error recovery process first drive modeassembly adjustment process first drive modemaintenance process first drive mode______________________________________
Third Embodiment
A third embodiment of the stage control method according to the present invention will now be described.
In an exposure apparatus, if the regions in which the instructed positioning operations are performed are different from each other or the regions overlap, only issuing instructed position information with instruction unit 20 enables an optimum drive mode to be selected automatically to perform the drive operation for driving the wafer chuck 56. For example, the present method can discriminate whether or not the amount of movement needed to move the wafer chuck 56 from the present position is within the stroke of the fine movement axis drive. This enables positioning of the exposure shot position and positioning of the fine alignment shot position to be distinguished from each other in the case where the positioning of the exposure shot position is performed. When the drive mode is determined in accordance with the amount of movement needed to move the wafer chuck 56 from the present position, the drive mode needed in a particular situation may be discriminated from another drive mode needing the wafer chuck 56 to perform a different amount of movement, as well as a mode requiring the use of the fine movement axis drive.
The correspondence among the instructed position, the amount of movement and the drive mode is as shown in Table 4.
TABLE 4______________________________________Correspondence between Instructed Position and Drive Mode Instructed Position Drive Mode______________________________________Exposure Amount of movement is within fourth drive modeShot stroke of fine-movement axisRegion drive operation Amount of movement exceeds third drive mode stroke of fine-movement axis drive operationPre-alignment position second drive modeWafer Replacement Position first drive modeWafer chuck retracted position when first drive modemask is replacedMask alignment position third drive mode______________________________________
This embodiment is shown in FIGS. 5 and 6. This instruction unit 120 shown in FIG. 5 differs from the instruction unit 20 shown in FIG. 1 in that the instruction unit 120 only supplies instructed position information I P to the drive mode control unit 111.
A stage controller 110 shown in FIG. 5, in which the stage control method according to this embodiment can be embodied differs from the stage controller 10 shown in FIG. 1 in that only instructed position information I P is supplied from the instruction unit 120 to the drive mode control unit 111 as shown in FIG. 5.
In the stage control method according to the present invention, instructed position information I P is supplied from the instruction unit 120 to the drive mode control unit 111. In the drive mode control unit 111, a drive mode corresponding to the thus supplied instructed position information I P is selected from Table 4 showing the correspondence between the instructed position and the drive mode so that the drive mode is set. In a case where the instructed position denoted by the thus supplied instructed position information I P is in the exposure shot region, the drive mode cannot be selected in accordance with only the instructed position. Therefore, the amount of movement of the wafer chuck 56 from its present position is used to select the drive mode. When the drive mode has been set as described above, drive shaft information I A , drive method information I M , and instructed position information I P corresponding to the present drive mode are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed. When the drive mode is set once, all positioning operations are performed in the present drive mode if the drive mode is not changed.
The stage control method according to this embodiment will now be described with reference to FIG. 6 in accordance with an actual exposure sequence. Since the structure of the stage portion and the stage positioning position are the same as those shown in FIGS. 2 and 3, the following description will be also provided with reference to FIGS. 2 and 3.
The wafer chuck 56 is positioned at the wafer replacement position Q U (see FIG. 3) and thus the wafer 1 is received from the wafer hand 70 in accordance with instructed position information I P (see FIG. 5) denoting the wafer replacement position Q U and supplied from the instruction unit 120 to the drive mode control unit 111. In the drive mode control unit 111, the drive mode is set to the first drive mode (see Table 4) corresponding to the wafer replacement position Q U because the thus supplied instructed position information I P denotes the wafer replacement position Q U . As a result, drive shaft information I A denoting the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, drive method information I M denoting the XY-directional major-movement drive method, and instructed position information I P denoting the wafer replacement position Q U , are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith. When the wafer chuck 56 has been positioned at the wafer replacement position Q U , the wafer 1 is supplied from the wafer hand 70 to the wafer chuck 56 in a wafer receiving step (step S51).
Then, the wafer chuck 56 is positioned at the pre-alignment position Q PA (see FIG. 3) and thus positioning of the wafer 1 along the direction of rotation around the Z axis is performed in accordance with instructed position information I P (see FIG. 5) denoting the pre-alignment position Q PA and supplied from the instruction unit 120 to the drive mode control unit 111. In the drive mode control unit 111, the drive mode is set to the second drive mode (see Table 4) corresponding to the pre-alignment position Q PA because the thus-supplied instructed position information I P denotes the pre-alignment position Q PA . As a result, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the major movement along the X-axis and major and fine movements along the Y-axis drive method, and instructed position information I P denoting the pre-alignment position Q PA are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith. When the wafer chuck 56 has been positioned at the pre-alignment position Q PA , the wafer 1 is positioned along the direction around the Z axis in a pre-alignment step (step S52).
Then, whether or not the mask 2 must be replaced is discriminated (step S53). If a discrimination has been made that the replacement of the mask 2 is not required, the method proceeds to step S56 (positioning the exposure shot position) to be described later.
If a discrimination has been made in step S53 that the replacement of the mask 2 is required, the wafer chuck 56 is positioned at the wafer chuck retracting position Q E (see FIG. 3) to replace the mask 2 in accordance with instructed position information I P (see FIG. 5) denoting the wafer chuck retracting position Q E and supplied from the instruction unit 120 to the drive mode control unit 111. Since the thus supplied instructed position information I P denotes the wafer chuck retracting position Q E , the drive mode is, in the drive mode control unit 111, set to the first drive mode (see Table 4) corresponding to the wafer chuck retracting position Q E . As a result, drive shaft information I A denoting the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, drive method information I M denoting the XY-directional major-movement drive method, and instructed position information I P denoting the wafer chuck retracting position Q E are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith. When the wafer chuck 56 has been positioned at the wafer chuck retracting position Q E , the mask 2 is replaced (step S54).
Then, the center of the wafer chuck 56 is positioned at the mask alignment position Q MA and thus the reference mark on the mask 2 is precisely positioned at the mask-axis stage reference 99 on the mirror 61 with which the laser interference meter measures the distance from the mirror 61 to the laser interference meter in accordance with instructed position information I P (see FIG. 5) denoting the mask alignment position Q MA and supplied from the instruction unit 120 to the drive mode control unit 111. Since the thus-supplied instructed position information I P denotes the mask alignment position Q MA , the drive mode is, in the drive mode control unit 111, set to the third drive mode (see Table 4) corresponding to the mask alignment position Q MA . As a result, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I m denoting the major and fine movements of X and Y axes drive method, and the instructed position information I P denoting the mask alignment position Q MA are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith. When the center of the wafer chuck 56 has been positioned at the mask alignment position Q MA , mask alignment is performed (step S55).
Then, the present exposure shot position (for example, the first exposure shot position Q S1 shown in FIG. 3) is positioned at the fine alignment position Q FA in accordance with instructed position information I P (see FIG. 5) denoting the center of the wafer chuck 56 when the first exposure shot position Q S1 is positioned at the fine alignment position Q FA and supplied from the instruction unit 120 to the drive mode control unit 111. In the drive mode control unit 111, the thus-supplied instructed position information I P denotes the instructed position in the exposure shot region and because the amount of movement needed for the wafer chuck 56 to perform exceeds the stroke of the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, the drive mode is set to the third drive mode (see Table 4) corresponding to the foregoing fact. As a result, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the major and fine movements of X and Y axes drive method, and instructed position information I P denoting the position of the center of the wafer chuck 56, are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith in a position exposure shot position step (step S56).
In order to precisely position the present exposure position for example, the first exposure shot position Q S1 shown in FIG. 3 and the exposure pattern P of the mask 2 are precisely positioned with respect to each other, and the amount of deviation between the first exposure shot position Q S1 and the exposure pattern P of the mask 2 is measured. Instructed position information I P (see FIG. 1) corrected in accordance with the measured amount of deviation and denoting the center of the wafer chuck 56 is supplied from the instruction unit 120 to the drive mode control unit 111. Since the instructed position is in the exposure shot region and the amount of movement is within the stroke of the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, the drive mode is, in the drive mode control unit 111, set to the fourth drive mode (see Table 4) corresponding to the foregoing fact. As a result, drive shaft information I A denoting the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, drive method information I M denoting the fine-movement XY-axes drive method, and instructed position information I P denoting the position of the center of the wafer chuck 56 are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith in a fine alignment step (step S57).
Then, exposure is performed (step S58), and whether or not a residual exposure shot is present is discriminated (step S59). If a discrimination has been made that the residual shot is present, the method returns to step S53 (in which whether or not the mask 2 must be replaced is discriminated).
If a discrimination has been made in step S59 that there is no residual exposure shot, the wafer chuck 56 is positioned at the wafer replacement position Q U (see FIG. 3) to send the wafer 1 to the wafer hand 70 in accordance with instructed position information I P (see FIG. 5) denoting the wafer replacement position Q U and supplied from the instruction unit 120 to the drive mode control unit 111. In the drive mode control unit 111, the drive mode is set to the first drive mode (see Table 4) corresponding to the wafer replacement position Q U , since the thus-supplied instructed position information I P denotes the wafer replacement position Q U . As a result, drive shaft information I A denoting the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52, drive method information I M denoting the XY-directional major-movement drive method, and instructed position information I P denoting the wafer replacement position Q U are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith. When the wafer chuck 56 has been positioned at the wafer replacement position Q U , the wafer 1 is sent from the wafer chuck 56 to the wafer hand 70 in a wafer receiving step (step S60).
Then, whether or not a next wafer (a wafer to be exposed to light) is present is discriminated (step S61). If a next wafer is present, the method returns to step S51 (receipt of the wafer 1). If the next wafer is not present, the operation is completed here.
A fourth embodiment of the stage control method according to the present invention will now be described.
The stage control method according to this embodiment is adapted to a proximity exposure apparatus for exposing the wafer to light in a state where the mask and the wafer are near (that is, the distance from the mask to the wafer is of the order of tens of micrometers). Since the structure of the stage portion and the position to which the wafer chuck is positioned are the same as those shown in FIGS. 2 and 3, this embodiment will now be described with reference to FIGS. 2 and 3.
As described above, when positioning is performed in the exposure shot region A by using the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 of the proximity exposure apparatus, the interference between the mask 2 and the wafer 1 is prevented by retracting the Z-directional tilt shaft 55 when the X-directional major-movement shaft 51 and the Y-directional major-movement shaft 52 are driven. As a result, safety of the mask 2 and wafer 1 can be secured.
The correspondence in the proximity exposure apparatus among the instructed position, the amount of movement from the present position and the drive mode is as follows:
TABLE 5______________________________________Correspondence between Instructed Position and Drive Mode Instructed Position Drive Mode______________________________________Exposure Amount of movement is within fourth drive modeShot stroke of fine-movement axisRegion drive operation Amount of movement exceeds fifth drive mode stroke of fine-movement axis drive operationPre-alignment position second drive modeWafer Replacement Position first drive modeWafer chuck retracted position when first drive modemask is replacedMask alignment position fifth drive mode______________________________________
The stage control method according to this embodiment will now be described with reference to an actual exposure sequence.
Since this method is the same as that of the stage control method according to the third embodiment of the present invention except for the steps of "mask alignment" and "positioning the exposure shot position", only these differences will be described.
(1) Mask Alignment
The center of the wafer chuck 56 is positioned at the mask alignment position Q MA and thus the reference mark on the mask 2 is positioned at the mask-axis stage reference 99 on the mirror 61 with which the laser interference meter measures the distance from the mirror 61 to the laser interference meter in accordance with instructed position information I P (see FIG. 5) denoting the mask alignment position Q MA and supplied from the instruction unit 120 to the drive mode control unit 111. In the mask alignment position Q MA , the drive mode is set to the fifth drive mode (see Table 5) corresponding to the mask alignment position Q MA because the thus-supplied instructed position information I P denotes the mask alignment position Q MA . As a result, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the Z-directional tilt shaft retraction drive operation performed by major and fine movements along the X and Y axes drive method, and instructed position information I P denoting the mask alignment position Q MA are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith. When the center of the wafer chuck 56 has been positioned at the mask alignment position Q MA , mask alignment is performed (corresponding to step S55 shown in FIG. 6).
(2) Locating Exposure Shot Position
In order to position the present exposure shot position (for example, the first exposure shot position Q S1 shown in FIG. 3) at the fine alignment position Q FA , instructed position information I P (see FIG. 5) denoting the position of the center of the wafer chuck 56 when the first exposure shot position Q S1 is positioned at to the fine alignment position Q FA is supplied from the instruction unit 120 to the drive mode control unit 111. Since the instructed position is in the exposure shot region and the amount of movement exceeds the stroke of the X-directional fine-movement shaft 53 and the Y-directional fine-movement shaft 54, the drive mode is, in the drive mode control unit 111, set to the fifth drive mode (see Table 5) corresponding to the foregoing fact. As a result, drive shaft information I A denoting the X-directional major-movement shaft 51, the Y-directional major-movement shaft 52, the X-directional fine-movement shaft 53, the Y-directional fine-movement shaft 54 and the Z-directional tilt shaft 55, drive method information I M denoting the Z-directional tilt shaft retraction drive operation performed by major and fine movements along the X and Y axes drive method, and instructed position information I P denoting the position of the center of the wafer chuck 56 are supplied from the drive mode control unit 111 to the drive control unit 112 so that the positioning operation is performed in accordance therewith (corresponding to step S56 shown in FIG. 6).
Although the invention has been described in its preferred form with a certain degree of particularly, it is understood that the present disclosure of the preferred form can be changed in the details of construction and the combination and arrangement of parts may be modified to without departing from the spirit and the scope of the invention as hereinafter claimed. | A method of controlling a stage includes the steps of setting a plurality of drive modes according to which the stage is driven, which correspond to a plurality of positioning processes for positioning an element supported by the stage, and driving the stage according to the plurality of drive modes corresponding to the plurality of positioning processes. An exposure apparatus employing such a method includes a stage mechanism on which a substrate is placed, an exposure device for exposing the substrate to light, a memory for storing data representing a plurality of drive modes according to which the stage mechanism is driven for positioning the substrate, a driver for driving the stage mechanism in accordance with the drive modes, and a controller for selecting one of the drive modes stored in the memory in accordance with a positioning process according to which the substrate is to be positioned, and for controlling the driver in accordance with the selected drive mode. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to storage and organization of documents and computer storage media, and more particularly to a compact storage and/or filing case having divided, compartmentalized document storage space and one or more 3.5" floppy disk slots.
2. Background
Many attempts have been made in the prior art for providing an organizer for documents and computer media either separately or in combination. As will be recognized, none of the prior art solutions offer a flexible protective compartmentalized apparatus for both documents and computer storage media, convenient use and ease of identification of and access to contents, and economical manufacture.
U.S. Pat. No. 4,664,258 discloses a diskette holder of the type which may be received in albums or table stands. The holder comprises a plurality of relatively stiff sheets to form a pocket for a floppy disk in the form of a sandwich-type structure. The pocket is then subsequently removable mounted in storage unit, such as a binder or box. This approach does not allow the facile storage of the computer-readable media with paper documents, such as directory listings, file printouts or hard copies, documentation, and the like.
U.S. Pat. No. 4,957,205 describes another computer disk holder attachable to a three ring notebook. The holder is essentially a rigid plastic frame page with plastic detents for holding the disks on the frame page. While this arrangement allows the filing of documents in the three ring binder with the computer readable storage media, the three ring binder format is far from ideal. The snap rings of the binder are often difficult to manipulate. The hard copies to be stored must be perforated with holes in a certain alignment, and if the documents are thick, such as software documentation booklets, perforation may require them to be disassembled before punching. Further, if the items stored are of differing sizes, the overall organization of the binder is substantially hindered.
U.S. Pat. No. 5,275,438 discloses a file folder with an attached computer disc pocket. The pocket includes a rear wall, a front wall, a cover flap and a retaining flap to prevent the loss of a disc contained therein. The walls of the file and the pocket may be made from translucent plastic to allow easy view of the file folder contents.
U.S. Pat. No. 5,394,981 discloses a box-type storage unit for computer diskettes and provides space for documentation. The box has a latched cover and contains loose-leaf plastic pages for holding the computer-readable storage media and the documentation. One major disadvantage of this system are that the box-type construction renders the case more suitable for archival purposes, e.g., for placement on a shelf, than for portability. The plastic pages limit the amount of storage available, and their pre-sized format makes the inclusion of many documents of varying size difficult to order according to the needs of the user: that is, the predominantly limiting sorting criterion is by size.
U.S. Pat. No. 4,730,727 discloses an accordion-type holder for diskettes having a cover. Disadvantageously, there is no provision for an easy way to include various sized documents with the floppies. A further disadvantage is the requirement for the use of adhesive labels on the exterior of the holder.
U.S. Pat. No. 5,193,681 discloses a spiral-bound notebook which can accommodate diskettes and documents. A major disadvantage with this apparatus is that the multipart construction is held together by a comb-type binding device, which in use can become unbound. Without the appropriate apparatus for binding the leaves of the book to the binding spine, it is very difficult to reintroduce the individual tines of the comb into the slots cut on the leaves should they separate.
U.S. Pat. No. 5,579,908 discloses a retaining envelope for computer discs that consists of a pocket sized to receive the disc and a mounting means for securing the pocket to any desired flat surface.
U.S. Pat. No. 5,193,681 discloses a fastenable book-like holder, organizer and storage device for a series of computer diskettes. A set of diskette envelopes leaved together with pliant covers bound by a device such as a popular plastic comb binding, and fastened by a device such as a hook and loop fastener so that the holder secures a set of computer floppy diskettes. The cover configuration includes an elongated flapped member which can be scored for easy folding around the end of the holder; which, upon closure, secures the contents, and the curve of which, when open, keeps contained diskettes from falling from the various leaves.
U.S. Pat. No. 4,202,585 discloses a modular storage container for flexible recording disks is made up of a plurality of lightweight, flat rectangular panels which are interconnected to form a corresponding number of storage compartments. The outside panels have handle grips to facilitate handling or transporting of the containers, and each storage compartment contains an actuating lever mechanism which through selective depression of an associated push rod having a tab located externally of the compartment, will cause a selected disk to be advanced from its storage location for removal and use. A series of tabs alternate in such a fashion as to allow the rods to be close together without touching one another; yet each tab may be depressed individually without interference from the other tabs.
U.S. Design Pat. No. 332,005 discloses a CD holder, comprising a plurality of plastic pages with CD-receiving sleeves attached to an outer wrapper for securing the pages. This arrangement does not provide for the inclusion of various documentation. If indeed documentation were included, it would likely be a standard-sized CD jewel box insert, which could share an individual envelope with the CD. This arrangement also suffers from the drawback of the lack of any means for interchangeably including a label on the outer surface to identify the contents.
It therefore remains desirable to arrive at improved apparatus for containing and organizing documents and computer readable storage media.
SUMMARY OF THE INVENTION
The present invention provides a flexible, protective portfolio-type organizer filing and storage system which provides for the compact storage of computer readable media, for example 3.5" floppy diskettes, and an accordion-type divided filing region for documents or other related material. The portfolio further provides the added benefit of facile and interchangeable label placement on the outer surface thereof for quick identification of the contents of the filing system at a glance.
According to the invention, a portable filing system is provided having a unitary cover subdivided into a front flap, a top, a back, a bottom and a front; the cover being constructed and arranged to provide an open-sided surrounding enclosure. A media holder is mounted to the front portion of said cover, and an accordion file is mounted to the interior of the enclosure defined by said cover. The file system has a closed configuration wherein the front flap is in overlying relationship with said front portion of the cover, and an open configuration where the front flap is elevated from the front portion of said closure. A closure retainer for maintaining the file system in the closed configuration is provided.
The instant invention allows for facile storage of computer-readable media with paper documents, such as directory listings, file printouts or hard copies, documentation, and the like. Advantageously, the instant invention is a self-contained unit in portfolio form, and therefore does not rely on difficult-to-manipulate snap rings of conventional binders. The hard copies to be stored may be stored in their natural state, and are not required to be perforated with holes in a certain alignment, slid into an envelope, or the like. Further, if the items stored are of differing sizes, the overall organization of the binder is not affected.
Another advantage of this system is that the portfolio-type construction renders the case more suitable for portability, while maintaining the convenient height dimension of a conventional binder for filing on a bookshelf, for example.
A further advantage is that the instant invention provides retainer for interchangeably providing a label on the outer surface to identify the contents. This retainer is conveniently dimensioned in a preferred embodiment to accommodate a half-sheet of standard letter-sized paper, so that custom labels are not required.
Other aspects of the invention are disclosed infra.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become more apparent in view of the following detailed description in conjunction with the accompanying drawing, of which:
FIG. 1 is a perspective view of the filing system of the instant invention in a first, closed configuration.
FIG. 2 is a perspective view of the filing system of the instant invention in transition between a first, closed configuration and a second, open configuration.
FIG. 3 is a perspective view of the filing system of the instant invention in transition between a first, closed configuration and a second, open configuration from another perspective.
FIG. 4 is a side plan view of the filing system of the instant invention in transition between a first, closed configuration and a second, open configuration.
FIG. 5 is a front, perspective view of the filing system of the instant invention in a second, open configuration.
FIG. 6 is a partial view cutaway of an accordion file according to one aspect of the instant invention
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described herein with reference to the preferred embodiment of a disk file according to the instant invention.
Referring to FIG. 1, a disk file system 10 is shown in a first, closed configuration. An accordion file 12 is wrapped in an outer cover 14. In the preferred embodiment, the accordion file is formed of translucent 0.18-0.22 mm gauge plastic to allow viewing of, or ascertaining the presence of, contents. The outer cover 14 is preferably of a relatively tough plastic, rigid enough to provide the desired stability to the system and protection to the contents. In a preferred embodiment the cover 14 is formed of 0.5-0.8 mm gauge polypropylene plastic.
If desired, the accordion file 12 may be omitted, converting the storage and organizing system of this invention into a convenient portfolio. If desired, the accordion file component can be made to be removable and replaceable, as per the needs of the user. Convenient locking materials for such a conversion include Velcro® hook and loop tabs, or other locking and unlocking members useful with lightweight products such as this.
The cover 14 is comprised of a plurality of regions separated by folds or living hinges. These parts can be seen by reference to FIGS. 1 and 2, and include a front flap 14a, a top 14b, a back 14c, a bottom 14d, and a front 14e. In a closed orientation, the front flap 14a of the cover 14 overlies the front 14e so as to surround the accordion 12 in an envelope which is open on the sides, as can be seen in FIG. 1. Conveniently, the file system 10 may be maintained in a closed orientation by an elastic band 16 attached to the front flap 14a.
Turning now to FIG. 2, the file system 10 is shown with the elastic band 16 moved from surrounding engagement with the corners of the file system, and the front flap 14a lifted from its engagement with the front 14e. As can be seen, the elastic band may be retained on the back of the front flap 14a with retainers 18, while the elastic passes through a small hole in the front flap 14a. As further may be seen, the accordion 12 is comprised of a Z-fold portion 20, which gives the accordion its expanding and contracting properties. As the front flap 14a is lifted, it can be appreciated that the front 14e of the cover 14 may have a cutout portion across the top thereof to provide enhanced visibility of divider tabs 24, discussed in further detail below. The cutout results in two tabs 30, which provide for mounting of the Z-fold portion 20 on the back side thereof. Such mounting is accomplished by conventional means, such as adhesive bonding, sonic welding, or heat welding.
Also seen in FIG. 2 is a media holder 26, which may be advantageously dimensioned to hold any machine readable medium. In a preferred embodiment, the holder 26 is dimensioned to receive two or more 3.5" floppy diskettes in side-by-side or overlying relationship.
FIG. 3 depicts the filing system of the instant invention being opened from a closed configuration to an open configuration. From this perspective, it can be readily appreciated that the filing system of the instant invention may be dimensioned so as to be conveniently stored on a bookshelf in upstanding, side-by-side relationship, or may be stacked. As can be seen, a label holder 28 may be mounted extending from the front flap 14 a to the back 14c across the top 14b. When in the closed configuration depicted in FIG. 1, the label holder 28 should be taught. The label holder is mounted to the front flap 14a and the back 14c at least at the two sides 28a thereof. In the preferred embodiment, the label retainer is constructed and arranged so as to define an envelope for a sheet of paper having the dimensions equaling one half of a sheet of letter sized paper. Advantageously, a standard sheet of letter sized paper may be folded into half, e.g. folding a sheet once laterally, to arrive at a folded sheet having the dimensions 81/2" by 51/2", and then inserted into the holder. This approach dispenses with the need for special labels, sheets that must be cut to size, or other inconvenient arrangements used in the prior art.
As further seen in FIG. 3 and by reference to FIG. 4, the Z-fold portion 20 of accordion 12 is mounted to the inside surfaces of front 14e and back 14c. It can be appreciated that the bottom 14d limits the outward expansion of the bottom part of the accordion 12, while the upper portion may easily expand outward in the direction of arrow A. Such expansion provides for facile access to the contents of the file system accordion 12, and also provides for expandability when the file is accommodating contents that are bulky.
From FIG. 5, it can be seen that spanning the Z-fold portions 20 of the accordion 20 are dividers 22, which may advantageously comprise divider tabs 24. These tabs may be labeled, denoted alphabetically or by other predetermined scheme, or may receive adhesive, pressure-sensitive labels, for example. The cutout of the front 14e of the cover 14 between the Z-fold mounting tabs 30 advantageously provides for easy viewing of the divider tabs 24.
Finally, FIG. 6 provides a section view of the accordion 12 depicting a section of the Z-fold portion 20 and a divider 22 attached thereto at an attachment region 32. This attachment may by conventional means, such as adhesive bonding, heat welding, sonic welding, or the like.
In a preferred embodiment, the file system 10 in a basic closed configuration as depicted in FIG. 1 is dimensioned to be about 13" wide, 93/8" tall and 11/8" deep. The preferred embodiment comprises two Z-fold members having 27 folds, defining pleats for holding 12 dividers. The dividers in the preferred embodiment are approximately 121/2" wide and 81/2" tall, not counting the divider tabs, which are approximately 5/8" tall and 1 1/4" wide. The media holder of the preferred embodiment defines two envelopes each having an interior approximately 45/8" wide and 3" tall, with an open top, such that a 31/2" floppy disk is easily accommodated. The preferred embodiment also provides a label holder 83/4" wide by 51/2" tall, which after attachment at the margins thereof to the cover along the two lateral sides provides an open-topped and open-bottomed interior envelope accommodating a half sheet of letter-sized paper, viz. 81/2" by 51/2".
Of course modifications of the preferred embodiment are foreseen. For example, the accordion may be made of other materials, such as polyethylene, polybutylene, other plastics, or cardboard or cardstock or other paperboard. The accordion may also be transparent or opaque, and may be colored in various schemes. The cover also may be made of other materials, including plastics, paper based stocks, cloth or leather, for example. Composite construction, for example using leather or cloth with metal support inserts is also envisioned.
The elastic band 16 may also be fabricated of other materials, such as a cloth tie, nylon webbing, and may further comprise clasps, fasteners, closures or clips well known in the art. Particularly foreseen is the use of hook and loop fasteners, such as Velcro®. Two bands may also be provided, one for each corner of the front flap, instead of one band.
The media holder 26 may of course be flexibly dimensioned to receive other media, such as CD-ROMS, 5.25" floppy diskettes, cassettes, DAT tapes, credit or magnetic swipe cards, flash-memory cards, PCMCIA cards, smart cards, optical flash passes, digital audio disks, or other media which have not yet found widespread acceptance in the market.
While in the preferred embodiment, the label holder 28 is dimensioned for use with letter-sized paper, the holder may of course be dimensioned for other common sizes, such as A4 or Legal size sheets, for example, or for a 3"×5" index card, or other popular sized card stock.
As used herein, the terms "front", "back", "top", "side", "bottom", "inner" and "outer" and words of similar meaning are intended to apply to the relative positions depicted in the drawings, since in use the file system may of course be oriented in a number of positions.
Although the invention has been shown and described with respect to exemplary embodiments thereof, various other changes, additions and omissions in the form and detail thereof may be made therein without departing from the spirit and scope of the invention. | A portable filing and storage system having a unitary cover subdivided into a front flap, a top, a back, a bottom and a front; the cover being constructed and arranged to provide an open-sided surrounding enclosure. A media holder is mounted to the front portion of said cover, and an accordion file is mounted to the interior of the enclosure defined by said cover. The file system has a closed configuration wherein the front flap is in overlying relationship with said front portion of the cover, and an open configuration where the front flap is elevated from the front portion of said closure. A closure retainer for maintaining the file system in the closed configuration is provided. | 1 |
BACKGROUND OF THE INVENTION
In high speed magnetic tape handlers, magnetic tape is reeled back and forth between a supply reel and a take-up reel passing over a record/play-back head. The tape is drawn across the head by a capstan usually driven by a fast response low inertia DC motor. In such machines the tape is accelerated and decelerated at extremely high rates posing a very severe problem on means for maintaining uniform tension on the tape in the vicinity of the record/play-back head at all times. The inertia of the supply and take-up reels is such that, although they may be driven by powerful servo motors, they cannot provide the required uniform tension. Accordingly, it is usual to provide a substantial vacuum buffer on each side of the capstan and between it and the servo controlled reels. These vacuum buffers are typically provided by means of rectangular straight channels generally about 2 to 3 inches wide and as long as dictated by the response time of the reel servos. Vacuum ports at appropriate points, particularly at the bottom of the tank, couple a vacuum system to the buffer channels. Additional small buffers may be provided usually one on each side of the record/play-back head, to accommodate rapid acceleration of the tape.
A typical high speed magnetic tape handler is constructed with the two reels (supply and take-up) mounted in the upper part of a cabinet enclosure with the capstan and head mounted below and the two vacuum tanks extending downward, centrally located and side-by-side. Illustrating the system with 101/2 inch diameter reels, a typical cabinet is of the order of 27 inches wide and 63 inches high. The result is a substantial area of unused space on each side of the vacuum tanks and below the reels. It is the object of the present invention to more efficiently use the cabinet area.
SUMMARY OF THE INVENTION
It has been found possible, in accordance with the present invention, to fold the vacuum tanks into L, U or other more complex shapes and thereby to very substantially reduce the panel area required to house a high speed magnetic tape handler. A typical tape handler, in accordance with the present invention, occupies less than half the panel space of an equivalent tape handler made in accordance with the teachings of the prior art. The unused panel space is reduced to a very low percentage of the total panel area. Generally, the present invention makes possible housing two high speed tape handlers on a panel area formerly required by only one. In addition, it has been found that the folded vacuum tank configuration provides a faster response to tape acceleration when compared with the prior art tanks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is simplified elevation view of a prior art high speed magnetic tape handler employing two vacuum buffer tanks.
FIG. 2 is a simplified elevation view of the preferred form of the present invention.
FIG. 3 is a modified form of the present invention.
FIG. 4 is another modified form of the present invention.
FIG. 5 is a detail of a portion of the form of the invention shown in FIG. 2.
FIG. 6 is an enlarged detail of a portion of the detail shown in FIG. 5.
FIG. 7 is an illustration of how the tape behaves at one point of its path in a folded vacuum tank.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in simplified form the elevation view of a typical prior art high speed magnetic tape handler. A supply reel 1 and a take-up reel 2 are mounted near the top of a cabinet 3. It can be assumed that a panel mounted inside the cabinet provides a suitable mounting for the reels and other components to be described below. The magnetic tape passes back and forth between the two reels rotated by suitable servo means for winding the tape in a selected direction as indicated at 65 and 66, with said tape driven by capstan 7 and over record/play-back head 8. Superimposed between the capstan and head and each of the reels is a vacuum tank for maintaining a constant tension on the tape at the head and at the same time permitting fast acceleration of the tape in either direction. Tank 5 is between the capstan and take-up reel 2, while tank 6 is between the head and supply reel 1. When the tape is accelerated or decelerated, only the low inertia loops in the vacuum tanks must respond instantaneously. Before the tape in the tanks is moved too far, the servo driven reels come into operation, usually in response to loop position sensors in the tanks, to restore the initial positions of the tape loop in the tanks.
Even with powerful fast acting servo motors driving the tape reels, it is still necessary to have buffer tanks of substantial length. Typically, tanks 5 and 6 are 30 inches long by 2 inches wide for a 200 i.p.s. tape drive. It can be seen that with the two reels side-by-side at the top of the cabinet and the 30 inch long vacuum tanks in the central area below, that there is a substantial area of unused panel area and cabinet space on each side of the vacuum tanks. It is the purpose of this invention to provide a form of folded vacuum tank which permits essentially doubling the efficiency of utilization of the panel space. In other words, two tape handlers can now be mounted in a cabinet and on a panel formerly carrying only one tape handler.
FIG. 2 is a simplified elevation view of the preferred form of the present invention. In this form the tape reels 1 and 2 are mounted one above the other and the magnetic tape 4 is passed through two similar folded vacuum tanks surrounding the reels and two high speed buffers in traveling from one reel to the other. Following the path of the magnetic tape 4 from supply reel 1, it turns corners around roller or air bearings 9, 10 and 18 until it approaches end of channel 15 provided with vacuum ports 16 and 17 where it turns back passing inside corners 13 and 11 provided with vacuum ports 14 and 12 respectively, to high speed buffer 19 provided with vacuum ports 20 and 21 where it again reverses direction passing over air bearing 22 and across tape guide 23 to record/play-back head 8. From this point it follows a path which is a mirror image of the path described up to this point, passing across a second tape guide 24, around drive capstan 7 and into a second high speed buffer 25 provided with vacuum ports 26 and 27, there reversing direction and passing inside corners 28 and 30 provided with vacuum ports 29 and 31 respectively, to the vicinity of end of channel 37 provided with vacuum ports 32 and 33 where it again reverses direction and, after cornering around rollers or air bearings 34, 35 and 36, passes onto take-up reel 2. The path is reversed in passing backward from take-up reel 2 to supply reel 1. The whole assembly can be rotated 90 degrees clockwise or oriented in any other desired manner.
The sum of the individual straight portions of the folded tank should be made to be approximately equal to the straight tank length of the prior art machines for a given tape speed design. However, the folded tank has been found to provide more uniform tension at the record/play-back head under high speed reversals and at high linear tape speeds. This is due to the fact that each corner of the folded tank acts as a high speed buffer which breaks up the total tape loop into two or more segments of lower mass and inertia. Thus, the form of folded tank shown in FIG. 2 and described above provides three segments in each loop, each of approximately one-third the inertia of a full straight loop as provided by the prior art.
FIG. 3 shows a modified form of the invention in which the vacuum tank is folded on one side of the supply and take-up reels providing a somewhat different form factor for the complete assembly. The reels 1 and 2 feed into similarly folded tanks only one of which need be described in detail. Looking at the upper folded tank, the magnetic tape 4 leaving supply reel 1 passes around a first corner around roller or air bearing 9, upward into a rectangular section 45 having corner vacuum ports 46 and 47, thence downward and around roller or air bearing 41, upward to a second rectangular section or pocket 42 provided with end vacuum parts 43 and 44, downward to rectangular section 38 provided with corner vacuum parts 39 and 40, upward to roller or air bearing 37, around it and downward to high speed buffer 19, upward to air bearing 22, around it and downward over guide 23 to record/play-back head 8. The path from head 8 back to take-up reel 2 is a mirror image of the path just described and operates in the same manner.
An examination of the tape path in accordance with FIG. 3 and described above will show that the tape loops are broken into at least three pieces and, furthermore, since each corner functions as a high speed buffer, that four high speed buffers have been effectively added (at 46, 47, 39 and 40). A high speed buffer is formed wherever the tape turns a corner provided with a vacuum port.
FIG. 4 is another modified form of a folded vacuum tank. The magnetic tape 4 leaving supply reel 1 passes around roller 9, upward into rectangular section 48 provided with corner vacuum vents 49 and 50, downward toward end section 51 provided with vacuum vents 52 and 53, then upward turning around over rollers or air bearings 54, 55 and 56, downward into high speed buffer 19, up over air bearing 22, and over guide 23 to record/play-back head 8. The path from head 8 back to take-up reel 2 is substantially a mirror image of the path just described although it is folded to fit inside channel 48.
While three forms of folded vacuum tank have been shown and described, other forms are possible in accordance with the teachings of the present invention. The essential requirements are: that the tank be folded at least once at any angle up to 180° conserving space and reducing the inertia of a given segment of tape and that the fold points be provided with vacuum ports.
FIG. 5 is an enlarged view of one form of the invention, being substantially like the form shown in FIG. 2 and described above. It shows that while the complete channel sides have been omitted from FIGS. 2, 3 and 4, that, actually, the vacuum tank channels are enclosed on all sides including the panel on which the channels are mounted and the door which may be opened to change reels. FIG. 5 also indicates how the end of the tape loop 57 does not sit at the end of the channel at 15 but is maintained in an intermediate position so that the loop can either pay out tape or take on more thus providing slack to allow time for the tape reels to come into play.
FIG. 6 is another enlarged detail showing a typical corner of a folded tank system. Tape 4 is confined between tank side 58-59 forming an outer corner and 63-64 forming an inner corner. At the inner corner, tape 4 passes over a roller or air bearing 60. At the outer corner there is provided a typical vacuum port 61 and the tape, under stable operating conditions, assumes a curve substantially as shown at 62. Under conditions of acceleration or deceleration the tape at 62 is drawn further into the corner or pulled further out.
FIG. 7 is an enlarged detail which can be taken to be a corner of the system similar to the one shown in FIG. 6 and described above. This Figure is provided to show how the tape 4 behaves as it turns a corner in the folded vacuum tank system. It advances around the corner in a bulge like that shown at 65.
In order to clarify the terms used in the claims the following definitions are made:
Coordinated means: refers to DC motor means such as servo drives which rotate the tape reels in unison so that there is no ambiguous relationship between the reels.
Complex path: describes the vacuum chamber configuration directing the tape in a folded path between the reels.
Tape guiding means: a roller or channel for directing the tape along a predetermined lateral path.
Vacuum chamber: a channel defined on four sides for confining the tape along a predetermined path.
Buffer means: small corners or cavities having vacuum properties which affect the tape tension only along a relatively short length of said tape. | The vacuum buffer tape loop tanks for high speed magnetic recorders formerly made in the form of long, straight channels, are folded into L, U or other more complex shapes whereby much more efficient usee is made of cabinet space for tape handling equipment. Greater acceleration of the tape by the driving capstan is also made possible by the folded tank. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to ultrasonic working of workpieces for making structural parts, especially for producing ceramic tooth crowns, as, for example, dental veneers, inlays, crowns or bridges from dental ceramic material. Due to their favourable biological-chemical properties, their high tissue-tolerance and their low tendency for plaque-accumulation, ceramic tooth replacement materials are generally discussed as being material systems of top quality.
More specifically, the invention relates to a process of producing a ceramic tooth restoration by ultrasonic machining apparatus in which a receiver for a profiled sonotrode crown is positioned on each side of the workpiece to be worked, the receiver being in opposing relation to one another, and wherein in a first machining step, the workpiece is held by a workpiece holder, a first sonotrode crown is activated and one of the workpiece halves is machined to the desired shape by bringing the first said sonotrode crown into form-fitting engagement with said workpiece, and wherein in a second machining step the workpiece is held by the sonotrode crown by the form-fitting engagement, and a second sonotrode crown is activated for machining the remaining half of the workpiece to the desired shape. The invention also relates to an ultrasonic machining apparatus for carrying out the process.
The process as above described and the ultrasonic machining device for carrying out the process are known from DE 39 28 684 C2 (HAHN)(corresponding to U.S. application Ser. No. 07/678,367). Particular reference is additionally made to this patent publication and the prior art named therein.
Further, the publication "Keramikbearbeitung" (Working of Ceramics), Carl Hanser Verlag, Munchen 1989, pages 423-443 discloses a process and a device for working brittle materials, e.g. ceramic, glass, glass-ceramics etc., with the aid of ultrasound. The mechanical energy of the oscillating tool is transferred to a lapping mixture in a working gap between the sonotrode crown and the tool, which leads to a formation of chip and finally to a projection of the sonotrode crown in the workpiece. However, these methods are restricted to the forming of one workpiece surface. The necessary shaping tools are made by conventional metal-cutting methods, e.g. turning on a lathe, milling, drilling, etc., or by electrical discharge machining. Moreover, geometrically complex shapes of small dimensions frequently cannot be made from conventional workpiece materials.
DE 40 29 285 A1 (SIEMENS) describes a sonotrode having its shaping part, i.e. its sonotrode crown, made at least partially from silicon. This choice of material serves to optimise the wear behavior. It furthermore facilitates the use of the so-called microstructure technique (Mikrostrukturtechnik) for forming the working surface of the sonotrode crown. The microstructure technique is known from the field of manufacture of semiconductor elements and comprises, for example, photolithography and isotropic and anisotropic etching methods.
The above-mentioned electrical discharge machining process for making structural parts for the working of dental prostheses is known, for example, from DE 37 35 558 C2 (HERAEUS) and DE 35 44 123 C2 (WALTER). The disadvantages thereof have been discussed in the above-mentioned DE 39 28 648 C2 (HAHN).
Due to the unavoidable and partly significant wear and the short tool life of the sonotrode crowns resulting therefrom, conventional precise mechanical or microelectronic manufacturing processes or manufacturing processes by electrical discharge machining are not economical for the making of sonotrode crowns.
Finally, DE 36 06 305 A1 (HANSEN) describes an ultrasonic machining tool comprising an ultrasonic generator (ultrasonic converter including amplifier) and a sonotrode. The sonotrode is fixedly clamped to the ultrasonic generator by a differential screw and centered by cylindrical shoulders. The sonotrode can thereby easily be substituted without necessitating a new adjustment of the workpiece.
SUMMARY OF THE INVENTION
The present invention provides a new process of ultrasonically making a structural part, particularly of a ceramic tooth restoration, and a corresponding ultrasonic machining apparatus; further, a process and an apparatus suitable therefor for making sonotrode crowns for use in the above process and for use in the above ultrasonic machining apparatus.
These objects are met in accordance with the first embodiment of the invention by, between the two machining steps, exchanging the first sonotrode crown with the second sonotrode crown attached to the opposing receiver and aligning both sonotrode crowns with respect to one another for continuing the machining of said workpiece, with the workpiece being held in form-fitting engagement or again being brought into form-fitting engagement with the first sonotrode crown.
In accordance with a modified form by the invention, a disposable model of the structural part is produced, a plastically deformable and hardening or curable material is deposited on the disposable model, and the sonotrode crowns are produced by directly molding them from the disposable model. In this method, the body formed by curing of the curable substance is separated along the equatorial line of the disposable model and the two body parts thus obtained are each worked to form complete sonotrode crowns.
The subject matter according to the invention improves the manufacture of small-lot production series significantly. Particularly, it enables an especially economical, less cost- and time-intensive manufacture of this kind of series. Only a single ultrasonic sound producing unit is needed for overall working of the workpiece without necessitating a re-adjustment in connection with any necessary change of the sonotrode crown. The modified form of the invention is based on the principles of the model and articulation technique and enables the production of exactly fitting complementary sonotrode crowns for overall machining of dental ceramic blanks.
A further feature of the invention is that the free edges of the sonotrode crowns correspond to the equatorial line of the tooth crown. This has a advantage of the particularly simple exact adjustment of the two sonotrodes with respect to one another, namely by detecting a form-fitting between the two sonotrode crown edges.
The further of the invention resides in providing two equal, preferably identical, devices for holding the sonotrode which, significantly facilitates interchangeability without needing a re-adjustment.
The variants of the mechanical partition the ultrasonic generator and sonotrode crown-holding device lead to a further simplification of the fitting interchangeablility of the sonotrode crown holding device. The term "ultrasonic generator" in this context refers to the actual generator, including any necessary amplifiers. This does not exclude the possibility that further amplifiers may be provided in the sonotrode itself.
The coupling of the sonotrode with the ultrasonic amplifier is per se known from DE 36 06 305 (HANSEN) or the corresponding U.S. Pat. No. 4,751,916. The additional threaded connection includes the threaded connection described in these two documents.
Means are provided at the end of the device adjacent to the ultrasonic generator for receiving and adjusting of the means supporting the sonotrode crowns, enabling the supporting engagement of the first sonotrode crown with the workpiece during a second working step. Adjustment means are provided permitting a convenient and exact positioning of the two sonotrode crowns with respect to one another.
The method includes the per se known functional reconstruction of the tool restoration to be formed (e.g. inlay, veneer, partial crown, crown, bridge etc.) from a thermoplastic modelling material, e.g. moulding wax.
The curable substance specified in claim 14 can be a known moulding wax or a polymer material.
The equatorial line defines the so-called model equator, for instance the tooth crown equator measured by the largest diameter of the model, related to the model longitudinal axis or the virtual working axis. This limitation guarantees that so-called "working shadows" are not formed during the cutting of the sonotrode crown into the workpiece. The model equator defines the plane, oriented essentially traverse to the longitudinal axis of the model, from which the outer surfaces of the tooth restoration are surrounded by monotonically or strictly monotonically tapered sections of the restoration. Therefore, the body formed by curing of the moulding substance is separated along the equatorial line of the disposable model.
A further feature of the invention is the provision of a key-lock which serves a later positionally exact adjustment of the two sonotrodes with respect to one another.
According to a further aspect of the invention a so-called "wax-up" may stay on the model base normally provided by a dental laboratory and will be adjusted releasably on one model sonotrode. Imaginarily, the "wax-up", in other words the model form, is separated into two "halves" along the prosthetical equator. Initially, the "occlusal" half of the restoration is covered with a low shrinking, fast curing polymer up to the equator and is fixedly aligned in the restorational axis to a prefabricated secondary sonotrode. After termination of the process steps, the wax model is carefully taken out of the sonotrode crown forms achieved by moulding.
The step of casting of the crown hollow form with liquid metal serves to optimise wear resistance of the sonotrode crowns by transforming the polymer sonotrode crowns into metal. The transforming occurs according to a casting process known in the dental field. Manual finishing of the sonotrode crowns is not necessary
In order to avoid the forming of burrs during subsequent ultrasonic machining with the sonotrode crowns, the manufacturing process may be carried out so that their free edge zones overlap in a scissor-fashion.
According to a further advantageous embodiment, the sonotrode crown is soldered, welded or glued to the adjacent sonotrode part.
The geometrical model in accordance with the invention ensures a mutual fitting adjustment of the sonotrode crown at maximum degrees of freedom for aligning of the sonotrode parts adjacent to the sonotrode crowns and further ensures sufficient working space for manual activity during the manufacture of the sonotrode crowns. In the following, the invention will be further described with reference to embodiments shown schematically in the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a longitudinal sectional view of a partial section of an ultrasonic machining device;
FIG. 2 shows an enlarged view of the primary sonotrode of FIG. 1;
FIG. 3 shows an apparatus for making sonotrode crowns by a geometrical model of an ultrasonic machining device and a process step of the making of sonotrode crowns;
FIG. 4 shows a further geometrical model of an ultrasonic machining device for making sonotrode crowns and a further process step of the making of sonotrode crowns;
FIG. 5 shows a sectional view along the line A--A in FIG. 4; and
FIG. 6 shows a further geometrical model of an ultrasonic machining device for making crowns.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment shown in FIG. 1 comprises an ultrasonic generator 2, which is mechanically coupled to a primary sonotrode 8 by means of a fixing screw 4 and a centering cone 6 with a shoulder, the sonotrode 8 including a conical flange 9 corresponding to the centering cone 6. In the following, the ultrasonic generator 2 and the primary sonotrode 8 are referred to as "ultrasonic transmitting device" 10. The ultrasonic transmitting device 10 is advanced in a known manner using an advancing control 12 toward the workpiece 14 to be machined, which in the present case is a dental ceramic workpiece 14, such that the machining gap betweenthe active sonotrode crown 16 and the workpiece surface has the desired dimensions. A secondary sonotrode 18 serves as a device for supporting thesonotrode crown 16, is formed to be conical at its end adjacent to the primary sonotrode 8 and is centered by a corresponding centering cone at the end of the primary sonotrode 8 facing the workpiece.
The secondary sonotrode 18 serves to support the sonotrode crown 16. The sonotrode crown 16 can be pressed, soldered, welded and/or glued to it, orit can be attached by any other known joining means.
The dental ceramic workpiece 14 is held in form-fitting engagement with a further passive sonotrode crown 20 at its side opposing the active sonotrode crown 16. FIG. 1 therefore illustrates the second working step mentioned in the introductory part of the description.
The passive sonotrode crown 20 is also positioned on a secondary sonotrode 22, which is formed like the opposing secondary sonotrode 18. Specifically, it has the same conical centering flange which is inserted in a corresponding centering cone of a receiving member 23. The identical form of the devices for supporting the sonotrode crowns 16, 20, (in the present case the secondary sonotrodes 18, 22) allows a simple exchange of the two secondary sonotrodes 18, 22 in the primary sonotrode 8.
The correct alignment of the two sonotrode crowns 16, 20 is achieved by a key, i.e. by at least one form-fitting location at their free edges. This form fit can be controlled by taking the workpiece 14 out of its working position, bringing said sonotrode crowns 16, 20 into form-fitting relationwith one another and inserting them into the centering cone 6 into this alignment. Subsequently, the workpiece 14 is brought into form-fitting relation with the passive sonotrode crown 20 again, and the active sonotrode crown 16 is advanced in the forward direction towards said workpiece 14.
Alternatively, a position-locking key of the sonotrode crowns can be provided by a groove and tongue arrangement in said centering cone 6 and the conical flanges for the secondary sonotrode(s) 18, 22.
The receiving member 23 for the passive sonotrode crown 20 is supported by two adjusting shafts or rods 24 which are aligned parallel to the advancing direction, i.e. the machining axis 26. If the workpiece 14 and the sonotrode crowns 16, 20 are arranged in their machining position, the receiving member 23 is fixed by a fixing screw 28.
The dental ceramic tooth restoration is finished as soon as the free edges of the sonotrode crowns 16, 20 meet one another. The tooth restoration is punched by the sonotrode crowns 16, 20 by machining from both sides in twosubsequent machining steps. The tooth restoration is always machined from one and the same direction in space, namely from the direction in which the ultrasonic transmitting device 10 is arranged.
In order to prevent the formation of burrs, the free ends of the edges of the sonotrode crowns 16, 20 overlap in a scissor-fashion.
FIG. 2 shows the primary sonotrode 8 in enlarged perspective. It is characterised by a centering conical flange 9 facing the generator and a conical flange 31 facing the workpiece. Preferably, the primary sonotrode 8 has a regular cylindrical outer wall with a diameter which is equal to the diameter of the receiving member 23, and a position key with the centering cone 6 of the ultrasonic generator 2, especially of the groove and tongue key type.
According to a further embodiment not shown in the drawings, it is the primary sonotrode 8 which serves as an exchangeable device for supporting the sonotrode crown 16. The secondary sonotrode 18 is in this case not necessary. Instead, the receiving member supporting the passive sonotrode crown 20 is also shaped as primary sonotrode 8.
The geometrical model of an ultrasonic machining apparatus shown in FIG. 3 serves to make two sonotrode crowns which are complementary to one anotherfor overall machining of a ceramic tooth restoration, in the present case acrown. The geometrical model comprises a base plate 32, shown in a longitudinal sectional view in FIG. 3, i.e. in a vertical sectional view, the sectional plane of which contains the machining longitudinal axis 26. The cross section of the base plate 32 corresponds to the section shown inFIG. 5 by another embodiment of a geometrical model. As is shown in these sectional views, two intersecting trough-shaped recesses 34 and 37 are formed in the base plate 32 such that column-shaped protrusions 36 protrude at the four corners of the base plate 32 in an upward direction. The column-shaped protrusions 36 have a rectangular cross-sectional shape in a horizontal sectional view.
A guiding rod 38 is provided on each column-shaped protrusion 36 which projects beyond said column-shaped protrusion 36 on both sides. Altogether, four guiding rods 38 are provided. All guiding rods 38 are aligned in parallel to the machining axis 26. They support, in pairs, a receiving member 40, 41. Each receiving member 40, 41 is shiftable on the guiding rods 38 in the direction of the machining axis 26 and can be positioned in any position on the guiding rods 38 by fixing screws 28 or by tension brackets or other means.
The receiving member 40 shown in the left part of FIG. 3 comprises a section 42 facing the workpiece which can be shifted in a plane which is orthogonal to the machining axis 26. This section 42 is therefore shiftable in all three space dimensions; thus, it is shiftable to a maximum extent. It can be connected to the section 43 being fixable on theguiding rods 38 by a cross support. In the present embodiment it is fixed by magnetic supports 44 and is therefore moveable in the orthogonal plane particularly easily. A magnet may be provided such as a permanent magnet or--to allow changing the magnetic force--an electromagnet with a controllable current supply. The shiftable section 42 projects over the trough-shaped groove or recess 34 and is therefore easily accessible. The wax model ("wax-up") 46 supplied from the dental laboratory together with a model base 48 is fixed by putty material in a recess 47 of the shiftablereceiving member 42. The putty 49 facilitates the alignment of the wax model 46--its prosthetical equatorial plane must be aligned with the machining longitudinal axis 26. The prosthetical equator is preferably determined in the dental laboratory and drawn on the "wax-up" 46. Its positional alignment is thereby facilitated.
After aligning the wax model 46 in the machining position, i.e. in the position in which the tooth restoration is, so to speak, "punched" by the sonotrode crowns at a later stage, the occlusal surface is coated with a low-shrinking, fast-curing polymer up to the equatorial line, in other words, it is directly moulded. The polymer layer is then aggregated until it reaches a crown-facing cone 50 and is fixed therewith. The crown-facingsection of the secondary sonotrode 22, called the sonotrode head, may have a thread instead of the cone 50. The secondary sonotrode 22 may further have a different form of retention for the sonotrode crown.
A sonotrode crown 54 manufactured in this way usually cannot yet be used for ultrasonic machining of a brittle hard material. In this case, it is transferred to a metal casting mould. Up to the transfer into the metal mould, it constitutes a presonotrode 54.--The secondary sonotrode 22 may also be referred to as a "semifinished secondary sonotrode", whereby the term "secondary sonotrode" refers to covering all of the semifinished secondary sonotrodes and secondary sonotrode crowns.
After the presonotrode 54 has been attached to the secondary sonotrode 22, the wax model 46 adheres exactly to the cured sonotrode crown surface.
The free edge surfaces of the presonotrode crown 54 ending at the equatorial line are now isolated and the model base 48 is carefully removed. Now a second "cervical" sonotrode crown is built up instead of the model base 48 in generally the same manner as the occlusal presonotrode crown 54. For this, a second secondary sonotrode is arranged in the shiftable receiving section 42 of the left receiving member 40, analogously to the first secondary sonotrode 22.
The cervical presonotrode crown is attached to the corresponding secondary sonotrode in the same manner as the occlusal presonotrode crown 54. Preferably, the same materials are used for making the second presonotrodecrown as for the first presonotrode crown 54. The presonotrode crowns may be fixed to their corresponding secondary sonotrode heads at the same timeas the moulding process or afterwards.
Subsequently, the "wax-up" 46 is carefully removed, for example by infusingin hot water--which may be done before or after the separation of the presonotrodes along the isolated equatorial line.
For optimising the wear behaviour of the sonotrode crowns, the sonotrodes including the attached sonotrode crowns are embedded in a refractory mould. The crowns are then removed, for example by burning out. The cavitythus formed is then poured out with metal. In this way, wear-resistant sonotrode crowns are directly cast with the head of the secondary sonotrodes. The sonotrode head carrying the sonotrode crown is retentivelyshaped in a suitable manner, for example by forming a reversed cone or by the above-mentioned thread. The joining may be optimised by additional soldering, welding or gluing of the joints.
A further possibility consists in the conical forming of the already-mentioned secondary sonotrode heat, which enables a removal of thesonotrode crown after curing. The sonotrode crowns are exactly repositionable through the conical head of the secondary sonotrode and cannow be pressed, glued, soldered and/or welded by conventional bonding methods.
As already mentioned, the subsequent ultrasonic machining is carried out intwo successive steps. First of all, the first sonotrode crown is completelymoulded using a suitable lapping suspension in a blank made of dental ceramics. Afterwards, the moulded blank is held by the first sonotrode crown and is machined by the second sonotrode crown from the contralateralside. The intrusion depth is limited by contact of the corresponding sonotrode crowns. A so-called "ultrasonic punching" of the desired structured part is achieved, wherein scissor-like overlapping edge regionsof the sonotrode crowns inhibits the forming of burrs.
A further embodiment of an apparatus for making of two complementary sonotrode crowns 54 according to the invention is shown in FIG. 4--howeverin a different state of machining as the embodiment of FIG. 3.
The two sonotrode crowns 54 are already fixed on the corresponding secondary sonotrodes or semifinished sonotrodes 18, 22. Only the wax model46 must be removed and the two sonotrode crowns 54 must be separated from one another. The step of casting-on of the sonotrode crowns 54 in the mentioned refractory mould is still to follow. In this embodiment, in a first process step the wax model 46 has been releasably fixed directly by the putty material 49 to the secondary sonotrode 18.
The vertical cross sectioned view in FIG. 5 along the line A--A of FIG. 4 shows a regular cylindrical receiving member 40 which lies on the likewisecircular cylindrical guiding rods 38 under line contact.
FIG. 6 finally shows a further embodiment of a geometrical model of an ultrasonic machining device for making sonotrodes which are complementary to each other.
In this embodiment, receiving members 40, 41 are attached in exactly the same way to two fixed supports 58 facing each other, just as the primary sonotrode 8 in the ultrasonic generator 2 of FIG. 1.
A primary sonotrode 8 may also be used directly as a receiving member 40 inthe geometrical model. | In a process and apparatus for the overall machining of a ceramic tooth restoration and producing of appropriate sonotrode crowns, these sonotrode crowns act on a workpiece one after the other, however from the same direction in space and are activated by the same ultrasonic transmitter. For the production of said sonotrode crowns, a geometrical model corresponding to the ultrasonic machining apparatus is used. | 0 |
This application is based on and claims priority under 35 U.S.C. § 119 with respect to Japanese Application No. 2003-090914 filed on Mar. 28, 2003, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention generally relates to a planetary gear structure. More particularly, the present invention pertains to a stopper plate of a planetary gear structure for holding pinion shafts.
BACKGROUND OF THE INVENTION
An example of a known planetary gear structure is disclosed in Japanese Utility Model No. 2508622. This known planetary gear structure is constructed to fit a plurality of pinion shafts within a carrier.
FIGS. 4–7 illustrate an example of a known planetary gear structure 11 which is adapted to be assembled within a transmission. The planetary gear structure 11 includes a single stopper plate 106 which holds six pinion shafts 101 within a carrier 100 . Each of the pinion shafts 101 has a slit 103 so as to engage with the stopper plate 106 . The stopper plate 106 has three projecting portions 107 , each of which is arranged on the outer circumference of the stopper plate 106 so that adjacent projecting portions 107 are spaced apart from one another at equal angular intervals. Each of the projecting portions 107 is engaged with a bore 108 of the carrier 100 as shown in FIG. 6 for fixing the stopper plate 106 against rotation after assembly. Here, the carrier 100 is attached to a housing 12 of the transmission.
To fix the pinion shafts 101 with the carrier 100 , each of the pinion shafts 101 is inserted into a respective receiving bore. Then, the stopper plate 106 is rotationally positioned so that the stopper plate 106 is near the predetermined pinion shafts 101 . This condition is shown by the broken line position in FIG. 5 . Further, the stopper plate 106 is rotated in the counter-clockwise direction so that the slit 103 of each pinion shaft 101 engages or receives a portion of the stopper plate 106 . This condition is shown by the solid line position in FIG. 5 . At that time, the projecting portions 107 are also engaged with the carrier 100 .
A purpose of the pinion shafts 101 is not only to rotatably support the pinions, but also to lubricate the oil-supplying passages 4 , 5 . The lubricating oil is supplied to a bearing supporting the pinions, engagement portions between the pinion and a sun gear, engagement portions between the pinion and a ring gear, and engagement portions between the pinions. Therefore, the purpose of the stopper plate 106 for holding pinion shafts 101 is not only to fix the pinion shafts 101 to the carrier 100 , but also to prevent the pinion shafts from rotating on their respective axes and allow the openings of the oil-supplying passages to be appropriately positioned.
However, with the planetary gear structure 11 shown in FIGS. 4–7 , because all of the pinion shafts 101 are fixed to the carrier 100 by way of the single stopper plate 106 , it is necessary that the position arrangements of the pinion shafts 101 be simultaneously done. Thus, the assembling time of the pinion shafts 101 is relatively long and the working thereof is somewhat troublesome. Further, because the stopper plate 106 is formed as a single piece, the fabrication of the stopper plate 106 can be relatively complicated.
SUMMARY OF THE INVENTION
According to one aspect, a planetary gear structure provided in a vehicle transmission comprises a carrier possessing a plurality of circumferentially spaced apart bores, a plurality of pinion shafts each adapted to receive a pinion gear, and at least three stopper plates. Each of the pinion shafts is positioned in one of the bores in the carrier so that the pinion shafts are circumferentially spaced apart from one another. The stopper plates are separate and spaced apart from one another, and are positioned between adjoining pairs of the pinion shafts. Each of the stopper plates engages two different ones of the pinion shafts to rotationally fix the pinion shafts against rotation relative to the carrier.
According to another aspect, a planetary gear structure comprises a carrier provided with a plurality of circumferentially spaced apart bores, a plurality of pinion shafts and a plurality of stopper plates. Each of the pinion shafts is adapted to receive a pinion gear and is positioned in one of the bores in the carrier so that the pinion shafts are circumferentially spaced apart from one another. The pinion shafts are each provided with a slit. The stopper plates are separate from one another and arranged between adjoining pairs of the pinion shafts. Each of the stopper plates engages the slit in two of the pinion shafts to fix the pinion shafts against rotation relative to the carrier.
In accordance with another aspect, a planetary gear structure comprises a carrier having a cylindrical portion, a plurality of pinion shafts mounted in the carrier along an axial direction of the cylindrical portion, and a stopper plate arranged between a pair of the pinion shafts so as to fix each of the pinion shafts against revolution about its own respective axis.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The foregoing and additional features and characteristics of the present invention will become more apparent from the following detailed description considered with reference to the accompanying drawing figures in which like reference numerals designate like elements.
FIG. 1 is an elevational view of one embodiment of the disclosed planetary gear structure according to the present invention.
FIG. 2 a cross-sectional view of the planetary gear structure taken along the section line II—II in FIG. 1 .
FIG. 3 is an elevational view of another embodiment of the disclosed planetary gear structure according to the present invention.
FIG. 4 is a cross-sectional view of a transmission with a known planetary gear structure.
FIG. 5 is an elevational view of the planetary gear structure shown in FIG. 4 .
FIG. 6 is a cross-sectional view of the planetary gear structure shown in FIG. 5 taken along the section line VI—VI in FIG. 5 .
FIG. 7 a cross-sectional view of the planetary gear structure shown in FIG. 5 taken along the section line VII—VII in FIG. 5 .
DETAILED DESCRIPTION
FIGS. 1 and 2 illustrate one version of the disclosed planetary gear structure according to the present invention. This disclosed version is a double-pinion type of planetary gear structure which can be used in a vehicle transmission. As shown in FIG. 1 , the planetary gear structure generally comprises a carrier 10 , six pinion shafts 1 and three stopper plates 6 . The carrier 10 possesses an inner circumferential wall 10 a and an outer circumferential wall 10 b . The outer circumferential wall 10 b is formed in the shape of a cylindrical portion within the carrier 10 . Both the pinion shafts 1 and the stopper plates 6 are located between the inner circumferential wall 10 a and the outer circumferential wall 10 b.
Each of the stopper plates 6 is arranged between a respective pair of adjacent pinion shafts 1 as shown in FIG. 1 . Each of the stopper plates 6 possesses two side portions 6 a , 6 b positioned at oppositely located portions of the plate. Both side portions 6 a , 6 b extend along the radial direction of the cylindrical portion. Each of the stopper plates 6 also possesses an inner end portion 6 c and an outer end portion 6 d . Once again, these inner and outer end portions are positioned at oppositely located portions of the plate. The stopper plates 6 can be positioned and dimensioned so that the inner end portion 6 c contacts the inner circumferential wall 10 a of the carrier 10 while the outer end portion 6 d contacts the outer circumferential wall 10 b when the stopper plates 6 are inserted into the carrier 10 .
The planetary gear structure also comprises a plurality of pinions 2 . Each of the pinions 2 is rotatably supported by a respective one of the pinion shafts 1 . Each of the pinion shafts 1 has a slit 3 that faces the respective stopper plates. Further, each of the pinion shafts 1 has oil passages 4 , 5 . The oil passage 4 extends in the axial direction of the pinion shaft 1 while the oil passage 5 extends in the radial direction of the pinion shaft. Each of the pinion shafts 1 is assembled and adjusted so that openings of the oil passages 4 , 5 face a specified portion where lubricating oil is necessary, for example the engagement portion between the pinion 2 and a sun gear or the engagement portion between the pinion 2 and a ring gear.
The assembly of the pinion shafts 1 into the carrier 10 with the stopper plate 6 can be carried out as follows. At first, the side portion 6 a of one of the stopper plates 6 is inserted into the slit 3 of one of the pinion shafts 1 , and the opposite side portion 6 b of that stopper plate 6 is inserted into the slit 3 of another one of the pinion shafts 1 to form a sub-assembly. Each of the other two stopper plates 6 is similarly inserted into the slits 3 of another pair of pinion shafts 1 to produce two other sub-assemblies. Each of the resulting sub-assemblies, in which the stopper plate 6 is sandwiched by two pinion shafts 1 , is arranged into the carrier 10 . That is, the two pinion shafts 1 of each respective sandwiched sub-assembly are inserted into respective bores in the carrier. When the stopper plates 6 are dimensioned in the manner described above, the inner end portion 6 c of each stopper plate 6 contacts the inner circumferential wall 10 a of the carrier 10 while the outer end portion 6 d of each stopper plate 6 contacts the outer circumferential wall 10 a of the carrier 10 . In this way, the stopper plates 6 are sandwiched between the circumferential walls 10 a , 10 b and are thus arranged within the carrier 10 . In the illustrated embodiment, the pairs of pinion shafts forming a sub-assembly are spaced apart at equal angular intervals as shown in FIG. 1 .
According to this embodiment, each of the stopper plates 6 holds a pair of pinion shafts 1 for fixing the pinion shafts against rotation about their respective axes and relative to the carrier. Because the carrier 10 comprises three stopper plates 6 , a total of six pinion shafts 1 can be appropriately positioned relative to the carrier 10 by the stopper plates 6 . Further, because each of the stopper plates 6 is supported by a pair of the pinion shafts 1 and the circumferential walls 10 a , 10 b of the carrier 10 , each of the stopper plates 6 cannot readily move in either the radial direction of the cylindrical portion of the carrier 10 or in the peripheral direction thereof. Thus, the arrangement of the stopper plates 6 is well-balanced. Therefore, compared to the known planetary gear structure described above, the assembly of the pinion shafts 1 and the plates 6 is easier and the assembly time is shortened. Further, as the shape and size of the plates 6 is relatively simple and small, the weight of the planetary gear system is reduced as is the cost associated with forming the plates 6 .
FIG. 3 illustrates another version of the disclosed planetary gear structure according to the present invention. This planetary gear structure is a single-pinion type of planetary gear structure which can be used in a vehicle transmission. As shown in FIG. 3 , a carrier 20 has a cylindrical portion. Three pinion shafts 21 are arranged at equal angular intervals relative to one another and are located within the cylindrical portion. Each of the pinion shafts 21 has a pair of slits 23 , 23 , positioned so that the pinion shafts, viewed from the end, are symmetrical about a plane extending along the length of the shaft and extending midway between the two slits. The planetary gear structure also includes three stopper plates 26 , with each stopper plate being arcuate in shape and extending over a portion of the circumferential extent of the carrier. Each stopper plate 26 is arranged between two adjoining pinion shafts 21 . More specifically, one side portion of each stopper plate 26 is positioned in the slit 23 of one pinion shaft 21 while the opposite side portion of each stopper plate 26 is positioned in the slit 23 in the adjoining pinion shaft 21 .
The assembly of this version of the disclosed planetary gear structure involves positioning each of the stopper plates between two adjacent pinion shafts, thus forming a sub-assembly with three pinion shafts and three stopper plates. This sub-assembly can then be assembled to the carrier by inserting the pinion shafts in the respective bores of the carrier.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents which fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby. | A planetary gear structure includes a carrier, a plurality of pinion shafts each inserted into a bore in the carrier, and a stopper plate arranged between a pair of the pinion shafts to hold the pinion shafts without any revolutions on its own axis. | 5 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a sintered bond, a starting material for producing it and a process for the production thereof, and also an electronic circuit containing the sintered bond.
[0002] Power electronics are used in many fields of technology. Especially in electrical or electronic appliances in which large currents flow, the use of power electronics is indispensible. The currents necessary in power electronics lead to thermal stressing of the electrical or electronic components present therein. Further thermal stress is caused by the use of such electrical or electronic appliances in places of operation having a temperature which is significantly above room temperature and may also change continually. Examples which may be mentioned are control instruments in the automobile sector which are arranged directly in the engine compartment.
[0003] In particular, many joins between power semiconductors or integrated circuits (ICs) among one another and also to support substrates are even today subject to long-term temperature stresses up to 175 degrees Celsius.
[0004] Joining of electrical or electronic components, for example on a support substrate, is usually effected by means of a bonding layer. A bonding layer of this type is a solder bond.
[0005] Use is usually made of soft solders based on tin-silver or tin-silver-copper alloys. However, such bonding layers display, particularly at use temperatures close to the melting point, a decrease in electrical and mechanical properties which can lead to failure of the assembly.
[0006] Lead-containing solder bonds can be used at higher use temperatures than soft solder bonds. However, lead-containing solder bonds are greatly restricted in respect of their permissible industrial applications by legal obligations for reasons of environmental protection.
[0007] An alternative for use at elevated or high temperatures, in particular above 200 degrees Celsius, is lead-free hard solders. Lead-free hard solders generally have a melting point above 200° C. However, when hard solder is used for producing a bonding layer, only few electrical or electronic components which can withstand the high temperatures during melting of the hard solders come into question as join partners.
[0008] One way out is the low-temperature bonding technology (NTV) in which silver-containing sintered bonds can be produced even at significantly lower temperatures than the melting point. Here, a paste containing chemically stabilized silver particles and/or silver compounds is used instead of a solder. Under the sintering conditions, in particular at elevated temperature and applied pressure, the stabilizing constituents are burnt out and/or the silver compounds are decomposed so that the silver particles or liberated silver atoms come into direct contact with one another and with the material of the join partners. A high-temperature-stable bond can be formed by interdiffusion and/or diffusion even at significantly lower temperatures than the melting point. However, when such sintered bonds are subjected to temperature changes, thermomechanical stresses and even crack formation in semiconductor components or even in the support substrate can occur.
[0009] The document DE 102009000192 A1 describes a sintering material for producing a sintered bond which can be formed as a sintering paste and comprises metallic structure particles provided with an organic coating and also metallic and/or ceramic auxiliary particles which are not organically coated and do not liberate gas during the sintering process.
SUMMARY OF THE INVENTION
[0010] The present invention provides a starting material for a sintered bond, which comprises metal-containing first particles and second particles, where the second particles contain, in particular, at least a proportion of a particle of core material whose coefficient of thermal expansion a at 20° C. is lower than the coefficient of thermal expansion a at 20° C. of the metal or metals of the first particles in metallic form and/or whose coefficient of thermal expansion a at 20° C. is ≦ 15 · 10 −6 K −1 and the D 50 of the second particles is greater than or equal to half the D 50 of the first particles and less than or equal to twice the D 50 of the first particles.
[0011] For the purposes of the present invention, the D 50 is the median of a particle size distribution, in particular of primary particles, in particular in accordance with DIN 53 206, which indicates the particle diameter, in particular primary particle diameter, above and below which the diameter of half of the particles is in each case and which corresponds to the diameter at which the cumulated distribution reaches the value 0.5. The D 50 of particles and in particular of mixtures of a plurality of different particles, e.g. first, second, third and/or fourth particles, can be determined, in particular, by means of electron microscopy, optionally in combination with energy-dispersive X-ray spectroscopy (EDX).
[0012] By the use of second particles which have a particle core material with a low coefficient of thermal expansion, the coefficient of thermal expansion α (CTE) of the starting material or of the sintered bonds produced therefrom can advantageously be significantly reduced. Experiments hitherto have shown that sintered bonds formed in this way can advantageously have a coefficient of thermal expansion α at 20° C. in the range from ≧3·10 −6 K −1 to ≦15·10 −6 K −1 , for example from ≧3·10 −6 K −1 to ≦10·10 −6 K −1 , in particular from ≧3·10 −6 K −1 to ≦7·10 −6 K −1 . Sintered bonds having such a low coefficient of thermal expansion cannot be achieved by means of the conventionally used silver sintering pastes, which usually have a coefficient of thermal expansion α at 20° C. of about 19.5·10 −6 K −1 , and are of particular interest for, in particular, semiconductor technology since here join partners are frequently joined together by means of sintered bonds which on the one hand, as in the case of chips, have a very low coefficient of expansion, for example about 3·10 −6 K −1 , or on the other hand, for example in the case of metallic circuit substrates, have a very high coefficient of expansion, for example about 16.5·10 −6 K −1 , which is one of the main causes for crack formation when subjected to changing temperatures. The second particles advantageously enable the coefficient of thermal expansion to be set so that it lies between the coefficients of thermal expansion of the join partners to be joined via the sintered layer, for example between 16.5·10 −6 K −1 (circuit substrate) and 3·10 −6 K −1 (chip). Thermomechanical stresses between the join partners and the sintered bond, which can lead to crack formation in the join partners in the event of temperature changes, can advantageously be reduced significantly in this way. The material costs can advantageously be reduced by the use of inexpensive second particles.
[0013] According to the present invention, it has been found that the particle size or particle size distribution of the first and second particles should not differ too greatly from one another in order to achieve optimal results, since an excessively high fines content of second particles can have an unfavorable effect on the sintering of the first particles and thus on the stability of the sintered microstructure, with an excessively high coarse content of second particles being able to lead to inhomogeneities and accordingly to macroscopic fluctuations in the materials properties, within the sintered bond.
[0014] Overall, sintered bonds having a significantly improved thermomechanical stability when subjected to temperature changes can thus advantageously be formed from the starting material of the invention.
[0015] For the purposes of the present invention, a starting material for a sintered bond can be a starting material which is used for producing a sintered bond, in particular for mechanical and electrical bonding of electrical and/or electronic components. The starting material of the invention can, for example, be a paste, a powder mixture or a sintering material preform.
[0016] For the purposes of the present invention, in particular, all elements of the alkali metal group, in particular Li, Na, K, Rb, Cs, and alkaline earth metal group, in particular Be, Mg, Ca, Sr, Ba, the transition metals, in particular Sc, Y, La, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, Hg, the lanthanides and the elements aluminum, gallium, indium, tin, thallium, lead and bismuth are considered to be metals.
[0017] For the purposes of the present invention, noble metals are the elements silver, gold, platinum, palladium, ruthenium, rhodium, osmium and iridium.
[0018] For the purposes of the present invention, silicon is considered to be a semimetal and not a metal.
[0019] Adjectives having the ending-containing, e.g. metal-containing, noble metal-containing, silver-containing and copper-containing, mean, for the purposes of the present invention, that at least one element of the element group given the ending-containing, for example one or more metals or one or more noble metals, or the element given the ending-containing, for example silver or copper, is present. Apart from the elemental form, in particular the metallic form, of the elements or element, for example elemental, i.e. metallic, silver, compounds of the elements or the element, for example silver carbonate, silver oxide and/or silver carboxylates, are therefore also encompassed.
[0020] For the purposes of the present invention, the term metallic refers, in particular, to a form in which metallic bonds are present between the atoms of one or more elements, in particular where the atoms form a lattice having freely mobile (delocalized) electrons.
[0021] In one embodiment, the particle core material is a chemically inert and physically stable material.
[0022] For the purposes of the present invention, a chemically inert material is a material which does not undergo any chemical reaction with the other materials of the starting material under the sintering conditions.
[0023] For the purposes of the present invention, a physically stable material is a material which does not display any phase transition, for example from solid to liquid (melting), under the sintering conditions.
[0024] In one embodiment, the D 50 of the second particles is greater than or equal to half the D 50 of the first particles and less than or equal to 1.5 times the D 50 of the first particles. In particular, the D 50 of the second particles can be greater than or equal to 0.75 times the D 50 of the first particles and less than or equal to 1.25 times the D 50 of the first particles. The thermomechanical stability of the sintered bond when subjected to temperature changes can advantageously be improved further in this way.
[0025] The D 50 of the first particles and/or second particles and the third particles described below can be, for example, in the range from ≧0.01 μm to ≦50 μm, in particular from ≧0.1 μm to ≦10 μm, for example from ≧1 μm to ≦7 μm. Particles having such a particle size distribution advantageously have a high specific surface area and therefore an increased reactivity. Thus, the necessary processing temperature and the process time for forming a sintered bond can advantageously be kept low.
[0026] If, for example, first particles having a D 50 of 3 μm are used, the second particles preferably have a D 50 in the range from ≧1.5 μm to ≦6 μm (from half to twice the D 50 of the first particles), for example from ≧1.5 μm to ≦4.5 μm (from half to 1.5 times the D 50 of the first particles), in particular from ≧2.25 μm to ≦3.75 μm (from 0.75 to 1.25 times the D 50 of the first particles).
[0027] In a further embodiment, the coefficient of thermal expansion a of the particle core material at 20° C. is ≦10·10 −6 K −1 , in particular ≦7.5·10 −6 K −1 , preferably ≦5·10 −6 K −1 . The coefficient of thermal expansion can thus advantageously be reduced more strongly and/or with a smaller amount of second particles.
[0028] In a further embodiment, the particle core material has a thermal conductivity λ 20/50 at 20° C. and 50% atmospheric humidity of ≧15 Wm −1 K −1 or ≧25 Wm −1 K −1 , preferably ≧50 Wm −1 K −1 , in particular ≧100 Wm −1 K −1 . This is particularly advantageous for increasing the power density of semiconductor chips.
[0029] In a further embodiment, the particle core material is selected from the group consisting of elemental silicon (Si), silicon oxide (SiO 2 ), silicon carbide (SiC), aluminum nitride (AlN), silicon nitride (Si 3 N 4 ), aluminum oxide (Al 2 O 3 ), metallic tungsten (W), metallic molybdenum (Mo), metallic chromium (Cr), metallic platinum (Pt), metallic palladium (Pd), boron carbide (BC), beryllium oxide (BeO), boron nitride (BN), preferably elemental silicon and silicon dioxide, silicon carbide, aluminum nitride, silicon nitride, aluminum oxide, and combinations thereof. These materials advantageously have a lower coefficient of thermal expansion, which, as mentioned above, is advantageous in order to avoid crack formation in the join partners. In addition, these materials are basically advantageously chemically inert during a thermal treatment of the starting material to form a sintered bond and, in a sintered bond which has been formed, are present in unchanged from within the metal matrix formed. In one embodiment, the second particles or at least the particle cores thereof can be composed of such a material. Particular preference is given to elemental silicon and/or silicon dioxide.
[0030] For example, the second particles can contain at least a proportion of elemental silicon and/or silicon dioxide. In particular, the second particles can have a particle core composed of elemental silicon and/or silicon dioxide, in particular elemental silicon. Elemental silicon and silicon dioxide have an extremely low coefficient of thermal expansion a (CTE) and have therefore been found to be particularly advantageous for, inter alia, reducing the coefficient of thermal expansion of the sintered bond. Even the addition of a small amount therefore advantageously enables a larger reduction in the coefficient of thermal expansion of the sintered bond than is the case for other additives to be achieved. In addition, elemental silicon and silicon dioxide advantageously have low Young's moduli, which can have an advantageous effect on the elasticity of the sintered bond. A reduction in the coefficient of thermal expansion of the sintered bond and the good elastic properties can in turn significantly reduce the thermomechanical stress between the sintered bond and the semiconductor component bonded thereto and thus the tendency for crack formation in the semiconductor component. Owing to the advantageous coefficients of expansion and Young's moduli of elemental silicon and silicon dioxide, a sintered bond composed of such a starting material can advantageously have a lower coefficient of expansion at the same or even a lower Young's modulus than a similar unfilled sintered bond, in particular one which has a correspondingly larger proportion of first particles instead of a proportion of second particles.
[0031] Both amorphous and crystalline, in particular polycrystalline, elemental silicon and/or silicon dioxide can in principle be used. The elemental silicon and/or silicon dioxide can in principle be used in all purities which can be obtained. In order to minimize the materials costs, it is possible to use, for example, raw silicon, for example silicon having a purity of ≧95%.
[0032] In a further embodiment, the particle core material is amorphous elemental silicon and/or amorphous silicon dioxide. Amorphous elemental silicon and amorphous silicon dioxide advantageously have a particularly low coefficient of thermal expansion and a low Young's modulus, with, in particular, the coefficient of expansion and the Young's modulus of amorphous elemental silicon being lower than that of crystalline elemental silicon and that of amorphous silicon dioxide being lower than that of crystalline silicon dioxide.
[0033] In a preferred embodiment, the particle core material is elemental silicon. For the purposes of the present invention, elemental silicon is preferably used since both its amorphous form compared to amorphous silicon dioxide and its crystalline form compared to crystalline silicon dioxide have a lower coefficient of expansion and a higher electrical conductivity and thermal conductivity. The use of elemental silicon therefore advantageously enables the coefficient of thermal expansion of the sintered bond to be significantly reduced, in particular with maintenance of good elastic properties.
[0034] The second particles can, in particular, each have a particle core having a coating applied thereto. The particle core is preferably composed of the particle core material, for example elemental silicon, silicon dioxide, silicon carbide, aluminum nitride, silicon nitride and/or aluminum oxide. The coating can be composed of a particle coating material which is different from the particle core material. If the particles are coated, the D 50 relates to the particle size including the coating.
[0035] In a further embodiment, the second particles are spherical, in particular essentially round, for example essentially ball-shaped, particles. Here, the term “essentially” means that small deviations from the ideal shape, in particular a spherical shape, for example by up to 15%, are encompassed. Avoidance of corners and edges advantageously enables excessive stresses and thus crack nuclei in the composite material to be avoided.
[0036] In a further embodiment, the first particles have a particle core with a first coating applied thereto and/or the second particles have a particle core with a second coating applied thereto.
[0037] The first and/or second coating and the third and/or further coating described below in each case advantageously encloses the particle cores essentially completely, but at least virtually completely. As a result, the coatings act firstly as a protective coating by means of which it can be ensured that the particles and the proportion of the material present in the respective coating remain chemically stable, which has an advantageous effect on the storage stability. In addition, agglomeration of the particles can be reduced or even avoided in this way. Furthermore, an in particular metal-containing, in particular metallic, coating, for example on the second, optionally the third and optionally the fourth particles, can improve the sintering of the coated particles, for example onto the first or other particles.
[0038] The coatings preferably make up a significantly smaller proportion of the particle volume than the particle cores. This has an advantageous effect on the sintering process and also the thermal and electrical properties of the starting material and of the sintered bond.
[0039] In a further embodiment, the first particles are noble metal-containing and/or copper-containing. As noble metal, particular preference is given to silver, gold, platinum and/or palladium. The first particles are preferably silver-containing.
[0040] In a further embodiment, the first particles contain, in particular, at least one metal, in particular at least one noble metal and/or copper, preferably silver, in metallic form and/or at least one organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, in particular a compound which can be converted into the metallic form of the at least one parent metal by a thermal treatment. The organic or inorganic metal compound can, for example, be selected from the group consisting of silver carbonate, silver oxide, silver lactate, silver stearate and combinations thereof. These compounds can advantageously be converted at high temperatures into the parent metal in metallic form.
[0041] In particular, the first particles can have a metal-containing, in particular noble metal-containing and/or copper-containing, for example silver-containing, particle core.
[0042] In one embodiment, at least part of the first particles have a particle core which contains at least one metal, in particular at least one noble metal and/or copper, preferably silver, in metallic form. For example, at least part of the first particles can be composed of at least one metal, in particular noble metal and/or copper, preferably silver, in metallic form.
[0043] In an alternative or additional embodiment, at least part of the first particles have a particle core which contains at least one organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, which, in particular, can be converted into the metallic form of the at least one parent metal by means of a thermal treatment.
[0044] In a specific embodiment, at least a first part of the first particles have a particle core which contains at least one metal, in particular at least one noble metal and/or copper, preferably silver, in metallic form and at least a second part of the first particles have a particle core which contains at least one organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, which can be converted into the metallic form of the at least one metal of the first part of the first particles by means of a thermal treatment.
[0045] As an alternative or in addition thereto, the first coating, for example of the first part of the first particles, can contain at least one organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, which, in particular, can be converted into the at least one parent metal in metallic form by a thermal treatment. The organic or inorganic metal compound can, here too, be selected, for example, from the group consisting of silver carbonate, silver oxide, silver lactate, silver stearate and combinations thereof. These compounds can advantageously be converted at high temperatures into the parent metal in metallic form.
[0046] As an alternative or in addition thereto, the first coating of the first particles or a further coating applied on top of the first coating of the first particles can contain a reducing agent by means of which a or the organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, can be reduced to the metallic form, for example at a temperature in the region of or optionally below the sintering temperature of the metallic form of the at least one parent metal.
[0047] As an alternative or in addition thereto, the second and/or third particles can also have a coating containing such reducing agents.
[0048] The proportion of reducing agent in the starting material is preferably selected so that it is present in a stoichiometric ratio to the organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, which is present in the starting material and is, in particular, to be reduced. A very high conversion of up to 99% or more can advantageously be achieved in this way.
[0049] As reducing agent, it is possible to use, for example, at least one alcohol from the group consisting of primary or secondary alcohols and/or at least one amine and/or formic acid and/or at least one fatty acid, in particular isostearic acid, stearic acid, oleic acid, lauric acid or a mixture of various fatty acids.
[0050] Overall, such reducing agent-containing first coatings can be applied in a simple manner to the first particles. In addition, the reducing agents mentioned display, in a thermal treatment of the starting material for forming a sintered bond, particularly good reducing behavior in respect of the organic or inorganic metal compounds or noble metal oxides present in the second coating of the second particles. Reducing agent-containing coatings enable the reducing agent to be advantageously distributed very uniformly and finely in the entire starting material. As a result, the sintering process within the starting material can proceed more uniformly and more quickly. This gives the advantage that a sintered bond produced from the starting material of the invention can have a very homogeneous sintered microstructure, in particular one having a high thermal and/or electrical conductivity. This effect can be reinforced further by the use of coatings which contain organic or inorganic metal compounds, in particular noble metal compounds and/or copper compounds, preferably silver compounds, corresponding to the first particles and are, for example, in direct contact with the reducing agent-containing coatings. The temperature at which the organic or inorganic metal compound is converted into the parent metallic form can advantageously be reduced here. This makes it possible for join partners joined via the sintered bond formed, for example electrical and/or electronic components of an electronic circuit, advantageously not to be subjected to high temperatures during formation of the sintered bond. Thus, heat-sensitive electrical and/or electronic components in electronic circuits, which due to the otherwise excessively high process temperatures could not be used in production of the bond, can be electrically and/or thermally contacted.
[0051] The second coating can be metal-containing, in particular noble metal-containing and/or copper-containing, preferably silver-containing. In one embodiment, the second coating contains at least one metal, in particular noble metal and/or copper, preferably silver, in metallic form. In another embodiment, the second coating contains at least one metal as an organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, which, in particular, can be converted into the metallic form, in particular of the at least one parent metal, in particular of the first particles, by a thermal treatment. The organic or inorganic metal compound can in this case also be selected for example from the group consisting of silver carbonate, silver oxide, silver lactate, silver stearate and combinations thereof. These compounds can advantageously be converted into the parent metal in metallic form at high temperatures.
[0052] As an alternative or in addition thereto, the second coating or a further coating applied on top of the second coating can contain a reducing agent by means of which the reduction of a or the organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, in particular of the metal/metals of the first particles, to the metallic form can be carried out, for example at a temperature in the region of or optionally below the sintering temperature of the metallic form of the at least one parent metal, in particular of the first particles.
[0053] In a further embodiment, the second coating contains at least one metal selected from the group consisting of silver, platinum, palladium, gold, tin and combinations thereof. The second coating preferably contains at least one of the metals of the first particles. In particular, the second coating can contain the same metals as the first particles, for example silver. The adhesion of the second particles in the starting material can advantageously be improved in this way. Since the layer thickness of the coating is preferably smaller than the radius of the particle cores, the coefficient of thermal expansion of the coating influences that of the sintered bond to a lesser extent than the coefficient of expansion of the particle core material. However, it can be advantageous to use platinum and/or palladium in the coating material in order to achieve further minimization of the coefficient of expansion of the sintering material.
[0054] Furthermore, the starting material can comprise third particles. The third particles, too, can have a particle core and optionally a third coating applied to the particle core. The third coating can be metal-containing, in particular noble metal-containing and/or copper-containing, preferably silver-containing. In one embodiment, the third coating contains at least one metal, in particular noble metal and/or copper, preferably silver, in metallic form. In another embodiment, the third coating contains at least one metal as an organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, in particular one which can be converted into the metallic form, in particular of the at least one parent metal, in particular of the first particles, by a thermal treatment. The organic or inorganic metal compound can, here too, be selected from, for example, the group consisting of silver carbonate, silver oxide, silver lactate, silver stearate and combinations thereof. These compounds can advantageously be converted at high temperatures into the parent metal in metallic form.
[0055] As an alternative or in addition thereto, the third coating or a further coating applied on top of the third coating can contain a reducing agent by means of which the reduction of a or the organic or inorganic metal compound, in particular noble metal compound and/or copper compound, preferably silver compound, in particular of the metal/metals of the first particles, to the metallic form can be carried out, for example at a temperature in the region of or optionally below the sintering temperature of the metallic form of the at least one parent metal, in particular of the first particles.
[0056] In a further embodiment, the third coating contains at least one metal selected from the group consisting of silver, platinum, palladium, gold and combinations thereof. The third coating preferably contains at least one of the metals of the first particles. In particular, the third coating can contain the same metals as the first particles, for example silver. The adhesion of the third particles in the starting material can advantageously be improved in this way. Since the layer thickness of the coating is preferably smaller than the radius of the particle cores, the coefficient of thermal expansion of the coating influences that of the sintered bond to a lesser extent than the coefficient of expansion of the particle core material. However, it can be advantageous to use platinum and/or palladium in the coating material in order to achieve further minimization of the coefficient of expansion of the sintering material.
[0057] The third particles preferably contain at least a proportion of at least one metal, for example tin, in particular in metallic form, which is converted by a thermal treatment, in particular in the region of or optionally below the sintering temperature of the metallic form of the metal/metals of the first particles, into an alloy comprising the metal or metals of the first particles, in particular an alloy which has a lower melting point than the metal or metals of the first particles in metallic form. In particular, the particle cores of the third particles can be formed therefrom. The processing temperature for formation of the sintered bond can advantageously be reduced further in this way. Furthermore, the alloys can be present as ductile phases within the sintered microstructure formed, as a result of which the sintered bonds formed are less susceptible to thermal and/or mechanical stresses, in particular changing stresses. Furthermore, tin, for example, has a low melting point, so that the particles composed of tin melt earlier during a thermal treatment of the starting material and bring about adhesive contact between all particles present in the starting material. This advantageously promotes the diffusion processes occurring during the sintering process.
[0058] In a further embodiment, the starting material comprises, based on the total weight of the constituents, ≧5% by weight, in particular ≧10% by weight, for example ≧20% by weight or ≧25% by weight, of second particles, in particular where the sum of the constituents of the starting material is 100% by weight. Such an amount of second particles makes it possible to achieve a significant reduction in the coefficient of thermal expansion of the sintered bond, in particular compared to a corresponding sintered bond which comprises a further proportion of first particles instead of the second particles.
[0059] In a further embodiment, the starting material comprises, based on the total weight of the constituents, ≦60% by weight, in particular ≦50% by weight, of second particles, in particular where the sum of the constituents of the starting material is 100% by weight. Such an amount of second particles in the starting material advantageously makes it possible to still produce a sintered layer which bonds or adheres well.
[0060] If the starting material further comprises third particles, the starting material comprises, based on the total weight of the constituents, a total of ≦60% by weight, in particular ≦50% by weight, of second and third particles, in particular where the sum of the constituents of the starting material is 100% by weight.
[0061] In a further embodiment, the starting material comprises, based on the total weight of the constituents, a total of from ≧5% by weight or ≧10% by weight to ≦60% by weight, in particular from ≧10% by weight or ≧20% by weight or ≧25% by weight to ≦50% by weight, of second particles or of second and third particles, in particular where the sum of the constituents of the starting material is 100% by weight.
[0062] In a further embodiment, the starting material comprises, based on the total weight of the constituents, from ≧25% by weight to ≦80% by weight of first particles, in particular where the sum of the constituents of the starting material is 100% by weight.
[0063] Furthermore, the starting material can comprise at least one solvent. For example, the starting material can comprise, based on the total weight of the constituents, from ≧5% by weight or ≧10% by weight to ≦25% by weight, in particular from ≧10% by weight to ≦20% by weight, of solvents, in particular where the sum of the constituents of the starting material is 100% by weight.
[0064] Furthermore, the starting material can comprise at least one or more additives, for example reducing agents and/or oxidants.
[0065] For example, the starting material can comprise a total of from ≧25% by weight to ≦80% by weight of first particles and from ≧5% by weight to ≦60% by weight of second particles or of second and third particles, in particular where the sum of the constituents of the starting material is 100% by weight. Furthermore, the starting material can comprise from ≧5% by weight to ≦25% by weight of solvents and/or from ≧0.1% by weight to ≦10% by weight of additives, in particular where the sum of the constituents of the starting material is 100% by weight.
[0066] The starting material is preferably provided as a paste. The viscosity of the paste can be set by means of the solvent added. It is likewise advantageous to provide the starting material in the form of a pellet or as a shaped body, in particular as a flat shaped body. In this case, the paste-like starting material is introduced into a mold or applied to a film. The solvent is subsequently driven off from the starting material by means of a thermal treatment. Here, it is possible to provide, in particular, a solvent which can be driven off without leaving a residue at a temperature in the region of or below the sintering temperature of the starting material. The starting material formed in this way can also be manufactured in the form of a large sheet which is then cut into small shaped bodies for the particular application.
[0067] The first, second, third and further coatings of the first, second and/or third particles present in the starting material can in principle be applied by means of known coating processes. These can be found in the known technical literature. Examples which may be mentioned are chemical and physical coating processes such as chemical or physical vapor deposition.
[0068] As regards further features and advantages of the starting material of the invention, explicit reference is made here to the information provided in connection with the use according to the invention, the sintered bond of the invention, the electronic circuit of the invention, the process of the invention and the figures.
[0069] The present invention further provides for the use of elemental silicon, silicon oxide, silicon carbide, aluminum nitride, silicon nitride, aluminum oxide, metallic tungsten, metallic molybdenum, metallic chromium, metallic platinum, metallic palladium, boron carbide, beryllium oxide, boron nitride and combinations for reducing the coefficient of thermal expansion a of a starting material for a sintered bond or of a sintered bond, in particular in a sintering paste, a sintering powder or a sintering material preform.
[0070] As regards further features and advantages of the use according to the invention, explicit reference is made here to the information provided in connection with the starting material of the invention, the sintered bond of the invention, the electronic circuit of the invention, the process of the invention and the figures.
[0071] The present invention further provides a sintered bond composed of a starting material of the invention.
[0072] Experiments hitherto have shown that a sintered bond formed from such a starting material can advantageously have a coefficient of thermal expansion α at 20° C. in the range from ≧3·10 −6 K −1 to ≦15·10 −6 K −1 , for example from ≧3·10 −6 K −1 to ≦10·10 −6 K −1 , in particular from ≧3·10 −6 K −1 to ≦7·10 −6 K −1 . Sintered bonds having such a low coefficient of thermal expansion cannot be achieved by means of the conventionally used silver sintering pastes, which usually have a coefficient of thermal expansion α at 20° C. of about 19.5·10 −6 K −1 , and are of particular interest for, in particular, semiconductor technology since here join partners are frequently joined together by means of sintered bonds which on the one hand, as in the case of chips, have a very low coefficient of expansion, for example about 3·10 −6 K −1 , or on the other hand, for example in the case of metallic circuit substrates, have a very high coefficient of expansion, for example about 16.5·10 −6 K −1 , which is one of the main causes for crack formation when subjected to changing temperatures. The second particles advantageously enable the coefficient of thermal expansion to be set so that it lies between the coefficients of thermal expansion of the join partners to be joined via the sintered layer, for example between 16.5·10 −6 K −1 (circuit substrate) and 3·10 −6 K −1 (chip). Thermomechanical stresses between the join partners and the sintered bond, which can lead to crack formation in the join partners in the event of temperature changes, can advantageously be reduced significantly in this way. The sintered bond produced from the starting material of the invention can also advantageously have a comparatively high thermal conductivity, measured at 20° C. and 50% atmospheric humidity, of ≧100 Wm −1 K −1 . This is particularly advantageous for increasing the power density of semiconductor chips. The addition of elemental silicon in particular can counter crack formation to a great extent, since elemental silicon has a particularly advantageous effect on the elasticity of the sintered bond because of its low Young's modulus. In addition, the sintered bonds of the invention can advantageously achieve electrical conductivities which are only slightly below that of pure silver.
[0073] The proportion of second particles is preferably set in such a way that the coefficient of thermal expansion α S of the sintered bond layer at 20° C. is less than or equal to the coefficient of thermal expansion α F1 of a first join partner (joined by means of the sintered bond) at 20° C. and greater than or equal to the coefficient of thermal expansion α F2 of a second join partner (joined by means of the sintered bond) at 20° C.
[0074] In one embodiment, the proportion of second particles in the starting material is set in such a way that the coefficient of thermal expansion α S of the sintered bond or of the middle region of the sintered bond is in a range: α F2 +0.2·(α F1 −α F2 )≦α S ≦α F2 +0.8·(α F1 −α F2 ), in particular α F2 +0.25·(α F1 −α F2 )≦α S ≦α F2 +0.75·(α F1 −α F2 ), where α F1 is the coefficient of expansion of a first join partner and α F2 is the coefficient of expansion of a second join partner and α F1 ≧α F2 . Crack formation in the event of changing temperatures can advantageously be significantly reduced in this way.
[0075] In a preferred embodiment, the proportion of second particles in the sintered bond increases stepwise or continuously from a boundary layer with a first join partner having a greater coefficient of expansion in the direction of a boundary layer with a second join partner having a smaller coefficient of thermal expansion, or, conversely, the proportion of second particles in the sintered bond decreases stepwise or continuously from a boundary layer with a first join partner having a smaller coefficient of expansion in the direction of a boundary layer with a join partner having a greater coefficient of thermal expansion. The differences between the coefficients of thermal expansion between boundary layers which are in contact with one another and thus crack formation in the event of temperature changes can be minimized particularly advantageously in this way. Such a gradient can, for example, be produced by application of a plurality of sintering paste layers having a decreasing or increasing proportion of second particles, for example by means of a printing process.
[0076] As regards further features and advantages of the electronic circuit of the invention, explicit reference is made here to the information provided in connection with the starting material of the invention, the sintered bond of the invention, the use according to the invention, the process of the invention and the figures.
[0077] The present invention further provides an electronic circuit having a sintered bond according to the invention.
[0078] As regards further features and advantages of the electronic circuit of the invention, explicit reference is made here to the information provided in connection with the starting material of the invention, the sintered bond of the invention, the process of the invention and the figures.
[0079] The invention further provides a process for forming a thermally and/or electrically conductive sintered bond. Here, a starting material of the invention is used as starting material.
[0080] The starting material can here be applied between two join partners. Preferred join partners are electrical and/or electronic components having contact points which are brought into direct physical contact with the starting material.
[0081] The proportion of second particles is preferably set in such a way that the coefficient of thermal expansion α S of the sintered bond layer at 20° C. is less than or equal to the coefficient of thermal expansion α F1 of a first join partner at 20° C. and greater than or equal to the coefficient of thermal expansion α F2 of a second join partner at 20° C.
[0082] In one embodiment, the proportion of second particles is set in such a way that the coefficient of thermal expansion α S of the sintered bond or of the middle region of the sintered bond is in a range: α F2 +0.2·(α F1 −α F2 )≦α S ≦α F2 +0.8·(α F1 −α F2 ), in particular α F2 +0.25·(α F1 −α F2 )≦α S ≦α F2 +0.75·(α F1 −α F2 ), where α F1 is the coefficient of expansion of a first join partner and α F2 is the coefficient of expansion of a second join partner and α F1 ≧α F2 . Crack formation in the event of temperature changes can advantageously be significantly reduced in this way.
[0083] In a preferred embodiment, the proportion of second particles in the sintered bond increases stepwise or continuously from a boundary layer with a first join partner having a greater coefficient of expansion in the direction of a boundary layer with a second join partner having a smaller coefficient of thermal expansion, or, conversely, the proportion of second particles in the sintered bond decreases stepwise or continuously from a boundary layer with a first join partner having a smaller coefficient of expansion in the direction of a boundary layer with a join partner having a greater coefficient of thermal expansion. The differences between the coefficients of thermal expansion of boundary layers which are in contact with one another and thus crack formation in the event of temperature changes can be minimized particularly advantageously in this way.
[0084] Such a gradient can, for example, be produced by application of a plurality of sintering paste layers having a decreasing or increasing proportion of second and/or third particles, for example by means of a printing process. Here, the starting material can be applied in the form of a printing paste to the contact points, for example by means of screen printing or stenciling. Application by injection or dispensing processes is likewise possible.
[0085] A further possibility is to arrange the starting material as shaped body between the join partners.
[0086] The sintered bond is subsequently formed by thermal treatment of the starting material.
[0087] For example, a processing temperature of ≦400° C., preferably ≦300° C., in particular ≦250° C., can be provided. The sintering process is optionally carried out under pressure in order to improve the sintering process. A pressure of ≦10 MPa, preferably ≦4 MPa or even ≦1.6 MPa, particularly preferably ≦0.8 MPa, is provided as process pressure. If the reducing agent has not been used in a stoichiometric amount but instead in excess, excess reducing agent can be burnt out completely if sufficient oxygen is supplied, for example under an air atmosphere. Join partners having contact points composed of a noble metal, for example gold, silver or an alloy of gold or silver, are preferably provided.
[0088] In an alternative possible variant of the process of the invention, the sintered bond is formed in vacuo and/or under a nitrogen atmosphere. Since in this case excess reducing agent cannot be burnt, a starting material in which the proportion of the organic or inorganic metal compound, in particular the metal compound to be reduced, present in the starting material is present in the second coating in a stoichiometric ratio to the proportion of the reducing agent present in the starting material should be provided. During the thermal treatment, the reducing agent is accordingly completely consumed. In addition, the organic or inorganic metal compound is completely converted into the metallic form. In this process variant, join partners having a contact point which does not contain noble metal and is instead composed, for example, of copper can advantageously also be provided. This enables inexpensive electrical and/or electronic components also to be employed.
[0089] As regards further features and advantages of the process of the invention, explicit reference is hereby made to the information provided in connection with the starting material of the invention, the use according to the invention, the sintered bond of the invention, the electronic circuit of the invention and the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0090] Further advantages and advantageous embodiments of the subject matter of the invention are illustrated by the drawings and described in the following description. It should be noted that the drawings merely have descriptive character and are not intended to restrict the invention in any way. The drawings show
[0091] FIG. 1 a schematic plan view of particles of a starting material according to the invention for a sintered bond according to a first embodiment which comprises first and second particles;
[0092] FIG. 2 a schematic plan view of particles of a starting material according to the invention for a sintered bond according to a second embodiment which comprises first, second and third particles;
[0093] FIG. 3 a - f schematic cross sections through embodiments of first particles;
[0094] FIG. 4 a - e schematic cross sections through embodiments of second particles;
[0095] FIG. 5 a, b schematic cross sections through embodiments of third particles;
[0096] FIG. 6 a schematic cross section through a first embodiment of an electronic circuit according to the invention;
[0097] FIG. 7 a schematic cross section through a second embodiment of an electronic circuit according to the invention; and
[0098] FIG. 8 a schematic cross section through a sintering oven in the production of a sintered bond or electronic circuit according to the invention.
[0099] In the figures, identical components and components having the same function are characterized by the same reference numerals.
DETAILED DESCRIPTION
[0100] FIG. 1 schematically shows first particles 10 and second particles 20 which are provided in a first embodiment of a starting material according to the invention for a sintered bond. FIG. 1 shows that the first particles 10 and second particles 20 have essentially the same sizes. The first particles 10 and second particles 20 preferably have as similar a particle size distribution as possible. In particular, the D 50 of the second particles 20 is greater than or equal to half the D 50 of the first particles 10 and less than or equal to twice the D 50 of the first particles 10 . Such a relationship between the particle size distribution of the first particles 10 and second particles 20 has been found to be particularly advantageous since a higher fine content of second particles can have an adverse effect on the sintering of the first particles, with a higher coarse content of second particles being able to lead to great inhomogeneities and accordingly to macroscopic fluctuations of the materials properties within the sintered bond.
[0101] FIG. 2 schematically shows first particles 10 , second particles 20 and third particles 30 which are provided in a second embodiment of a starting material according to the invention for a sintered bond. In the embodiment shown, said particles are also essentially equal in size and have a similar particle size distribution.
[0102] The starting material can, in the embodiments illustrated in FIGS. 1 and 2 , contain metal-containing first particles 10 of one or more of the embodiments shown in FIGS. 3 a to 3 f . For example, the first particles 10 can be noble metal-containing and/or copper-containing, in particular silver-containing, particles. In the interests of simplicity, the figures are explained below for the example of silver-containing first particles 10 .
[0103] FIG. 3 a shows a first particle 10 which is composed of silver in metallic form.
[0104] FIG. 3 b shows a first particle 10 which is composed of an organic or inorganic silver compound, for example silver carbonate (Ag 2 CO 3 ) and/or silver oxide (Ag 2 O, AgO), which can be converted into metallic silver by a thermal treatment.
[0105] FIG. 3 c shows a first particle 10 which has a particle core 11 composed of silver in metallic form and a first coating 12 which is applied thereto and is composed of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, which can be converted into metallic silver by a thermal treatment.
[0106] FIG. 3 d shows a first particle 10 which has a particle core 11 composed of silver in metallic form and a first coating 12 which is applied thereto and is composed of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, which can be converted into metallic silver by a thermal treatment. In addition, the particle 10 shown in FIG. 3 d has a further coating 13 which is applied on top of the first coating 12 and contains a reducing agent, for example a fatty acid, by means of which the reduction of the organic or inorganic silver compound to metallic silver can be carried out.
[0107] FIG. 3 e shows a first particle 10 which has a particle core 11 composed of silver in metallic form and a first coating 12 which is applied thereto and contains reducing agent, for example fatty acid, where the reduction of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, to metallic silver can be carried out by means of the reducing agent. The organic or inorganic silver compound can be a constituent of another first particle 10 , second particle 20 or third particle 30 .
[0108] FIG. 3 f shows a first particle 10 which has a particle core 11 composed of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, which can be converted into metallic silver by a thermal treatment. In addition, the first particle 10 has a first coating 12 which is applied to the particle core 11 and contains a reducing agent, for example fatty acid, by means of which the reduction of the organic or inorganic silver compound to metallic silver from metallic silver can be carried out.
[0109] FIG. 4 a shows a second particle 20 whose particle core is composed of a material which has a low coefficient of thermal expansion α at 20° C. of ≦10·10 −6 K −1 , in particular ≦7.5·10 −6 K −1 , preferably 5·10 −6 K −1 . The material here can be, for example, elemental silicon, silicon oxide, silicon carbide, aluminum nitride, silicon nitride, aluminum oxide, metallic tungsten, metallic molybdenum, metallic chromium, metallic platinum, metallic palladium, boron carbide, beryllium oxide and/or boron nitride. In addition, these materials advantageously have a good thermal conductivity λ 20/50 at 20° C. and 50% atmospheric humidity of ≧50 Wm −1 K −1 , in particular ≧100 Wm −1 K −1 , which is particularly advantageous for increasing the power density of semiconductor chips.
[0110] FIG. 4 b shows a second particle 20 which has a particle core 21 composed of a material with a low coefficient of thermal expansion α at 20° C. of ≦10·10 −6 K −1 , in particular of ≦7.5·10 −6 K −1 , preferably 5·10 −6 K −1 . A second coating 22 composed of silver, platinum or palladium in metallic form is in this case applied to the particle core 21 .
[0111] FIG. 4 c shows a second particle 20 which has a particle core 21 composed of a material with a low coefficient of thermal expansion α at 20° C. of ≦10·10 −6 K −1 , in particular of ≦7.5·10 −6 K −1 , preferably 5·10 −6 K −1 . In addition, the particle 20 has a second coating 22 which is applied to the particle core and is composed of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, which can be converted into metallic silver by a thermal treatment.
[0112] FIG. 4 d shows a second particle 20 which has a particle core 21 composed of a material with a low coefficient of thermal expansion α and a second coating 22 which is applied thereto and contains a reducing agent, for example fatty acid, by means of which the reduction of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, which is a constituent of another first particle 10 , second particle 20 or third particle 30 to metallic silver can be carried out.
[0113] FIG. 4 e shows a second particle 20 which has a particle core 21 composed of a material with a low coefficient of thermal expansion and a second coating 22 which is applied thereto and is composed of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, which can be converted into metallic silver by a thermal treatment. In addition, the particle 20 shown in FIG. 4 e has a further coating 23 which is applied on top of the second coating 22 and contains a reducing agent, for example a fatty acid, by means of which the reduction of the organic or inorganic silver compound to metallic silver can be carried out.
[0114] FIG. 5 a shows a third particle 30 which contains a metal, for example tin, which forms an alloy with silver as a result of a thermal treatment and/or has a melting point lower than that of metallic silver.
[0115] FIG. 5 b shows a third particle 30 which has a particle core 31 composed of a metal, for example tin, which forms an alloy with silver as a result of a thermal treatment and/or has a melting point lower than that of metallic silver. In addition, the third particle shown in FIG. 5 b has a third coating 32 which is applied to the particle core 31 and is composed of an organic or inorganic silver compound, for example silver carbonate and/or silver oxide, which can be converted into metallic silver by a thermal treatment.
[0116] FIG. 6 shows a first embodiment of an electronic circuit 70 which has a substrate 65 having at least one contact point 66 . The contact point 66 of the substrate 65 is joined to a contact point 61 of a chip 60 by means of a sintered bond 100 ′ produced from a starting material 100 according to the invention.
[0117] FIG. 7 shows a second embodiment of an electronic circuit 70 which has a first substrate 65 having at least one contact point 66 . The first contact point 66 of the first substrate 65 is joined to a first contact point 61 of a chip 60 by means of a first sintered bond 100 produced from a starting material 100 according to the invention. In turn, a second contact point 61 ′ of the chip 60 is joined to a contact point 66 ′ of a second substrate 65 ′ by means of a second sintered bond 100 which is likewise produced from the starting material 100 of the invention.
[0118] FIG. 8 shows a sintering oven 80 and also an electronic circuit 70 arranged in a process space 90 of the sintering oven 80 . The electronic circuit 70 has a substrate 65 having at least one first contact point 66 composed of copper. A chip 60 having at least one second contact point 61 composed of a silver alloy is arranged on the substrate 65 . Between the at least first contact point 66 composed of copper and the at least second contact point 61 composed of the silver alloy, a starting material 100 according to the invention has been applied as paste. The starting material 100 contains a proportion of a mixture of first particles 10 and second particles 20 corresponding to FIGS. 1 to 4 e.
[0119] To form a sintered bond 100 ′ between the at least first contact point 66 of the substrate 65 and the at least second contact point 61 of the chip 60 , the electronic circuit 70 with the starting material 100 is subjected to a thermal treatment. To carry out the thermal treatment, the sintering oven 80 contains a heating device within the process space 90 . A vacuum or a protective gas atmosphere, for example, is present in the process space 90 during the thermal treatment of the starting material 100 .
[0120] The starting material 100 is, for example, applied as a paste in which the first particles 10 and second particles 20 and optionally the third particles 30 are present in dispersed form.
[0121] The thermal treatment of the electronic circuit 70 triggers physical and/or chemical reaction processes in the starting material 100 . Here, reducing agent optionally present, for example a fatty acid, can react with an optional organic or inorganic silver compound, for example silver carbonate and/or silver oxide, to form metallic silver at a temperature in the region of or optionally below the sintering temperature of silver. A largely complete conversion into silver can be achieved by means of the above-described embodiments of the particles containing silver compounds.
[0122] The metal-containing first particles 10 sinter together to form an electrically conductive sintered microstructure. Here, the second particles or the particle cores thereof behave as inert material. The coatings 12 , 13 , 22 , 23 , 31 , 32 described in connection with FIGS. 3 c to 5 b can aid sintering within the sintered microstructure. After formation of the sintered bond 100 ′, the elemental material of the second particles 20 is present as a fine dispersion within the metallic silver matrix of the sintered micro-structure 100 ′. In addition, third particles 30 corresponding to FIGS. 5 a and 5 b can also be cosintered in the silver matrix.
[0123] The third particles 30 , for example composed of tin, present, optionally as a mixture with the first and second particles 10 and 20 , in the starting material 100 melt at an earlier juncture during the thermal treatment and aid contact of the material of all particles 10 , 20 , 30 present in the starting material 100 . In addition, the third particles 30 can form alloys with the constituents of the first particles 10 and optionally particle coatings 12 , 13 , 22 , 32 . These alloys are then present as ductile phases within the silver matrix formed in the sintered microstructure.
[0124] Contacting of the first and second contact points 61 , 66 of the substrate or of the chip 65 likewise occurs by means of the sintered bond 100 ′ formed. Contacting of the first contact point 66 composed of copper during the thermal treatment is possible without corrosion phenomena since contacting is carried out in vacuo or under a protective gas atmosphere. As a result, a non-precious material, for example composed of copper, also remains free of oxidation products during the thermal treatment to form the sintered bond 100 ′. | The present invention relates to a starting material for producing a sintered connection. In order to avoid the formation of cracks in the joining partners in the case of fluctuating thermal loading, the starting material comprises second particles 20 in addition to metallic first particles 10 , wherein the second particles 20 at least proportionately contain a particle core material which has a coefficient of thermal linear expansion α at 20° C. which is less than the coefficient of thermal linear expansion α at 20° C. of the metal or of the metals of the first particles in metallic form, and wherein the D 50 value of the second particles 20 is greater than or equal to half the D 50 value of the first particles 10 and less than or equal to two times the D 50 value of the first particles 10 . In addition, the present invention relates to a corresponding sintered connection 100 ′, to an electronic circuit 70 and also to a process for forming a thermally and/or electrically conductive sintered connection. | 7 |
RELATED APPLICATION
[0001] The present application claims priority under 35 USC §120 from U.S. Ser. No. 60/737,681 filed Nov. 17, 2005.
BACKGROUND
[0002] The present invention relates generally to fastener-driving tools used for driving fasteners into workpieces, and specifically to combustion-powered fastener-driving tools, also referred to as combustion tools or combustion nailers.
[0003] Combustion-powered nailers are known in the art for driving fasteners into workpieces, and examples are described in commonly assigned patents to Nikolich U.S. Pat. Re. No. 32,452, and U.S. Pat. Nos. 4,522,162; 4,483,473; 4,483,474; 4,403,722; 5,197,646; 5,263,439 and 5,713,313, all of which are incorporated by reference herein. Similar combustion-powered nail and staple driving tools are available commercially from ITW-Paslode of Vernon Hills, Ill. under the IMPULSE® and PASLODE® brands.
[0004] Such nailers incorporate a housing enclosing a small internal combustion engine or power source. The engine is powered by a canister of pressurized fuel gas, also called a fuel cell. A battery-powered electronic power distribution unit produces a spark for ignition, and a fan located in a combustion chamber provides for both an efficient combustion within the chamber, while facilitating processes ancillary to the combustion operation of the device. Such ancillary processes include: mixing the fuel and air within the chamber, turbulence to increase the combustion process, scavenging combustion by-products with fresh air, and cooling the engine. The engine includes a reciprocating piston with an elongated, rigid driver blade disposed within a cylinder body.
[0005] A valve sleeve is axially reciprocable about the cylinder and, through a linkage, moves to close the combustion chamber when a work contact element at the end of the linkage is pressed against a workpiece. This pressing action also triggers a fuel-metering valve to introduce a specified volume of fuel into the closed combustion chamber.
[0006] Upon the pulling of a trigger switch, which causes the spark to ignite a charge of gas in the combustion chamber of the engine, the combined piston and driver blade is forced downward to impact a positioned fastener and drive it into the workpiece. The piston then returns to its original or pre-firing position, through differential gas pressures created by cooling of residual combustion gases within the cylinder. Fasteners are fed magazine-style into the nosepiece, where they are held in a properly positioned orientation for receiving the impact of the driver blade.
[0007] Nailers of the type described above are operated in sequential or repetitive firing modes (also referred to as sequential or repetitive modes), each of which places unique operating demands on the engine or combustion power source. In the case of the sequential mode, the fastening operation requires deliberate action by the operator to position and operate the tool. This in turn affords more time for the engine operational events to be performed. Such events include valve sleeve closing, fan motor start and acceleration, fuel injection, fuel mixing, ignition, combustion and drive cycles, piston return, valve sleeve opening, and scavenging and replacement of spent gases with a fresh charge of air. With the necessary time provided for full process completion, repeatable nailer performance is achieved.
[0008] In the case of the repetitive firing mode, the time for the cycle operations is significantly reduced, which can lead to erratic nailer operation. This can be the result of poor fuel/air mixtures due to improper scavenging of spent gases, not enough mixing time, and/or insufficient turbulence for effecting combustion.
[0009] Thus, there is a need for improving the cycle operation of combustion nailers depending on nailer operating modes.
BRIEF SUMMARY OF THE INVENTION
[0010] The above-listed need is met or exceeded by the present motor control for a combustion nailer based on operating mode which features a control system that provides fan motor performance in accordance with an associated nailer operating mode. When the nailer is operated in a sequential fire mode, the motor operating parameters are distinct from those during a repetitive fire operating mode. More specifically, in the preferred embodiment, the present control system powers ON the fan when the repetitive fire mode is activated. The activation is accomplished by manipulating the operating switches of the tool, such as combinations of trigger or chamber/head switch activations. Alternatively, the activation may be accomplished with a manually operated switch. The powering ON of the motor with the onset of the repetitive fire operating mode allows the motor time to accelerate to operating RPM and promote rapid fuel/air mixing in preparation for the first intended operation. Another aspect of the present control system is that the fan motor is operated at higher RPM under repetitive fire operating mode than under the sequential fire operating mode.
[0011] More specifically, a combustion nailer configured for selectively operating in one of a sequential and a repetitive mode includes a combustion engine at least in part defining a combustion chamber, a fan motor associated with the combustion chamber and a control system for controlling operation of the nailer, the control system being configured for powering the fan motor at a first speed when the nailer is operating in the sequential mode, and a second speed when the nailer is operating in the repetitive mode.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 is a front perspective view of a fastener-driving tool incorporating the present fan motor control system; and
[0013] FIG. 2 is a fragmentary vertical cross-section of the tool of FIG. 1 shown in the rest position.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring now to FIGS. 1 and 2 , a combustion-powered fastener-driving tool, also known as a combustion nailer, incorporating the present control system is generally designated 10 and preferably is of the general type described in detail in the patents listed above and incorporated by reference in the present application. A housing 12 of the tool 10 encloses a self-contained internal power source 14 ( FIG. 2 ) within a housing main chamber 16 . As in conventional combustion tools, the power source or combustion engine 14 is powered by internal combustion and includes a combustion chamber 18 that communicates with a cylinder 20 . A piston 22 reciprocally disposed within the cylinder 20 is connected to the upper end of a driver blade 24 . As shown in FIG. 2 , an upper limit of the reciprocal travel of the piston 22 is referred to as a pre-firing position, which occurs just prior to firing, where ignition of the combustion gases initiates the downward driving of the driver blade 24 to impact a fastener (not shown).
[0015] Depending on the selected operational mode, when the nailer 10 is in a sequential mode, through depression of a trigger 26 associated with a trigger switch (not shown, the terms trigger and trigger switch are used here interchangeably), an operator induces combustion within the combustion chamber 18 , causing the driver blade 24 to be forcefully driven downward through a nosepiece 28 ( FIG. 1 ). The nosepiece 28 guides the driver blade 24 to strike a fastener that had been delivered into the nosepiece via a fastener magazine 30 .
[0016] Adjacent to the nosepiece 28 is a workpiece contact element 32 , which is connected, through a linkage 34 to a reciprocating valve sleeve 36 , an upper end of which partially defines the combustion chamber 18 . Depression of the tool housing 12 against the workpiece contact element 32 in a downward direction as seen in FIG. 1 (other operational orientations are contemplated as are known in the art), causes the workpiece contact element to move from a rest position to a pre-firing position. This movement overcomes the normally downward biased orientation of the workpiece contact element 32 caused by a spring 38 (shown hidden in FIG. 1 ). Other locations for the spring 38 are contemplated.
[0017] Through the linkage 34 , the workpiece contact element 32 is connected to and reciprocally moves with, the valve sleeve 36 . In the rest position ( FIG. 2 ), the combustion chamber 18 is not sealed, since there is an annular gap 40 including an upper gap 40 U separating the valve sleeve 36 and a cylinder head 42 , which accommodates a spark plug 46 , and a lower gap 40 L separating the valve sleeve 36 and the cylinder 20 . A chamber switch 44 is located in proximity to the valve sleeve 36 to monitor its positioning. In the preferred embodiment of the present tool 10 , the cylinder head 42 also is the mounting point for at least one cooling fan 48 and an associated fan motor 49 which extends into the combustion chamber 18 as is known in the art and described in the patents which have been incorporated by reference above. In the rest position depicted in FIG. 2 , the tool 10 is disabled from firing because the combustion chamber 18 is not sealed between the cylinder head 42 and the cylinder 20 , and the chamber switch 44 is open.
[0018] Firing is enabled when an operator presses the workpiece contact element 32 against a workpiece. This action overcomes the biasing force of the spring 38 , causes the valve sleeve 36 to move upward relative to the housing 12 , closing the gaps 40 U and 40 L, sealing the combustion chamber 18 and activating the chamber switch 44 . This action also induces a measured amount of fuel to be released into the combustion chamber 18 from a fuel canister 50 (shown in fragment).
[0019] In the sequential operating mode, upon pulling the trigger 26 , the spark plug 46 is energized, igniting the fuel and air mixture in the combustion chamber 18 and sending the piston 22 and the driver blade 24 downward toward the waiting fastener for entry into the workpiece. In an alternative mode of operation known as repetitive firing, ignition is initiated by the closing of the chamber switch 44 , since the trigger 26 has already been pulled and the corresponding switch closed. As the piston 22 travels down the cylinder 20 , it pushes a rush of air which is exhausted through at least one petal, reed or check valve 52 and at least one vent hole 53 located beyond the piston displacement ( FIG. 2 ). At the bottom of the piston stroke or the maximum piston travel distance, the piston 22 impacts a resilient bumper 54 as is known in the art. With the piston 22 beyond the exhaust check valve 52 , high pressure gasses vent from the cylinder 20 . Due to cooling of the residual gases, internal pressure differentials created in the cylinder 20 cause the piston 22 to be forced back to the pre-firing position shown in FIG. 2 .
[0020] Referring now to FIGS. 1 and 2 , to accommodate these design concerns, the present tool 10 preferably incorporates a combustion chamber control device, generally designated 60 and configured for preventing the reciprocation of the valve sleeve 36 from the closed or firing position until the piston 22 returns to the pre-firing position. This holding or locking function of the control device 60 is operational for at least the minimum period of time required for the piston 22 to return to the pre-firing position. Thus, the operator using the tool 10 in a repetitive cycle mode can lift the tool from the workpiece where a fastener was just driven, and begin to reposition the tool for the next firing cycle. Due to the shorter firing cycle times inherent with repetitive cycle operation, the lockout device 60 ensures that the combustion chamber 18 will remain sealed during tool repositioning, and the differential gas pressures maintained so that the piston 22 will be returned before premature opening of the chamber 18 , which would interrupt piston return. It should be understood that the lockout device 60 as shown is only exemplary of many types of similar devices which could be used to perform the same function.
[0021] More specifically, and referring to FIG. 2 , the combustion chamber control device 60 includes an electromagnet 62 configured for engaging a latch 64 which transversely reciprocates relative to the valve sleeve 36 for preventing the movement of the valve sleeve for a specified amount of time. This time period is controlled by a control program 66 ( FIG. 1 ) embodied in a central processing unit or control module 67 (shown hidden), typically housed in a handle portion 68 ( FIG. 1 ) of the housing 12 . The control program 66 , the CPU 67 and the associated wiring and components is collectively referred to as the control system.
[0022] From copending U.S. patent application Ser. No. 11/028,450 filed Jan. 3, 2005, which is incorporated by reference, it is contemplated to configure the control system so that the user can select between sequential mode and repetitive mode operation by manipulation of the trigger 26 and/or the chamber switch 44 . More specifically, if the nailer is operated so that the chamber switch 44 is closed before the trigger 26 , the nailer 10 will operate in sequential mode. Alternatively, if the trigger 26 is activated or pulled and released in a specified pattern, for example two trigger operations within 500 msec, and thereafter held activated with the chamber switch 44 open, the nailer is selected to operate in the repetitive mode of operation.
[0023] As described in greater detail in copending application Ser. No. 11/028,450, the tool 10 is default set to operate in sequential-fire mode and operate as is commonly known in the art in view of the patents incorporated by reference herein. The operational cycle begins with the valve sleeve 36 and the workpiece contact element 32 in the rest position, and the trigger 26 released. In this condition, all tool functions are inactive. To switch the nailer 10 into a firing mode (either sequential or repetitive cycle), the program 66 monitors switch activity—nothing occurs until one of the switches is closed. If the chamber switch 44 is closed upon the start of a user initiated operational cycle, the subsequent pulling of the trigger 26 will result in a sequential operation of the nailer engine. If the chamber switch 44 is released prior to the pulling of the trigger 26 , no operations related to the combustion cycle occur, the program 66 resumes monitoring the switches.
[0024] Alternately, if the chamber switch 44 is open and the trigger 26 is closed or pulled, the control program 66 looks for requirements to begin and maintain repetitive cycle operation. Specifically, an important feature of the control program 66 is that the trigger 26 needs to be fully closed, fully released, and fully closed again all within 500 msec to put the tool 10 into the repetitive cycle mode. Thereafter, to maintain repetitive cycle operation the trigger 26 must remain depressed or pulled to maintain the repetitive cycle mode once that mode has been selected. If during the repetitive cycle, no chamber activity occurs within preset time, such as 5 seconds, the program 66 discontinues that mode of operation and resumes operation after all the chamber switch 44 and trigger 26 are opened.
[0025] As an alternative to the automatic selection of operational modes depending on the condition of the chamber switch 44 or the trigger 26 , it is also contemplated that an external switch 70 ( FIG. 1 ) be provided that is connected to the control program 66 . The switch 70 may be user activated to control the operational mode (sequential/repetitive) of the nailer 10 .
[0026] An important feature of the present nailer 10 is that the control system is configured so that the fan motor 49 is powered ON with the onset of the repetitive operating mode. This feature allows the motor time to accelerate to operating RPM and to promote rapid fuel/air mixing in preparation for the first intended operation.
[0027] An additional feature is for the motor 49 to operate the fan RPM at a different speed during repetitive cycle operation than in sequential operation. More specifically, the control program 66 operates the fan motor 49 at a higher speed during repetitive fire than in sequential mode. This is because during repetitive operation, cycle interval times are reduced and the increased fan motor RPM will compensate for the reduction. Also, higher fan motor RPM will reduce fuel/air mixing times and any consequential ignition delays. Further, the scavenging of spent gases and replacement with a fresh air charge will occur in less time. Lastly, the increased RPM produces more cooling air flow (CFM) through the nailer 10 to keep tool operating temperatures at acceptable levels. This compensates for the increase heating effect of the engine that can occur during rapid and recurrent nailer operations.
[0028] The fan motor RPM ranges of interest are in the general range of 10,000-12,000 for sequential fire operation, and 12,000-15,000 for repetitive operation. In the preferred embodiment, the control system operates the fan motor RPM at a relatively fixed 10,500 RPM for sequential operation, and 13,000 RPM for repetitive operation. However, it will be appreciated that these values, as well as the above RPM ranges, may vary to suit the application, the particular nailer, or the desired operating conditions of the nailer. It is contemplated that the fan motor speed in repetitive cycle operation is approximately 20-50% faster than in sequential fire mode.
[0029] Although both modes can operate at the higher values associated with repetitive cycling, such operation is not preferred since excessive battery consumption, increased dirt intake and increased motor component wear will result.
[0030] Thus, it will be seen that the present nailer includes an improved control system which provides differentiated fan motor operating parameters for each nailer operational mode. The present motor control enhances repeatable nailer performance and compensates for the operational demands of repetitive cycle operation including scavenging of spent gases, and reduced engine operating temperatures.
[0031] While particular embodiments of the present motor control based on operating mode for a combustion nailer has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims. | A combustion nailer configured for selectively operating in one of a sequential and a repetitive mode includes a combustion engine at least in part defining a combustion chamber, a fan motor associated with the combustion chamber and a control system for controlling operation of the nailer, the control system being configured for powering the fan motor at a first speed when the nailer is operating in the sequential mode, and a second speed when the nailer is operating in the repetitive mode. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to an electrophotographic image forming apparatus equipped with a fixing device such as a copying machine, printer, facsimile, and so on. Specifically, this invention relates to an electrophotographic image forming apparatus equipped with a fixing device that fixes by clamping, pressing, and heating a paper sheet by two bodies of rotation.
[0002] In general, a conventional fixing device fixes a toner image to a transfer sheet by letting a transfer sheet with a toner image pass through a nip area which is formed by two bodies of revolution (rollers) in pressure contact, heating, and pressing the toner image against the transfer sheet.
[0003] When the image forming apparatus is of the color type, the transfer sheet is apt to have more toner and consequently it is apt to twine itself around the body of rotation when a toner image is heated and pressed. To prevent this, the nip area is dented in the side of the unfixed toner image. In this case, the roller which is in contact with the backside of the transfer sheet must be harder than the roller which is contact with the toner image side of the transfer sheet. In this case, the nip area is not wide enough for a poor-fixing transfer sheet such as a cardboard. Therefore, to fix such a poor-fixing transfer sheet, we must increase the fixing temperature or reduce the processing speed. As the result, the warm-up time becomes longer and the print productivity becomes lower. Additionally, after passing through the fixing device, such a hard transfer sheet may be curled to the nip shape. As the cardboard is hard and the nip area need not be convex in the side of the roller facing to the backside of the paper, it is possible to decrease the hardness of the roller in the backside of the transfer sheet and to make the nip area flat. However, in this status, a thin paper sheet may twine itself around the roller in the side of the unfixed toner.
[0004] To solve the above problems, there have been disclosed various technologies such as a technology (e.g. Patent Document 1) that uses a plurality of rollers to select optimum conditions such as roller temperatures, diameters, circumferential speeds, and surface hardness according to water content and thickness of the transfer sheets and a technology (e.g. Patent Document 2) that select rollers according to the kinds of transfer sheets to suppress wrinkles of an envelope that holds a toner image and to assure the transparency of a color toner image on an OHT sheet (transparent sheet).
[0005] Further, another technology (e.g. Patent Document 3) discloses a method of providing a roller to the unfixed toner image side of a transfer sheet, a belt to the opposite side of the transfer sheet, and a plurality of pressing members that press the belt against the roller, selecting one of the pressing members which have different lengths (widths) perpendicular to the movement of the transfer sheet, and causing the selected pressing member to press the belt against the roller with the pressing force changed.
Patent Document 1: Japanese Non-examined Patent Publication S54-95246 Patent Document 2: Japanese Non-examined Patent Publication H04-166878 Patent Document 3: Japanese Non-examined Patent Publication 2001-5312
[0009] However, when some rollers are selected, their temperatures must be controlled simultaneously and the power consumption is required too much in the standby status. If this temperature control is omitted to suppress the standby power consumption, it takes much time before the selected rollers reach the preset control temperatures. In other words, it takes a lot of time for the first printout and the fixing may be insufficient. Further, if controlling is made to reduce the circumferential speeds of rollers, the print productivity becomes lower. Therefore, it is not enough to simply provide rollers that are different in temperature, diameter, circumferential speed, and surface hardness and to select them according to the operating conditions because of the long warm-up time after roller selection and the low print productivity. Furthermore, the technology disclosed by Patent Document 3 cannot assure the fixing and paper passing abilities of various kinds of transfer sheets under a changing print environment singly by changing the length (or width) of the pressing member perpendicular to the movement of the transfer sheet.
SUMMARY OF THE INVENTION
[0010] An object of this invention is to provide an image forming apparatus having a fixing device that can assure an overall fixing performance such as fixing ability, peeling ability, wrinkle-free properties, and optimization of temperature distribution.
[0011] This purpose can be attained by the means below.
[0012] An image forming apparatus having a fixing device for fixing a toner image onto a transfer sheet, comprising two bodies of rotation at least one of which is belt-shaped and pressed together to form a nip section, a heat source for heating at least one of the bodies of rotation, and a driving source for rotating at least one of two bodied of rotation to let a transfer sheet pass through the nip section and fix a toner image onto the transfer sheet, wherein the image forming apparatus further comprises
a plurality of pressing members for pressing the belt-shaped body of rotation against the other body of rotation, a moving means for moving one of the pressing members towards the nip section and stopping there, a control means for controlling movement and stopping of the pressing member, and at least one of means for setting any of the size, type, brand, thickness, basis weight, smoothness, glossiness, and stiffness of the transfer sheet to be printed on an operation section, means for detecting any of the size, thickness, basis weight, smoothness, glossiness, and stiffness of the transfer sheet before fixing, and means for detecting the environmental temperature or humidity around the image forming apparatus and the temperature or water content of the transfer sheet and one of the pressing members is moved to the nip section before the transfer sheet reaches the nip section.
[0018] This invention can provide a fixing device that can assure the overall fixing performance by securing a pressing member that presses a transfer sheet against the roller via the belt and selecting a pressing member according to the condition of the transfer sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic vertical sectional view of the whole image forming apparatus.
[0020] FIG. 2 is an explanatory sectional view of the pressing member moving means.
[0021] FIGS. 3 ( a ) to 3 ( d ) each shows details of the pressing pad.
[0022] FIGS. 4 ( a ) to 4 ( d ) each shows an example of a detecting means that detects a condition related to the transfer sheet before transferring.
[0023] FIGS. 5 ( a ) and 5 ( b ) each shows part of an operation panel provided on the top of the image forming apparatus.
[0024] FIG. 6 shows a mechanism that places the pressing means inside the heating belt and pressing the belt against the pressing roller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] First we explain a fixing device in accordance with this invention and an image forming apparatus which is equipped therewith.
[0026] It is to be understood that the description of embodiments below is not intended to limit the technical range of this invention by terms in the description.
[0027] FIG. 1 is a schematic vertical sectional view of the whole image forming apparatus.
[0028] In FIG. 1 , the major components are a photosensitive member 10 , a Scorotron charger 11 as a charging means, an image writer 12 as an image writing means, a developer 13 as a developing means, a cleaning device 14 for cleaning the surface of the photosensitive member 10 , a cleaning blade 15 , a developing sleeve 16 and an intermediate transfer belt 20 . The image forming apparatus 1 consists of the photosensitive member 10 , the Scorotron charger 11 , the developer 13 , the cleaning device 14 , and so on. The image forming means 1 of four colors (yellow Y, magenta M, cyan C, and black K) are the same in mechanical configuration. So, in FIG. 1 , the reference characters are assigned only for the configuration of the yellow image forming means as the representative.
[0029] The image forming means 1 of four colors (yellow Y, magenta M, cyan C, and black K) are provided in that order of Y, M, C, and K along the movement of the intermediate transfer belt 20 . The photosensitive members 10 are respectively in contact with the tensioned surface of the intermediate transfer belt 20 and rotate there in the same direction as the movement of the intermediate transfer belt 20 at the same line speed.
[0030] The intermediate transfer belt 20 are supported and tensioned by a driving roller 21 , a grounding roller 22 , a tension roller 23 , a neutralization roller 27 , and a driven roller 24 . A belt unit 3 consists of these rollers, the intermediate transfer belt 20 , a transfer device 25 , and a cleaning device 28 .
[0031] The intermediate transfer belt 20 is driven by the rotation of a driving roller 21 by a driving motor (which is not shown in the figure).
[0032] The photosensitive member 10 is made of a cylindrical metallic base such as an aluminum cylinder which has a photoconductive layer such as an electroconductive layer, a-Si layer or an organic photosensitive layer (OPC) on its circumferential surface and rotates counterclockwise (in the arrow direction of FIG. 1 ) with the conductive layer. grounded.
[0033] An electric signal corresponding to the image data sent from an image reader 80 is converted into an optical signal by an image formation laser and the optical signal is projected to the photosensitive member 10 by the image writer 12 .
[0034] The developer 13 is equipped with a cylindrical non-magnetic stainless-steel or aluminum developing sleeve 16 which is at a preset space away from the circumference of the photosensitive member 10 and rotates in the same direction as the photosensitive member 10 at the most closest position.
[0035] The intermediate transfer belt 20 is an endless belt of a volume resistivity of 10 6 to 10 12 Ω·cm. It is a semi-conductive seamless belt of 0.015 to 0.05 mm thick prepared by dispersing a conductive material in engineering plastic such as modified polyimide, thermosetting polyimide, ethylene-tetrafluoro-ethylene copolymer, vinylidene polyfluoride, and nylon alloy.
[0036] The transfer device 25 has a function of transferring a toner image from the photosensitive member 10 onto the intermediate transfer belt 20 when receiving a d.c. current of a polarity opposite that of the toner. The transfer device 25 can be a corona discharger or a transfer roller.
[0037] The transfer roller 26 can move to touch or detach from the grounding roller 22 and transfer the toner image from the intermediate transfer belt 20 to a transfer sheet P.
[0038] The cleaning device 28 is provided opposite the driven roller 24 with the intermediate transfer belt 20 therebetween. After the intermediate transfer belt 20 transfers the toner image onto the transfer sheet P, the charge of toner left on the transfer belt 20 is weakened by the neutralization roller 27 which has an a.c. voltage superimposed with a d.c. voltage whose polarity is opposite the polarity of the toner. Then the toner on the surface of the transfer belt 20 is scraped away by the cleaning blade 29 . The fixing device 4 in accordance with this invention will be explained in detail below.
[0039] The other components are paper pickup rollers 70 , timing rollers 71 , paper cassettes 72 , paper feed rollers 73 , an operation panel 85 , and a controller B 1 as a control means.
[0040] Below will be explained the fixing device 4 in accordance with this invention.
[0041] FIG. 2 is an explanatory sectional view of the pressing member moving means.
[0042] In FIG. 2 , the heating roller 41 is a cylindrical aluminum mandrel 413 coated with an elastic heat resisting layer 412 and an outer separation layer 411 . The heating roller 41 is heated to a preset temperature by a halogen heater 46 as a heating source in the hollow part of the heating roller 41 . The temperature is detected by a non-contact temperature sensor 414 provided near the surface of the heating roller 41 and sent to the controller B 1 . The controller B 1 controls the surface temperature of the heating roller 41 to a preset temperature by turning on and off the halogen heater 46 .
[0043] The pressing belt 47 is a polyimide belt coated with a silicone rubber layer and a thin PFA resin layer. When a transfer sheet P having a toner image comes into the nip section which is a fixing area by means of the paper guides and the like, the pressing belt 47 and the pressing pad (pressing head) A 1 catch and press the transfer sheet P against the heating roller 41 to fix the toner image onto the transfer sheet P.
[0044] The pad moving mechanism 42 consists of a cylindrical pad supporting roller 420 , and pressing pads (A 1 , A 2 , A 3 , and A 4 ). The rigid pad supporting roller 420 made of a rigid material has a plurality of longitudinal grooves M to hold the pressing pads (pressing heads) (A 1 , A 2 , A 3 , and A 4 ).
[0045] At least one of the pressing pads (A 1 , A 2 , A 3 , and A 4 ) is different from the other pressing pads in hardness, heat capacitance, thickness or heat capacitance distribution along and perpendicular to the movement of the pressing belt.
[0046] The heat conductivity of the pad supporting roller 420 is preferably low. The pad supporting roller 420 is mounted on a rotary shaft 425 which is driven by a driving section (which is not shown in the figure).
[0047] By an instruction of the controller B 1 , the rotary shaft 425 is rotated a preset angle to move any of the pressing pads (A 1 to A 4 ) to the heating roller 41 , stopped and held at a preset position to press the heating roller 41 and form a nip section T.
[0048] Therefore, the nip sections T formed by respective pressing pads (A 1 to A 4 ) are different in pressure, nip length, and fixing condition.
[0049] Although this embodiment uses four pressing pads (A 1 to A 4 ), four or more pressing pads can be used.
[0050] Referring to FIG. 1 , still other components are guide plates G, a belt driving roller 43 , a tension roller 44 , a driven roller 45 , a halogen heater 46 , and ejection rollers 48 .
[0051] FIG. 3 shows details of the pressing pad.
[0052] In FIG. 3 ( a ), the pressing pad (A 1 to A 4 ) is an elastic silicone rubber member 422 coated with Teflon®-related sliding sheet 423 .
[0053] At least one of the pressing pads (A 1 to A 4 ) is different from the other pressing pads in hardness, heat capacitance, thickness “t” along the movement of the transfer sheet, thickness “h” perpendicular to the movement of the transfer sheet, distribution of thickness “h” perpendicular to the movement of the transfer sheet, distribution of heat capacitance perpendicular to the movement of the transfer sheet, and distribution of hardness perpendicular to the movement of the transfer sheet.
[0054] The base of the elastic member 422 is low heat conduction silicone rubber of a heat conductivity of 0.05 to 0.25 W/m·k and coated with a sliding sheet 423 made from Teflon®-related plastic resin (PTFE, etc.) to reduce the friction between the pressing belt 47 and the elastic member.
[0055] As shown in FIG. 3 ( b ), it is possible to make the pressing pads (A 1 to A 4 ) thicker in the center “h” (than the ends). Further as shown in FIG. 3 ( c ), it is possible to divide the pressing pad in one groove into a plurality of pieces (1 to n), make the pieces 422 higher in hardness towards the center of the groove (or lower towards the outer ends of the pad). Furthermore as shown in FIG. 3 ( c ), it is possible to divide the pressing pad in one groove into a plurality of pieces (1 to n), make the pieces 422 lower in heat conductivity towards the center of the groove (or higher towards the outer ends of the pad). Still further, as shown in FIG. 3 ( d ), it is possible to curve the groove M and make the pressing pad thicker in the center “h” (or lower in the ends).
[0056] The pressing pads (A 1 to A 4 ) of these different configurations are respectively bonded to the grooves, selected and moved under a selected condition (size, type, brand, thickness, basis weight, smoothness, glossiness, and stiffness of the transfer sheet to be printed) when the condition is preset on the operation section.
[0057] When a condition (size, thickness, basis weight, smoothness, and glossiness of the transfer sheet) is detected before image transferring and the result of detection is sent to the control section B 1 in advance, a pressing pad satisfying the condition is selected.
[0058] Further, when an environmental temperature or humidity of the image forming apparatus and the temperature or water content of the transfer sheet is detected and the result of detection is sent to the control section B 1 in advance, a pressing pad satisfying the condition is selected.
[0059] The optimum fixing is enabled by the nip section T formed by the selected pressing pad (A 1 to A 4 ) and the heating roller 41 .
[0060] A program created by experimental data is used to select a pressing pad that satisfies a condition (size, quality, brand, thickness, basis weight, smoothness, glossiness, stiffness, environmental temperature or humidity, and temperature or water content of the transfer sheet). The program is stored in the control section B 1 .
[0061] FIG. 4 shows an example of a detecting means that detects a condition related to the transfer sheet before transferring.
[0062] FIG. 4 ( a ) is a detecting means that measures the thickness of the transfer sheet P. In FIG. 4 ( a ), the ends of the roller 74 a are supported by bearings provided on the frame which is not shown in the figure. The roller 74 b is a displacement roller which is supported by bearings to move perpendicularly to the movement of the transfer sheet. The sensor S 1 is a displacement detection sensor such as an ultrasonic sensor S 1 .
[0063] When the transfer sheet P is clamped and carried by the rollers ( 74 a and 74 b ), the roller 74 b moves from the dotted-line position to the solid-line position by the thickness “e” of the transfer sheet P. The displacement sensor S 1 detects this displacement and sends the displacement information to the control section B 1 . The control section B 1 selects a pressing pad fit for the thickness.
[0064] FIG. 4 ( b ) shows a detector that measures the smoothness and the glossiness of the transfer sheet P. In FIG. 4 ( b ), the sensor S 2 detects the quantity of light reflected on the transfer sheet P to measure the roughness and glossiness of the surface of the transfer sheet, and sends its information to the control section B 1 . The control section B 1 selects a pressing pad fit for the roughness and glossiness.
[0065] FIG. 4 ( c ) shows a detector that measures the stiffness of the transfer sheet P. In FIG. 4 ( c ), a pair of rollers 75 in the delivery path transfer the transfer sheet P. The sensor S 3 for detecting the quantity of light reflected on the transfer sheet is provided a preset distance “f” from the delivery roller pair 75 .
[0066] The transfer sheet P is clamped and carried by the delivery roller pair 75 and its leading edge is detected.
[0067] The sheet P warps much if the stiffness of the transfer sheet P is low or small if the stiffness of the transfer sheet P is high. The quantity of light that the sensor S 3 receives is dependent upon the magnitude of this warp. The sensor S 3 detects the stiffness of the transfer sheet from the relationship between the light quantity and the warp magnitude and sends the result of detection to the control section B 1 . The control section B 1 selects a pressing pad fit for the stiffness.
[0068] FIG. 4 ( d ) shows a detector for measuring the water content of the transfer sheet. In FIG. 4 ( d ), the roller pair 77 is a pair of conductive delivery rollers to clamp and carry the transfer sheet. As a voltage E is applied to this roller pair 77 , the resistance between the rollers (equivalent to the paper resistance) becomes low and the current A becomes greater when the water content of the transfer sheet is high. Contrarily, when the water content of the transfer sheet is low, the resistance becomes high and the current A becomes lower. The information of this current A is sent to the control section B 1 , and the control section B 1 selects a pressing pad fit for the water content.
[0069] Additionally, a sensor for detecting the environmental temperature or humidity of the image forming apparatus is provided inside near the casing of the image forming apparatus and a sensor for detecting the temperature of the transfer sheet is provided in the paper feed section. Their information is sent to the control section B 1 and used to select an optimum pressing pad. The casing of the image forming apparatus has apertures (narrow enough to prevent invasion of fingers) near the sensor for detecting the environmental temperature or humidity of the image forming apparatus.
[0070] The transfer sheet sizes can be automatically detected by a well-known means in a paper cassette 72 .
[0071] FIG. 5 shows part of an operation panel provided on the top of the image forming apparatus.
[0072] The operation panel has a paper property selection field.
[0073] FIG. 5 ( a ) shows a list of paper property items to be selected.
[0074] FIG. 5 ( b ) shows an example of paper property items.
[0075] As already explained, paper properties can be detected and selected by sensors provided in the paper feed and delivery paths. Further there has been a method of enabling the operator to enter paper properties and controlling selection of an optimum pressing pad. This method will be explained in detail below.
[0076] In FIG. 5 , the operation panel 85 has a paper property selection field 851 which is a means to set paper properties.
[0077] When the operator sets any paper properties (size, type, brand, thickness, basis weight, smoothness, and glossiness of the transfer sheet) on the paper property selection field 851 , the control section B 1 selects a pressing pad that satisfies the preset condition.
[0078] Although the above embodiment uses a roller as a body of rotation that is in contact with unfixed toner and a belt as another body of rotation that is in contact with the backside of the transfer sheet, the configuration of FIG. 6 can attain the effect of this invention.
[0079] FIG. 6 shows a mechanism that places the pressing means inside the heating belt and pressing the belt against the pressing roller.
[0080] The fixing method of FIG. 6 uses a heating roller 41 A, a belt driving roller 43 , a tension roller 45 , heats the heating belt 47 A, presses the transfer sheet P with a toner image against the heating roller by the pressing means 43 A and heats the transfer sheet. Two halogen heaters ( 46 A and 46 B) are controlled individually to turn on and off by the control section B 1 according to the outputs of the temperature sensors ( 415 and 414 ). The belt heating roller 41 A is made of a cylindrical aluminum mandrel coated with fluorine resin or the like. Its configuration is basically the same as that of FIG. 2 and its explanation is omitted.
[0081] A program that enables the operator to enter property values (thickness, basis weight, smoothness, glossiness, and so on) is stored in the control section B 1 . By entering values using the ten-key pad 852 (see FIG. 5 ), the operator can select a pressing pad fit for the preset condition. | A fixing section for use in an image forming apparatus, is provided with a heating member, a pressing member in which the heating member and the pressing member are arranged to form a nipping section therebetween and a belt member inserted through the nipping section and for fixing the toner image on the recording sheet by conveying the recording sheet through the nipping section; and a control section for obtaining recording sheet information regarding at least characteristics and a size and for controlling the fixing section. The pressing member comprises plural pressing heads differing in at least one of a physical characteristics and a shape from each others and the control section select one head of the plural pressing heads in accordance with the recording sheet information and control the fixing section to press the recording sheet through the belt member with the selected one head. | 6 |
RELATED APPLICATIONS
This application claims priority under 35 U.S.C. § 371 from PCT Application No. PCT/GB00/04760, filed in English on Dec. 13, 2000, which claims the benefit of Great Britain Application Serial No. 9929353.2 filed on Dec. 13, 1999, the disclosures of which are incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
This invention relates to methods for the synthesis of metallocenes.
BACKGROUND OF THE INVENTION
Amino-functionalised titanocenes are of increasing interest because of their potential to act as highly active and selective olefin polymerisation catalyst precursors [1,2,3,4]. The neutral amino function can reversibly co-ordinate to the metal centre, potentially stabilising highly reactive intermediates formed during homogeneous catalytic processors. High catalytic activity has been found with group IV metallocenes as well as with metallocenes involving other metals. For instance, half-sandwich complexes of chromium in which the pendant amino function is co-ordinated to the metal centre have been shown to be highly active olefin polymerisation catalysts [5]. Furthermore, the pendant amino function can interact with inorganic support materials, thereby incorporating traditional metallocene catalysts into heterogeneous catalysts.
Quaternisation of the pendant amino group can result in water stable and soluble species [1,2,4]. Such species may not only provide water soluble catalytic compounds but are also useful as anti-tumour drugs having advantages over the known anti-tumour drug titanocene dichloride. Although titanocene dichloride is an efficient anti tumour agent [6,7], it has low solubility and is unstable in aqueous solution. The greater stability and solubility of amino-functionalised titanocenes renders these materials, and their dihydrochloride derivatives, potentially more suitable as anti-tumour agents as well as providing more suitable models for studying the mechanism of action of titanocene dichloride as an anti tumour agent
Known synthetic methods for the preparation of the dihydrochloride salts of amino-functionalised titanocenes involve the deprotonation of the neutral cyclopentadiene to give lithium, sodium or thallium salts [2,3,4]. In situ deprotonation can be achieved by the addition of an external base [8]. The reaction of the metal salt with TiCl 4 results from the formation of the neutral metallocene which is then reacted with HCl to give the dihydrochloride salt Accordingly such a process involves 3 steps from the cyclopentadiene to the dihydrochloride salt. There is a need for an improved process involving fewer steps and producing the dihydrochloride salt in relatively high yield.
STATEMENTS OF INVENTION
According to the present invention there is provided a method for the preparation of a metallocene halide salt having at least one cyclopentadiene group substituted by a basic group, said method comprising reacting together a metal halide with a cyclopentadiene substituted by said basic group.
Accordingly the present invention provides a single step process for the preparation of an amino-functionalised metallocene which can be produced in high yield. It is believed that this single step process is possible because the method utilises the presence of an “internal base” rather than by making use of an external base in the known 3 step process.
The method of the present invention may be applied to the preparation of metallocenes of both early and late transition metals including the group IV metals Ti, Zr and Hf.
Preferably the metal halide is a homoleptic halide, more preferably a homoleptic chloride, an example being TiCl 4 .
Preferably the substituted cyclopentadienyl carries a pendant Lewis base. More preferably the Lewis base is provided by an amino group, for instance, a tertiary amino group, examples being —CH 2 CH 2 N(CHCH 3 ) 2 and —CH 2 CH 2 N(CH 2 ) 5 .
Preferably the cyclopentadienyl is contacted with the metal halide in the presence of an inert solvent such as toluene.
Preferably the substituted cyclopentadiene and the metal halide are reacted together at ambient temperature or below. One reactant may be added to the other in a dropwise fashion. The addition may be carried out more quickly the lower the temperature.
The metallocene halide salt prepared by the method of the present invention may be converted to the neutral metallocene by contacting the salt with a base. Furthermore the metallocene halide salt may be converted to other species. For example, contacting the metallocene halide salt with an alkylating agent results in the formation of an alkyl substituted metallocene.
The method of the present invention represents a new and facile route to metallocene halide salts in high yield. The method is therefore highly advantageous over the known three steps synthetic routes.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described in greater detail and with reference to FIGS. 1 and 2 of the accompanying drawings which illustrate the synthetic routes which will be described.
By way of example, FIG. 1 illustrates the known synthetic route and the method of the present invention for the preparation of an amino-functionalised titanocene; the method of the invention is shown as step (v).
The titanocene dihydrochloride salt 2 can be synthesised either by direct reaction of two equivalents of the neutral cyclopentadiene 1 and TiCl 4 in toluene or by reaction of the sodium salt 3 with TiCl 4 followed by reaction with HCl. The substituted cyclopentadiene 1 can be synthesised as previously described by Herrmann and co-workers [9]. The dihydrochloride salt is isolated as a dark orange solid which is soluble in a polar solvent such as methanol, water and acetonitrile.
The neutral titanocene 4 can be obtained by reaction of the dihydrochloride 2 with two equivalents of MeLi and by reaction by the sodium salt 3 with T Cl 4 in ether. The highly air and moisture sensitive titanocene 4 can be isolated as a crystalline, deep orange solid and is soluble in aprotic, polar and non-polar solvents such as ether and toluene. An analytically pure sample can be obtained by recrystallisation from ether.
Reaction of the dihydrochloride 2 with four equivalents of MeLi results in the formation of the thermally stable dimethylated species 5, as illustrated in FIG. 2 . Species 5 is a highly air sensitive red oil.
Accordingly the present invention provides a synthetic route for a titanocene dihydrochloride which is both air stable and water soluble and avoids a number of synthetic steps in which the reagents are air and water sensitive. The resultant “protected” titanocene can be stored indefinitely and the neutral titanocene can be generated by reaction with a base. Deprotonation can be carried out in situ by a cocatalyst such as MAO (methylalumunoxane) to give the neutral metallocene dichloride as the catalyst precursor. Furthermore, reaction with four equivalents of an alkylating agent generates the dialkyl substituted titanocene.
SPECIFIC EXAMPLES
Examples of the preparation of titanocene compounds will now be described.
Synthesis of (CpCH 2 CH 2 N(CH 2 ) 2 ) 2 )TiCl 2 (1)
Method 1: From NaCpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 and TiCl 4
1.37 g (0.0069 mol) of NaCpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 was added as a slurry in 100 ml of THF to 0.38 ml (0.66 g, 0.0034 mol) TiCl 4 in 75 ml of THF. On addition an orange colour developed in the toluene and a colourless precipitate formed. The reaction mixture was left to stir for 1 h after which the solvent was removed in vacuo. The product was extracted in 100 ml of toluene. Recrystallisation from toluene affords the product as dark orange crystals.
Method 2: From (CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 .2HCl
Two equivalents of MeLi (0.0018 mol, 1.26 ml, 1.4M solution in Et 2 O were added dropwise to a suspension 0.48 g of (CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 .2HCl (0.00088 mol) in 100 ml of toluene. The mixture was stirred for 2 h after which an orange colour had developed in the toluene. The solution was filtered and the solvent removed in vacuo. The residue was extracted in 50 ml of toluene and the solvent was removed in vacuo leaving 1 as a dark orange solid. 1 H NMR (C 6 D 6 ): δ 2.54 (t, 4H, CpCH 2 ), δ 2.07 (t, 4H, CpCH 2 CH 2 ), δ 2.3689 (m, 8H, N(CH 2 ) 2 ) δ 1.55 (m, 8H, N(CH 2 ) 2 (CH 2 ) 2 ), δ 1.37 (M, 4H, N(CH 2 ) 2 (CH 2 ) 2 (CH 2 ), 6.26, 5.89 (pt, 8H, CpH). 13 C NMR (C 6 D 6 ): δ 29.16 (CpCH 2 ), δ 59.6 (CpCH 2 CH 2 ), δ 55.10 (N(CH 2 ) 2 , δ 26.74 (N(CH 2 ) 2 (CH 2 ) 2 ), δ 25.16 (N(CH) 2 (CH 2 ) 2 (CH 2 ), δ 114.98, 123.31 (Cp ring C, δ 136.65 (Cp ring quaternary). Anal. Calcd for (CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 (449.32); C, 61.16; H, 7.70; N, 5.94. Found: C, 61.4; H, 7.85; N, 6.10.
Synthesis of (CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 .2HCl (2)
Method 1 (Illustrative of the Method of the Invention): from TiCl 4 and HCpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2
Two equivalents of freshly distilled HCp CH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 (3.0 g, 0.0169 mol) in toluene (50 ml) were added dropwise to a solution of TiCl 4 (1.6 g, 0.0085 mol) in toluene (150 ml) at −78° C. The solution was stirred for 30 minutes during which time a dark orange solid had precipitated. The mixture was warmed to room temperature and stirred for an additional 4 h. The toluene was removed in vacuo and the solid was washed with ether and dried in vacuo leaving 2 as a dark orange solid.
Yield=4.1 g, 89%.
Method 2: from (CpCH 2 CH 2 N(CH 2 )N(CH 2 ) 2 ) 2 TiCl 2 and HCl
To a solution of 0.10 g of 1 (in deuterated benzene in an NMR tube) was added an excess of HCl (40% solution. Immediately a dark orange solid precipitated. The benzene was removed in vacuo and the solid was dissolved in CD 3 N.
1 H NMR MeOD): 1 H NMR (C 6 D 6 ): δ 3.31 (t, 4H, CpCH 2 ), δ 3.45 (t, 4H, Cp CH 2 CH 2 ), δ 3.61, 3.00 (m, 8H, N (CH 2 ) 2 ) δ 1.95, 1.87 (m, 8H, N(CH 2 ) 2 (CH 2 ) 2 ), δ 1.54 (m, 4H, N(CH 2 ) 2 (CH 2 ) 2 CH 2 ), 6.72, 6.48 (pt, 8H, CpH). 13 C NMR (C 6 D 6 ): δ 26.43 (CpCH 2 ), δ 57.10 (CpCH 2 CH 2 ), δ 54.39 (N(CH 2 ) 2 ) δ 24.23 (N(CH 2 ) 2 (CH 2 ) 2 ), δ 22.64 (N(CH 2 ) 2 (CH 2 ) 2 CH 2 ), δ 124.64, 116.95 (Cp ring C), δ 133.33 (Cp ring quaternary). MS (FAB; m/z (relative intensity, %): 472 ([CpCH 2 CH 2 NH(CH 2 ) 2 (CH 2 ) 2 ) 2 )TiCl 2 ] + , 7.43).
Synthesis of (Cp(CH 2 ) 2 N(CH 2 ) 5 ) 2 TiMe 2 (3)
To a suspension of 2 in Et 2 O (0.5 g, 0.92 mmol, 50 ml Et 2 O) was added two equivalents of MeLi (1.4 M, 1.3 ml, 1.84 mmol) in Et 2 O with vigorous stirring. Evolution of a gas was immediately apparent. The mixture was left to stir at room temperature for 2 h, during which a deep orange solution had formed and a colourless solid precipitated. The Et 2 O was removed in vacuo and the product was extracted in toluene to leave the product as a dark red-brown oil.
Synthesis of [(Cp CH 2 CH 2 N(Me)(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 ] Cl − 2 (4)
Two equivalents (0.19 g, 0.0013 mol) of methyl iodide were added to 0.30 g (0.00067 mol) of CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 in 50 ml of toluene. The reaction mixture was stirred for 30 minutes after which a bright orange precipitate had formed and no colour remained in the toluene. The toluene was filtered from the product which was washed with diethyl ether to leave 4 as a powder red solid.
1 H NMR (MeOD): 1 H NMR (C 6 D6): δ 3.31 (t, 4H, CpCH 2 ), δ 3.45 (t, 4H, Cp CH 2 CH 2 ), δ 3.61, 3.00 (m, 8H, N (CH 2 ) 2 ) δ 1.95, 1.87 (m, 8H, N(CH 2 ) 2 (CH 2 ) 2 ), δ 1.54 (m, 4H, N(CH 2 ) 2 (CH 2 ) 2 CH 2 ), 6.72, 6.48 (pt, 8H, CpH). 13 C NMR (C 6 D 6 ): δ 26.43 (CpCH 2 ), δ 57.10 (CpCH 2 CH 2 ), δ 54.39 (N(CH 2 ) 2 ) δ 24.23 (N(CH 2 ) 2 (CH 2 ) 2 ), δ 22.64 (N(CH 2 ) 2 (CH 2 ) 2 CH 2 ), δ 124.64, 116.95 (Cp ring C), δ 133.33 (Cp ring quaternary). MS (FAB; m/z (relative intensity, %): 472 ([CpCH 2 CH 2 NH(CH 2 ) 2 (CH 2 ) 2 ) 2 )TiCl 2 ] + , 7.43).
Synthesis of (Cp(CH 2 ) 2 N(CH 2 ) 5 ) 2 TiMe 2 (3)
To a suspension of 2 in Et 2 O (0.5 g, 0.92 mmol, 50 ml Et 2 O) was added two equivalents of MeLi (1.4 M, 1.3 ml, 1.84 mmol) in Et 2 O with vigorous sting. Evolution of a gas was immediately apparent The mixture was left to stir at room temperature for 2 h, during which a deep orange solution had formed and a colourless solid precipitated. The Et 2 O was removed in vacuo and the product was extracted in toluene to leave the product as a dark red-brown oil.
Synthesis of [(Cp CH 2 CH 2 N(Me)(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 ]Cl − 2 (4)
Two equivalents (0.19 g, 0.0013 mol) of methyl iodide were added to 0.30 g (0.00067 mol) of CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 in 50 ml of toluene. The reaction mixture was stirred for 30 minutes after which a bright orange precipitate had formed and no colour remained in the toluene. The toluene was filtered from the product which was washed with diethyl ether to leave 4 as a powder red solid.
Synthesis of (CpCH(CH 2 ) 2 (CH 2 ) 2 NCH 3 ) 2 TiCl 2 (5)
Analogous to the preparation of (CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 , the sodium salt NaCpCH(CH 2 ) 2 (CH 2 ) 2 NCH 3 (0.73 g, 3.92 mmol in 50 ml of THF) was added to a solution of TiCl 4 (0.38 g, 1.96 mmol in 100 ml of THF). The mixture was stirred for 2 hours after which a brown precipitate had formed and the solution had turned a deep red colour. The solution was filtered and solvent removed under vacuum to leave a dark orange solid
Synthesis of (CpCH(CH 2 ) 2 (CH 2 ) 2 NCH 3 ) 2 TiCl 2 .2HCl (6)
Analogous to the preparation of (CpCH 2 CH 2 N(CH 2 ) 2 (CH 2 ) 2 ) 2 TiCl 2 .2HCl, the product can be synthesised by the direct reaction of NaCpCH(CH 2 ) 2 (CH) 2 NCH 3 and TiCl 4 in toluene and by reaction of (CpCH(CH 2 ) 2 (CH 2 ) 2 NCH 3 TiCl 2 with HCl.
Selected NMR Data
Chemical Shifts of
Cyclopentadienyl Protons
Compound
(δ, ppm)
Solvent
1
6.26, 5.88
C 6 D 6
2
6.68, 6.56
CD 3 CN
6.72, 6.48
CD 3 OD
6.57, 6.47
D 2 O
3
5.53, 5.87
C 6 D 6
4
6.75, 6.59
CD 3 CN
5
6.37, 6.25
CDCl 3
6
6.75, 6.70
CD 3 OD
References:
(1) Jutzi, P.; Redeker, T. Eur. J. Inorg. Chem . 1998, 663-674.
(2) Jutzi, P.; Redeker, T.; Neumann, B.; Stammler, H.-G. Organometallics 1996, 15, 4153-4161.
(3) Blais, M. S.; Chien, J. C. W.; Rausch, M. D. Organometallics 1998, 17, 3775-3783.
(4) Jutzi, P.; Kleimeier, J. J. Organomet. Chem . 1995, 486, 287-289.
(5) Jolly, P.; Ionas, K.; Verkovnic, G. P. I. German Parent 19630580 A1, 1998
(6) Kopf-Maier, P. In Complexes in Cancer Chemotherapy ; Keppler, B. K., Kd.; VCH: Weinheim, N.Y., 1993; pp 259.
(7) Toney, J. H.; Marks, T. J. J. Am. Chem. Soc . 1885, 107, 947-953.
(8) Sinnema, P.-J.; van der Veen, L.; Spek, A. L.; Veldman, N.; Tauben, J. H. Organometallics 1997, 16, 4245-4247.
(9) Herrmann, W. A., Morawietz, T. P.; Mashima, K. J. Organomet. Chem . 1995, 486, 291-295. | The invention provides a method for the preparation of a metallocene halide salt having at least one cyclopentadiene group substituted by a basic group, the method comprising reacting together a metal halide with a cyclopentadiene substituted by a basic group. In a preferred embodiment, the substituted cyclopentadiene is substituted with an amino group and the metal halide titanium tetrachloride. The invention provides a single step process for the preparation of metallocene derivatives which are useful in the formulation of medicaments and as polymerisation catalyst precursors. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to air entangled yarns and, in particular, to an apparatus and technique for combining natural and manmade spun yarns with continuous filament yarns and the products produced thereby.
2. Description of the Prior Art
It is well known that spun yarns formed from stable fibers may be used to produce fabrics having superior aesthetic properties such as a soft hand and a warmer appearance. However, spun yarns have limited stretchability and articles of apparel made from spun yarn alone must be made to closer tolerances in order to be comfortable to the wearer. This limitation is particularly troublesome in articles of apparel, such as men's hosiery, where it is desirable that only a limited number of sizes be produced in order to keep inventory costs low. Other yarn types are available, such as continuous multifilament stretch nylon, which possess the prerequisite stretchability. However, fabrics produced from these materials have generally not received wide consumer acceptance due to their poor "feel".
One way of producing a fabric which has the feel of spun yarns and the stretchability of continuous filament yarns has been by creating a composite yarn or fabric. A composite includes two or more yarns having complementary characteristics.
One method of producing a composite is plaiting. Plaiting involves knitting two different yarns in such a manner that one yarn becomes the face of the article and the other one the back of the article. Plated knit fabrics are particularly suitable for men's hosiery. A second method for producing a composite yarn is plying. Ply yarn is made by having two or more yarns that have been twisted together. Ply yarns may be equally wrapped about one another or one of the yarns may serve as the core and the other as an outer layer about the core. For example, core-spun sewing thread is made with a core of manmade filament yarn and covered with high quality cotton to give a strong thread with the surface and friction properties of cotton. Both of these processes are slow, high cost processes. For example, plaiting produces a large number of second quality goods due to mis-plaits when the inner yarn (for example, the nylon yarn) delivers unevenly and flips over to top. The resulting sock will be streaked after dying. In addition, ply yarns have a tendency to separate, thereby increasing the likelihood that one loop will be missed by the knitting machine and result in a defect.
On the other hand, yarns consisting of two or more continuous multifilament yarns have been produced by entangling the relative filaments about one another with jets of high velocity fluid. Samples of these yarns and the processes which produced them are shown in U.S. Pat. No. 3,940,917 issued to Strachan and U.S. Pat. No. 3,991,548 issued to Toronyi. However when continuous filament yarns and spun yarns have been combined, unstable or wild loops are formed.
One technique for eliminating these loose loops includes a process of continuously drawing the continuous filaments under controlled temperature conditions, air jet texturizing the drawn yarn, and then subjecting the textured yarn to saturated steam while restraining the yarn from shrinking during the steam treatment. An example of such a process is shown in U.S. Pat. No. 4,567,720 issued to Price. However, the process as taught by Price is directed to removing the unstable or wild loops which have already been formed in the air jet and requires a close control of the process temperatures.
As a result, air entangled continuous multifilament and spun yarns have been used primarily to produce a randomized novelty yarn which exhibit essentially no uniform characteristics. An example of such a process is shown in U.S. Pat. No. 4,212,152 issued to Roman. The Roman reference provides a particularly detailed discussion of the problems and processes for producing such novelty yarns.
It has thus become desirable to develop a process for producing a composite continuous multifilament and spun yarn which prevents the formation of unstable and wild loops which have previously plagued conventional fluid jet entangling apparatuses. The resulting yarn is suitable as a replacement for plied and plaited yarn and may be produced by a much faster process at lower costs, improved efficiency, and quality, thereby reducing the amount of second quality goods.
SUMMARY OF THE INVENTION
The present invention solves the aforementioned problems associated with the prior art by providing a technique and products thereof for producing a composite continuous multifilament and spun yarn which combines the characteristics of the spun and continuous multifilament yarns without creating unstable or wild loops as has been the case with the prior art devices. According to the present invention, the yarn ends of continuous multifilament and spun yarns are moved from the respective supply package under predetermined tensions. The two yarn ends are then passed through individual, separated yarn guides prior to entering the fluid jet. The individual yarn guides are spaced upstream from the fluid jet and with respect to one another. The distance between the individual yarn guides is adjustable. In the preferred embodiment, the spacing between the individual yarn guides is varied until the two yarn ends just merge as they enter the jet. A fluid within the jet is flowed in a direction perpendicular or slightly inclined with respect to the flow of the merged ends so as to effect intermingling along the length of the merged ends. The composite yarn exiting the fluid jet is collected on a conventional takeup package. The composite continuous multifilament and spun yarn produced according to the present invention is characterized by having the tactile and mechanical characteristics of ply yarn without the unstable or wild loops which are normally associated with conventional air jet processing.
Accordingly, one aspect of the present invention is to provide a process and apparatus for combining a continuous multifilament and spun yarn to produce a composite yarn that exhibits the complementary characteristics of continuous multifilament and spun yarns.
Another aspect of the present invention is to provide a composite yarn which is uniformly entangled along its length and which does not exhibit the unstable or wild loops which are formed by conventional air jet processing of continuous multifilament and spun yarns.
Still another aspect of the present invention is to produce a fabric from such a yarn which is particularly well-suited for articles of apparel requiring both comfort and stretchability.
These and other aspects of the present invention will be more clearly understood after a review of the following description of the preferred embodiment of the invention, when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of an apparatus for producing a composite yarn according to the present invention.
FIG. 2 is a photograph of a composite yarn comprised of 100 d/34 filament continuous multifilament stretch nylon and 20/1 spun polyester.
FIG. 3 is a photograph enlarging a segment of the yarn shown in FIG. 2 to a 10 x size.
FIG. 4 is a photograph of a composite yarn also comprised of 100 d/34 filament continuous multifilament stretch nylon and 20/1 spun polyester.
FIG. 5 is a photograph enlarging a segment of the yarn shown in FIG. 4 to a 10 x size.
FIG. 6 is a photograph of a composite yarn comprised of 74 d/34 filament continuous multifilament stretch nylon and 20/1 spun polyester.
FIG. 7 is a photograph enlarging a segment of the yarn shown in FIG. 6 to a 10 x size.
FIG. 8 is a photograph of a composite yarn comprised of 2 ply 70 d/34 filament continuous multifilament stretch nylon and 20/1 spun polyester.
FIG. 9 is a photograph enlarging a segment of the yarn shown in FIG. 8 to a 10 x size.
FIG. 10 is a photograph of a composite yarn comprised of 2 ply 70 d/34 filament continuous multifilament stretch nylon and 20/1 spun polyester.
FIG. 11 is a photograph enlarging a segment of the yarn shown in FIG. 10 to a 10 x size.
FIG. 12 is a photograph of a composite yarn comprised of 2 ply 70 d/34 filament continuous multifilament stretch nylon and 20/1 spun rayon.
FIG. 13 is a photograph enlarging a segment of the yarn shown in FIG. 12 to a 10 x size.
FIG. 14 is a photograph of a composite yarn comprised of 2 ply 70 d/34 filament continuous multifilament stretch nylon and 20/1 spun polyester.
FIG. 15 is a photograph enlarging a segment of the yarn shown in FIG. 14 to a 10 x size.
FIG. 16 is a photograph of a composite yarn comprised of 2 ply 70 d/34 filament continuous multifilament stretch nylon and 20/1 spun rayon.
FIG. 17 is a photograph enlarging a segment of the yarn shown in FIG. 16 to a 10 x size.
FIG. 18 is a photograph of a composite yarn comprised of 2 ply 70 d/34 filament continuous multifilament stretch nylon and 20/1 spun polyester.
FIG. 19 is a photograph enlarging a segment of the yarn shown in FIG. 18 to a 10 x size.
FIG. 20 is a photograph of a fabric knit from the composite yarn shown in FIGS. 18 and 19, enlarged to a 10 x size.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in general, and to FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing the preferred embodiment of the invention and are not intended to limit the invention hereto.
Turning now to FIG. 1, the preferred arrangement of the apparatus, generally designated 10, is shown. Yarn supply packages 12,14 supply continuous multifilament yarn and spun yarn, respectively. Conventional tensioning devices 16 are located adjacent to the yarn supply packages 12,14 for receiving yarn ends Y 1 and Y 2 and imparting a sufficient amount of resistance to allow controlled removal of the yarn ends. A yarn guide assembly, generally designated 18, is located downstream of the tensioning devices 16. The yarn guide assembly 18 includes a first yarn guide 20 for guiding yarn end Y 1 and a second yarn guide 22 for guiding yarn end Y 2 . Yarn guides 20,22 are movably mounted to a yarn guide support 26. In the preferred embodiment, the distance D between yarn guides 20,22 is preferably 1/2 to 11/2 inches. However, the distance D may be varied in order to ensure that the yarn ends Y 1 ,Y 2 are apart.
A fluid jet assembly, generally designated 30, is located downstream of the yarn guide assembly 18. In the preferred embodiment, the distance L is preferably five inches. Thus in the preferred embodiment, the included angle A is approximately 2-5 degrees.
The fluid jet assembly 30 includes an entrance port 32 for receiving the yarn ends Y 1 and Y 2 . Fluid jet assembly 30 also includes a fluid supply line 34 which is connected to the jet body 36 by means of adapter 42. Numerous types of interlacing jets can be used in the present process, however, in the preferred embodiment, a PS10 fluid jet manufactured by Petree & Stoudt, located in Greensboro, N.C. has produced the best results. While the PS10 is non-forwarding-type jet, it has been found that forwarding jets up to at least 10° forwarding angle can perform satisfactorily.
A third thread guide 44 is located downstream of the fluid jet assembly 30 for receiving the combined yarn ends Y 1+2 after it exits the assembly 30. The composite yarn Y 1+2 is then wound onto takeup package 46. Any of several types of textile yarn handling machines may be adapted to incorporate the present apparatus. However, one machine which is particularly well-suited is the Guidici Model TG4 texturing machine, manufactured by Davide Giudici & Figli S.N.C. located at Lecco (Como) Italy. When used for the present invention, the heated texturizing boxes normally associated with the texturizing machine are disabled.
It should be noted that the apparatus according to the present invention does not normally require any overfeed. However, a feedroll assembly (not shown) could be added downstream of the fluid jet assembly 30 to slightly overfeed the yarn to the takeup package 46 so that the density thereof can be varied depending on the type of yarn being produced as well as the type of yarn ends being combined.
The fluid jet assembly 30 is connected to a supply of compressed fluid, such as air, with the pressures of the air ranging between 30-50 psi. Maintaining the operating level of air pressure is important in achieving the proper combining effect. However, it may be varied depending upon the types of yarns combined. Samples of specific yarn combinations and process parameters are more fully described hereinafter in the description of FIGS. 2 through 19.
The takeup package 46 receives the composite yarn Y 1+2 at a speed of between 125 and 190 meters per minute with a preferred speed of approximately 125 meters per minute.
Various types of yarns can be used in the present invention including spun yarns having counts of 5 to 50/1 with fiber types including rayon, cotton, polyester, acrylics, wood and polyester cotton blends. Continuous multifilament yarns may include both nylon and polyester yarns with deniers ranging from 20 to 200 and either one or two ply or multiple ply.
A further understanding of the present invention can be had from consideration of the following examples corresponding to FIGS. 2 through 19 which are set forth to illustrate certain preferred embodiments.
The table shown below provides a summarized comparison of the visual appearance of FIGS. 2 through 19. Details concerning the various yarns being combined and the critical process and apparatus variables are set forth therein. In addition, critical product characteristics including stretch per yard, number of tacks per yard and the presence and size of slubs or loops are also summarized.
__________________________________________________________________________ Takeup Tension Between Feed Jet Jet Tack Stretch LoopFIGS.Yarns Speed Supply & Jet Geometry Geometry PSI per Yd Per Yd Slubs Size__________________________________________________________________________2-3 20/1 Spun Polyester 125-190 mpm 0-20 g Fed 0.08" est. 30 10 11/4" -- 2-3"100d/34 Filament TogetherStretch Nylon(S-Torque)4-5 20/1 Spun Polyester Same Same Same 0.08" est. 50 48 11/4" -- 1"100d/34 FilamentStretch Nylon(S-torque)6-7 20/1 Spun Polyester Same Same Same 0.08" est. 40 24 11/4" -- 2-3"74d/34 FilamentStretch Nylon(S-torque)8-9 20/1 Spun Rayon Same Same Same .062" 40 50 11/4" -- 1/2"2 ply 70d/ (10" For-34 Filament warding)Stretch Nylon10-1120/1 Spun Polyester Same Tension lower Same Same 50 70 11/4" Yes 1/4"2 ply 70d/ on spun34 FilamentStretch Nylon12-1320/1 Spun Rayon Same 0-20 g Fed Same 40 80 11/4" -- 1/4"2 ply 70d/ Separately34 FilamentStretch Nylon14-1520/1 Spun Polyester Same Same Same Same 40 80 11/4" -- 1/4"2 ply 70d/34 FilamentStretch Nylon16-1720/1 Spun Rayon Same Same Same .062" 40 80-85 11/4" -- <1/4"2 ply 70d/ (Non-for-34 Filament warding)Stretch Nylon18-1920/1 Spun Polyester Same Same Same Same 45 90 11/4" -- 02 ply 70d/34 FilamentStretch Nylon__________________________________________________________________________
Turning first to FIGS. 2 and 3, the composite yarn (Example 1) was produced from a 100 denier/34 filament stretch nylon (S-torque) 50 and a 20/1 spun polyesters. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 140 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 1, the feed geometry was configured such that the yarns were fed together prior to entering the fluid jet. The fluid jet geometry included an entrance orifice size of approximately 0.08 inches and an operational pressure of approximately 30 psi.
The tack frequency of the resulting yarn averaged approximately 10 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present, however, the loops size varied between 2-3 inches. This yarn would be unacceptable yarn for producing knitted stretch socks since the loop size is sufficiently large to cause defects to be produced when the needles miss one of the two loops.
The composite yarn in Example 1 exhibits areas where the two yarns cross over and are tacked together, such as shown at 52 in FIGS. 2 and 3. In addition, there are areas in this yarn in which loops 54 are formed, and other areas where the yarns exhibit a parallel relationship as at 56. There are still other spaces where the yarns appear to be plied together as at 58.
Turning next to FIGS. 4 and 5, the composite yarn (Example 2) also was produced from a 100 denier/34 filament stretch nylon (S-torque) 60 and a 20/1 spun polyester 61. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 2, the feed geometry also was configured such that the yarns were fed together prior to entering the fluid jet. The fluid jet geometry included an orifice size of approximately 0.08 inches and an operational pressure of approximately 30 psi.
The tack frequency of the resulting yarn averaged approximately 48 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present, however, the loop size was approximately 1 inch. This would be unacceptable yarn for producing knitted stretch socks since the loop size is still sufficiently large to cause defects to be produced when the needles miss one of the two loops.
The composite yarn in Example 2 exhibits areas where the two yarns cross over and are tacked together, such as shown at 62 in FIGS. 4 and 5. In addition, there are areas in this yarn in which loops 64 are formed, and other areas where the yarns exhibit a parallel relationship as at 66. There are still other spaces where the yarns appear to be plied together as at 68.
Turning next to FIGS. 6 and 7, the composite yarn (Example 3) was produced from a 70 denier/34 filament stretch nylon (S-torque) 70 and a 20/1 spun polyester 71. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 3, the feed geometry was configured such that the yarns were fed together prior to entering the fluid jet. The fluid jet geometry included an orifice size of approximately 0.08 inches and an operational pressure of approximately 40 psi. The tack frequency of the resulting yarn averaged only approximately 24 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present, however, the loops size varied between 2-3 inches. This would be unacceptable yarn for producing knitted stretch socks since the loop size is sufficiently large to cause defects to be produced when the needles miss one of the two loops.
The composite yarn in Example 3 exhibits areas where the two yarns cross over and are tacked together, such as shown at 72 in FIGS. 6 and 7. In addition, there are areas in this yarn in which loops 74 are formed, and other areas where the yarns exhibit a parallel relationship as at 76. There are still other spaces where the yarns appear to be plied together as at 78.
Turning now to FIGS. 8 and 9, the composite yarn (Example 4) was produced from a 2 ply 70 denier/34 filament stretch nylon 80 and a 20/1 spun rayon 81. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 4, the feed geometry was configured such that the yarns were fed together prior to entering the fluid jet. The fluid jet geometry included an orifice size of approximately 0.062 inches (10° forwarding) and an operational pressure of approximately 40 psi.
The tack frequency of the resulting yarn averaged approximately 50 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present and the loop size was approximately 1/2 inch. This would be a marginally acceptable yarn for producing knitted stretch socks since the loop size may still be sufficiently large to cause defects to be produced when the needles miss one of the two loops.
The composite yarn in Example 4 exhibits areas where the two yarns cross over and are tacked together, such as shown at 82 in FIGS. 8 and 9. In addition, there are areas in this yarn in which loops 84 are formed, and other areas where the yarns exhibit a parallel relationship as at 86. There are still other spaces where the yarns appear to be plied together as at 88.
Turning next to FIGS. 10 and 11, the composite yarn (Example 5) was produced from a 2 ply 70 denier/34 filament stretch nylon 90 and a 20/1 spun polyester 91. The takeup speed varied between 125-190 meters per minute with a preferred speed of approxi-mately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. However, the tension on the spun yarn was lower. In Example 5, the feed geometry was configured such that the yarns were fed together prior to entering the fluid jet. The fluid jet geometry included an orifice size of approximately 0.062 inches and an operational pressure of approximately 50 psi.
The tack frequency of the resulting yarn averaged approximately 70 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. Slubs 95 were present, however, while numerous, the loop size was only about 1/4 inch. This would be unacceptable yarn for producing knitted stretch socks since loops size are sufficiently large to cause defects to be produced when the needles miss one of the two loops. However, it could be useful as a novelty yarn.
The composite yarn in Example 5 exhibits areas where the two yarns cross over and are tacked together, such as shown at 92 in FIGS. 10 and 11. In addition, there are areas in this yarn in which loops 94 are formed, and other areas where the yarns exhibit a parallel relationship as at 96. There are still other spaces where the yarns appear to be plied together as at 8.
Turning now to FIGS. 12 and 13, the composite yarn (Example 6) was produced from a 2 ply 70 denier/34 filament stretch nylon 100 and a 20/1 spun rayon 101. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 6, the feed geometry was configured such that the yarns were fed separately prior to entering the fluid jet. The fluid jet geometry included an orifice size of approximately 0.062 inches and operational pressure of approximately 40 psi.
The tack frequency of the resulting yarn averaged approximately 80 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present and the loop size was about 1/4 inch. This would be an acceptable yarn for producing knitted stretch socks since the loop size is sufficiently small to prevent defects produced when the needles miss one of the two loops.
The composite yarn in Example 6 exhibits areas where the two yarns cross over and are tacked together, such as shown at 102 in FIGS. 12 and 13. In addition, there are areas in this yarn in which loops 104 are formed, and a small number of other areas where the yarns exhibit a parallel relationship as at 106. There are still other spaces where the yarns appear to be plied together as at 108.
Turning next to FIGS. 14 and 15, the composite yarn (Example 7) was produced from a 2 ply 70 denier/34 filament stretch nylon 110 and a 20/1 spun polyester. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 7, the feed geometry was configured such that the yarns were fed separately prior to entering the fluid jet. The fluid jet geometry included an orifice size of approximately 0.062 inches and an operational pressure of approximately 40 psi.
The tack frequency of the resulting yarn averaged approximately 80 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present and the loop size was about 1/4 inch. This would be an acceptable yarn for producing knitted stretch socks since the loop size is sufficiently small to prevent defects.
The composite yarn in Example 7 exhibits areas where the two yarns cross over and are tacked together, such as shown at 112 in FIGS. 14 and 15. In addition, there are areas in this yarn in which loops 114 are formed, and a small number of other areas where the yarns exhibit a parallel relationship as at 116. There are still other spaces where the yarns appear to be plied together as at 118.
Turning now to FIGS. 16 and 17, the composite yarn (Example 8) was produced from a 2 ply 70 denier/34 filament stretch nylon 120 and a 20/1 spun rayon 121. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 8, the feed geometry also was configured such that the yarns were fed separately prior to entering the fluid jet. The fluid jet geometry included an orifice size of approximately 0.062 inches and an operational pressure of approximately 40 psi.
The tack frequency of the resulting yarn averaged approximately 80-85 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present and the loop size was less than 1/4 inch. This would be a more acceptable yarn than Examples 6 and 7 for producing knitted stretch socks since the loop size is more than small enough to prevent defects produced when the needles miss one of the two loops.
The composite yarn in Example 8 exhibits areas where the two yarns cross over and are tacked together, such as shown at 122 in FIGS. 16 and 17. In addition, there are areas in this yarn in which loops 124 are formed, and other areas where the yarns exhibit a parallel relationship as at 126. There are still other spaces where the yarns appear to be plied together as at 128.
Turning finally to FIGS. 18 and 19, the composite yarn (Example 9) was produced from a 2 ply 70 denier/34 filament stretch nylon 130 and a 20/1 spun polyester 131. The takeup speed varied between 125-190 meters per minute with a preferred speed of approximately 125 meters per minute. The tension between the yarn supplies and the fluid jet varied between 0-20 grams. In Example 9, the feed geometry also was configured such that the yarns were fed separately prior to entering the fluid jet. The fluid jet geometry also included an orifice size of approximately 0.062 inches (non-forwarding) and the operational pressure was increased slightly to approximately 45 psi.
The tack frequency of the resulting yarn averaged approximately 90 tacks per yard. The stretch per yard of the yarns was approximately 11/4 inches. No slubs were present and the loop size appeared to be zero to the naked eye. This is the most acceptable yarn for producing knitted stretch socks since the loops are practically non-existent.
The composite yarn in Example 9 exhibits areas where the two yarns cross over and are tacked together, such as shown at 132 in FIGS. 18 and 19. In addition, there are areas in this yarn in which loops 134 are formed, and other areas where the yarns exhibit a parallel relationship as at 136. There are still other spaces where the yarns appear to be plied together as at 138.
FIG. 20 is a photograph of a piece of fabric knit from a composite yarn comprised of a spun polyester yarn and a stretch nylon similar to Example 9 and described in FIGS. 18 and 19 above. The fabric shown in FIG. 20 demonstrates that a knit fabric knit from a yarn produced according to the present invention results in the formation of the fabric that has generally uniform surface characteristics therein.
Certain modifications and improvements would occur to those skilled in the art in reading of the foregoing description. By way of example, yarn sizes could be varied beyond the limits specified and various other fibers, such as acrylics, could be used and still produce the above described effect. Furthermore, changes, such as takeup speed and tension, may also require changes in the jet geometry and air pressure which would be within the ordinary skill in the art. It should be understood that all such modifications and improvements have been deleted herein for the sake of preciseness and readability but are probably within the scope of the following claims. | A technique for combining at least two unlike yarn ends to produce a composite yarn. One of the two unlike yarn ends is a spun yarn and the other of the two unlike yarn ends is a continuous multifilament yarn. The technique includes removing each of the two yarn ends from respective supply packages under predetermined tensions. The yarn ends are separated to maintain a predetermined included angle between the yarn ends. The separated yarn ends are then fed through an entangling jet to combine the yarn ends and collected on a take-up package. In the preferred embodiment, the included angle between the yarn ends varies between 3 and 17 degrees. The resulting air entangled yarn has an average number of 80 tacks per yard and an average loop size of 174 inch or less. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention in the field of biology provides a novel method and culture system for long term culture of functional hepatocytes by first preparing hepatocyte spheroids and inoculating these into a specialized bioreactor that is a rotating wall vessel wherein the cells are cultured under conditions that promote three-dimensional aggregation and cellular differentiation.
[0003] 2. Description of the Background Art
[0004] Hepatocyte Spheroids
[0005] Landry, J. et al., J. Cell Biol. 101: 914-923 (1985) described the spontaneous formation of spheroidal aggregates when primary rat liver cells were incubated on a nonadherent plastic dish. Three distinct cell morphologies were noted: surface monolayer cells; hepatocytes grouped as islands with deposition of extracellular matrix components; and structures resembling bile ducts. Tong, J Z, et al., Exp. Cell Res. 189:87-92 (1990), studied multicellular spheroids formed from newborn rat liver cells and detected secretion of liver proteins, specifically albumin and transferrin, for up to 60 days when the culture medium was supplemented with dexamethasone, glucagon, insulin, and epidermal growth factor. These investigators (Tong, J Z, et al., Exp. Cell Res. 200:326-332 (1992)) also observed maintenance of liver-specific functions in spheroid cultures of adult rat hepatocytes, demonstrating metabolism of lidocaine by the cytochrome P450 (CYP) enzyme 3A2, for up to 14 days. CYP 1A1 was strongly induced by methylcholanthrene, remaining constant for up to 22 days.
[0006] Interestingly, the presence of serum factors inhibited spheroid formation under certain conditions (Koide, N. et al., Exp. Cell Res. 186:227-235 (1990)).
[0007] One of the present inventors and his colleagues (A. P. Li et al., In Vitro Cell. Dev. Biol. 28A:673-677 (1992a)) was the first to report spheroid formation by human hepatocytes. Their simple, yet proven, method involved seeding 5×10 6 hepatocytes in culture medium on a 100-mm plastic dish and shaking at 50 rpm overnight. This method caused 90% of the cells to aggregate in the form of spheroids, which were shown to possess many of the morphological characteristics of intact liver.
[0008] U.S. Pat. No. 5,624,839 disclosed that lipid-bound glycosaminoglycan promoted spheroid formation.
[0009] Cytochrome P450s (CYPs)
[0010] CYPs are a family of enzymes, localized to the cytoplasmic side of the endoplasmic reticulum of the liver cell, that catalyze the oxidation of organic compounds, resulting in increased water solubility which promotes excretion from the cell. CYPs are obviously important for processing xenobiotics. Table 2 lists a number of CYP enzymes in rat liver that are responsible for metabolism (and detoxification) of a number of drugs.
[0011] Once hepatocytes are isolated from the liver and are grown in conventional primary cultures, the activity of these important enzymes is rapidly lost. This loss is particularly prominent for rat hepatocytes which lose 80% of their CYP activity in the first 24 hours of culture (Paine, A J, In: Berry, M N et al. (eds.), The Hepatocyte Review , Kluwer Academic Publishers, Netherlands, pp. 411-420, 2000).
[0012] Rotating Wall Culture Vessels
[0013] Rotating wall vessels or RWVs area class of bioreactors developed by and for NASA beginning in about 1990 that were designed to grow suspension cultures of animal cells in a quiescent environment that simulates microgravity. RWVs were first described in a number of U.S. patents (U.S. Pat. Nos. 5,026,650; 5,153,131; 5,153,133) assigned to NASA, and thereafter in several additional patents (U.S. Pat. Nos. 5,437,998; 5,665,594; 5,702,941) assigned to Synthecon, Inc., who served as a contractor and licensee of NASA Other patents describe the same principle as the RWV, i.e., horizontal rotation for mixing or suspending cells in culture medium. With the exception of Ingram et al. (U.S. Pat. No. 5,523,228), however, these patents do not disclose the culture of freely suspended cells. For example, in Rhodes et al. (U.S. Pat. No. 5,104,802), cells are confined inside a hollow fiber rotating with the culture vessel. U.S. Pat. No. 6,117,674 described a process for propagating a pathogen in a three-dimensional tissue mass in RWV culture. The foregoing patents are all incorporated by reference in their entirety.
[0014] During operation, an RWV is completely filled with medium and rotates about a horizontal axis. Oxygenation occurs in a bubble-free manner via a silicone rubber membrane that covers the back wall of the cultivation chamber. Cells are evenly distributed and semi-buoyant during cultivation, and mixing is accomplished without stirring by end-over-end rotation of the vessel (Schwarz, R P, et al., J. Tiss. Cult. Meth. 14:51-58, 1992; Cowger, N L, et al., Biotechno. Bioeng. 64:14-26, 1999).
[0015] RWVs have proven beneficial to the cultivation of many cell types for tissue engineering applications. Unlike conventional vessels, a RWV accommodates three-dimensional (3D) assembly and co-location of dissimilar cell types in a gently mixed environment. The result is more extensive 3D growth with increased cell-cell and cell-matrix interactions and cellular differentiation that more closely resembles organized living tissue (Spaulding, G F, et al., J. Cell. Biochem. 51:249-251, 1993). These properties of RWVs have been exploited to grow and study primary cells from various normal tissues (Goodwin, T J, et al., Proc. Soc. Exp. Biol. Med. 202:181-192, 1993; Freed, I. F. et al., In Vitro Cell. Dev. Biol. 33:381-385, 1997) and cells from tumors. For example, aggregates of human prostate tumor cells were more differentiated in terms of their growth, morphology, and cytoskeletal protein expression when cultured in a RWV compared to “control” tumor cells grown in conventional spinner flasks or static cultures (Clejan, S. et al., Biotechnol. Bioeng. 50:587-597, 1996). Khaoustov, V I, et al., In Vitro Cell. Dev. Biol. 35:501-509. 1999) described the culture of human hepatocytes in an RWV, primarily providing morphological descriptions, though this document disclosed continuous albumin secretion and urea nitrogen production over a period of 20 days.
[0016] Of the existing patent disclosures describing functional hepatocytes in vitro, with utility as “artificial livers,” none describe or suggest the use of freely suspended cells in a rotating bioreactor. For example, Li et al. (U.S. Pat. No. 5,270,192) disclosed a hepatocyte bioreactor in which hepatocytes or aggregates are entrapped inside a matrix of glass beads. In connection with hepatocyte spheroid formation, U.S. Pat. No. 5,624,839 (noted above) disclosed a composition that promoted this process.
[0017] Citation of the above documents is not intended as an admission that any of the foregoing is pertinent prior art. All statements as to the date or representation as to the contents of these documents is based on the information available to the applicant and does not constitute any admission as to the correctness of the dates or contents of these documents.
SUMMARY OF THE INVENTION
[0018] The present invention is directed to the use of a rotating wall vessel (RWV) for the cultivation of hepatocytes in the form of spheroids to generate cultures that maintain many important properties of intact liver. These properties include long-term viability and maintenance of cellular function for periods on the order of months, and enzyme activities comparable to fresh cells. The type of RWV in the present invention is termed a High Aspect Ratio Vessel (“HARV”) which is depicted in the patent cited above and in other related publications. See also, Cowger and O'Connor, 1997, “Application of simulated microgravity to insect-cell culture,” In: Maramorosch, K et al. (eds), Invertebrate Cell Culture, Novel Directions and Biotechnology Applications , Science Publishers, Enfield, N.H., p. 131-138, hereby incorporated by reference.
[0019] The present invention is directed to a method for cultivation of mammalian hepatocytes in a viable functional state for a prolonged period, preferably at least about 7-0.30 days, which comprises the steps of:
(a) culturing a single cell suspension of mammalian hepatocytes for a period of between about 12 and about 168 hours, preferably between about 24 and 72 hours in a flat surface-containing culture vessel under conditions that permit aggregation of hepatocytes into spheroids comprising viable cells; (b) obtaining the spheroids and introducing them into a rotating wall vessel culture chamber where the spheroids remain in suspension during subsequent culture with rotation; (c) incubating the vessels under conditions of rotation such that the spheroids remain in suspension and the hepatocytes remain viable and capable of metabolizing drugs or toxins via enzymes of the cytochrome P450 system, which drugs or toxins are ones that are normally metabolized by hepatocytes in vivo.
[0023] Pre-aggregation may be performed in any culture vessel where adherence to the vessel surface is inhibited or discouraged. Vessels coated with materials such as polymethacrylate or poly-L-lysine that inhibit electrostatic or other interactions that cause cells to adhere may be used. Any form of stirring or mixing, including conventional spinner cultures, may be used at this stage, as long as the conditions promote aggregation and spheroid formation.
[0024] The source of primary hepatocytes may be any of a number of mammalian species, preferably human, but also rat, mouse, pig, rabbit, or nonhuman primate.
[0025] The methods disclosed herein for culture and testing of hepatocytes, can also be used with other cell types, particularly cells that do not thrive or function adequately-without pre-attachment to other cells or to solid supports. Such cells include primary mammalian cells that do not originate in the liver, and various types of stem or progenitor cells.
[0026] The culture medium in the present invention can be any basal medium, or combination thereof, that supports hepatocyte viability, including Waymouth MB 752/1; Williams' Medium E; Eagle's MEM; Dulbecco's MEM/Ham's F12; RPMI 1640; or Leibovitz L-15. Preferably, the medium contains supplements, that help maintain hepatocyte morphology and differentiated function. These supplements can be conveniently categorized as: (1) growth factors, such as epidermal growth factor (EGF); (2) hormones, preferably peptide hormones such as insulin and glucagon; and (3) glucocorticoids, such as dexamethasone and hydrocortisone.
[0027] Any of the known RWVs can be used herein, although a preferred RWV is a HARV.
[0028] In another embodiment, this invention provides a method for evaluating the metabolism of an agent that is metabolized by mammalian liver cells in vivo, comprising
(a) culturing mammalian hepatocytes as described above; (b) adding the agent being evaluated to the hepatocyte culture in the culture vessels for a period of time sufficient for enzymes of the hepatocytes to metabolize the agent and converting it to one of more metabolites thereof; (c) identifying the presence of, or measuring the concentration of, the one or more metabolites in the medium or cells of the culture,
thereby evaluating the metabolism of the agent.
[0032] Also included is a method for producing a product, preferably a biomolecule such as a liver protein, e.g., albumin, that is made by, and, optionally, secreted by, normal mammalian hepatocytes in vivo, comprising
(a) culturing mammalian hepatocytes as described above, optionally in the presence of an agent that induces synthesis and/or secretion of the product, for a period of time sufficient to stimulate the synthesis and/or secretion of the molecule; (b) obtaining the product from the medium or cells of the culture,
thereby producing the product.
[0035] Also provided is a method for cultivation of mammalian hepatocytes in a viable functional state, which comprises inoculating a HARV with pre-aggregated hepatocytes or nascent hepatocyte spheroids, in a culture medium and incubating the hepatocytes and under conditions wherein hepatocytes are viable and metabolically active for a period of at least about 4 days, preferably at least about 7 days, more preferably at least about 14 days, even more preferably at least about 30 days.
[0036] In another embodiment, the present invention is directed to a method for propagating Hepatitis C virus (HCV) in cultured hepatocytes, comprising:
(a) culturing primate hepatocytes as described above; (b) inoculating the cultured hepatocytes with an inoculum of HCV, for example serum from an HCV infected subject, and permitting the virus to infect, replicate in and be released from the hepatocytes; (c) harvesting the medium of the culture which contains the HCV, thereby growing HCV.
[0040] The above method may further comprise the step (d) enriching or isolating the HCV from the medium.
[0041] The amount or titer of HCV present in the harvested medium or in the enriched or isolated preparation may be measured, preferably using one or more of the following criteria: (i) presence of HCV negative-strand RNA; (ii) presence, of HCV positive-strand RNA; (iii) transmission of infection to cells of a fresh hepatocyte culture by transfer of the medium or enriched/isolated Viral preparation; and (iv) infection of chimpanzees by intravenous inoculation of the medium or isolated/enriched virus, preferably at a dose of at least about 10 4 CID 50 .
[0042] Also provided herein is a method for testing an agent for its activity as an inhibitor of HCV replication or propagation in hepatocytes, comprising:
(a) culturing primate, preferably human, hepatocytes in accordance with claim 1 ; (b) inoculating the cultured hepatocytes with an inoculum of HCV and permitting the virus to infect, replicate in and be released from the hepatocytes; (c) before, during or after step (b), adding to the virus-infected cultures the agent being tested for inhibitory activity; (d) to a parallel culture or set of cultures of hepatocytes infected with HCV as in steps (a) and (b), adding negative control agent that does not inhibit HCV replication or propagation (e) harvesting the medium of the cultures of (c) and (d); and (f) measuring the amount or titer of HCV present in the harvested medium,
wherein a lower amount or titer of virus in the cultures of (c) compared to the cultures of (d) is indicative that the agent is an inhibitor.
[0049] The foregoing method may further include the use of a positive control group in which an agent or combination of agents known to inhibit HCV replication or propagation is added to a parallel culture or set of cultures. The amount or titer of resulting virus in the presence of the positive control inhibitor or inhibitors should be significantly less than the amount in the cultures of (d) above, thereby indicating that the virus replication or propagation in the cultures is inhibitable by the positive control agent. The amount of virus in the test group (c) may be higher than, similar to or lower than the positive control, depending on the inhibitory potency of the test agent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 is a schematic representation of the novel method for processing primary hepatocytes and preparing spheroids for inoculation into the HARV bioreactor.
[0051] FIGS. 2A and 2B show large viable aggregates composed of multiple hepatocytes in HARV cultures at day 11 ( FIG. 2A and day 16 ( FIG. 2B ) using the method of the invention. Very few cells in these aggregates stain with trypan blue (seen as black coloring in these grayscale photographs), indicating high viability. The overall color of these spheroid aggregates ranges from tan to dark brown, as would be expected from a large mass of viable liver cells.
[0052] FIG. 3 shows a transmission electron micrograph (TEM) of rat hepatocytes from HARV culture showing numerous rough endoplasmic reticulum (rer); mitochondria (mi); lysosomes (l); Golgi apparatus (g); membrane junctions (m) with interdigitation of the membranes, and storage vesicles (v) that may be lipid droplets.
[0053] FIG. 4 is a graph showing albumin production over time by spheroids cultured in Petri dishes versus spheroids cultured in HARVs.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] Following their discovery that single cells suspensions of hepatocytes do not survive or function adequately following their inoculation into any of a number of culture vessels or systems, including RWVs, the present inventors discovered that pre-aggregation of the hepatocytes for a period of between about 24 hours and 7 days in culture dishes before transfer to the RWV permits the hepatocytes to survive and function as normal liver cells for prolonged periods. This approach and culture-system permits many practical uses of these long term cultures that have heretofore not been possible, as described below.
[0055] It was initially believed that certain advantages accompanied the use of fresh hepatocytes as a single cell suspension to inoculate the RWV. These advantages included saving time and effort compared to “pre-aggregation” (see below) and the potential for a steady maintenance of enzyme activity. However, experiments conducted with single-cells showed the rapid loss of viability after several hours in either of two types of RWVs, which may be related to inadequate oxygen tension. In petri dishes, pO 2 is stable at 130 to 140 mm Hg. In contrast, in the RWV, the pO 2 of oxygen-saturated medium falls rapidly following inoculation to less than 60 mm Hg.
[0056] Hepatocyte spheroids (discussed in more detail below) survive and function well in the HARV bioreactor but not in the Slow-Turning Lateral Vessel (STLV), also known as a Cylindrical Cell Culture Vessel. The HARV is designed with a larger ratio of gas-exchange surface area-to-volume and thus oxygenates more efficiently than the STLV.
[0057] Other factors likely contribute to the fate of single cells inoculated into the RWV. The addition of serum to the medium shows potential to improve the outcome. Higher production of three metabolites of dextromethorphan were observed when single-cell rat hepatocytes were cultured in medium supplemented with 2% serum. Metabolite production was enhanced by 40-70% in the presence of serum. After 24 hours, hepatocytes cultured as cells in serum-free medium were nonviable whereas, in the same cultures with serum, approximately 50% of the cells formed aggregates and remained viable.
[0058] In view of the foregoing disadvantages of single cell hepatocyte suspensions, the present inventors conceived of, and demonstrated that pre-aggregation of hepatocytes into spheroids before adding them to the HARV bioreactor resulted in the sought-after characteristics of long-term hepatocyte cultures, characterized primarily by prolonged cell viability of the culture and normal hepatocyte function. Such longevity of viability and differentiated function may be any period of time exceeding that which was previously known for hepatocytes, e.g., at least about 4 days, preferably at least about 7 days, more preferably at least about 14 days or even more than 30 days.
[0059] Thus, the present invention comprises inoculating a HARV with pre-aggregated hepatocytes or nascent spheroids. The procedure for preparing the spheroids is described in more detailed below and depicted schematically in FIG. 1 . Use of pre-aggregated hepatocytes in such a bioreactor results, not only in successful cultures, but cultures possessing many advantages over other culture types that were known in the art.
[0060] The present bioreactor and culture system has many uses, some of which are listed and discussed below.
Pathogen Infectivity Studies
[0061] Hepatitis C is an important pathogen for which no vaccine is yet available. There is no reliable in vitro method for culturing hepatitis viruses—and an urgent need in the art for such a capability for the development of new therapeutics. The present long term hepatocyte culture will permit cultivation of Hepatitis C virus.
Studies of Long-Term Liver Toxicity of Drugs
[0062] There is a need for a convenient and reliable laboratory tool to study liver toxicity of any new drug under development or to evaluate agents which are considered to have chronic liver toxicity such as those whose effects are manifest only over long periods of exposure in vivo. The present hepatocyte culture system is ideally suited for such studies, as illustrated by the present Examples showing metabolite formation in vitro.
Mass Production of Secreted Liver Biomolecules, Particularly Proteins and Lipids.
[0063] Commercial production of biomolecules from hepatocytes is enabled by the bioreactor and culture system of the present invention. Albumin production is exemplified below. The present invention is especially advantageous for production of liver-derived compositions that have been difficult to obtain by other means. The present system is ideal for production of bioactive metabolites from prodrugs. Thus, a prodrug type of compound may be added to the present RWV hepatocyte cultures for large scale production of its active metabolite which may be difficult to prepare economically by conventional chemical synthesis. It is believed that scale-up to larger volume cultures can be accomplished by those of ordinary skill in the art without undue experimentation.
Isolation of Hepatocytes
[0064] Hepatocytes are isolated from perfused liver using well-established methods, e.g., Li et at, 1992b, J. Tissue Culture Meth. 14:139-146). Likewise, the procedure for preparing hepatocyte aggregates or spheroids has been published by Li et. al., 1992a, supra and is outlined in FIG. 1 .
[0065] In the present inventors' laboratory, rat hepatocytes cells are commonly derived from male Sprague-Dawley rats weighing 225-250 g. Porcine, monkey or ape hepatocytes as well as human hepatocytes, which are prepared from donor livers obtained from accident victims or other recently deceased donors in whom liver function is believed to be normal, are prepared in a similar manner, though volumes are adjusted accordingly.
[0066] In the “pre-aggregation” or “spheroid-formation” stage of culture, the isolated hepatocytes are cultured in 100-mm diameter sterile petri dishes, or an equivalent thereof, with 10 mL of Waymouth's 752/1 medium, pH 7.28, or an equivalent thereof. Medium is preferably supplemented with the following: 2:24 g/L sodium bicarbonate, 2.38 g/L HEPES buffer, 11.2 mg/L alanine, 12.8 mg/L serine, 24 mg/L asparagine, 0.3 mL heptanoic acid, 5 mg/L linoleic acid, 0.175 mg/L aminolevulinic acid, 5 mg/L insulin, 5 mg/L transferrin, 5 μg/L selenous acid, 39.2 μg/L dexamethasone, 0.25 mg/L amphotericin B, 84 mg/L gentamicin sulfate, 84 mg/L amikacin sulfate, 100 U/mL penicillin G sodium, and 100 mg/L streptomycin sulfate. Those of ordinary skill in the art will know how to select these additives and manipulate their concentrations to achieve the objectives of this invention with ordinary experimentation that is not undue.
[0067] Any conditions that prevent cell adherence to the bottom of the dish (or other surface of alternate vessels) are preferred during this stage. Although cell concentration is typically about 10 6 cells/mL, and 0.5-1×10 6 is preferred, a broader range of concentrations may be used, for example, between about 10 4 and 10 8 cells/mL, as long as the selected concentration permits and preferably promotes, spheroid formation.
[0068] The preferred bioreactor is a RWV such as the 10-mL HARV produced by Synthecon, Inc. (Houston, Tex.), filled with medium of the above, composition (or equivalent) and containing about 5×10 7 pre-aggregated rat hepatocytes, though a broader range of cell concentrations may be used. Various drugs or other substrates may be added to the bioreactor and the metabolites collected for analysis of hepatocyte activity as is exemplified below. In a typical HARV, the bottom member of the vessel is composed of a paraformaldehyde-based plastic, in a preferred embodiment, Delrin® (or another tough plastic such as that used for molded articles, gears, etc.). A silicone rubber membrane is fixed onto its surface with silicone sealant. On the vessel's top member, composed of a plastic polymer such as poly(4,4′-isopropylidine diphenylcarbonate or poly(4,4′-carbonato-2,2′-diphenylpropane (in one embodiment, Lexan®), are two stainless-steel syringe ports for sampling and feeding. A larger filling port with a cap is present on preferred larger HARVs, but not on the 10-mL model. When the vessel's two members are bolted together, a chamber is formed—commonly having a 10-mL culture volume that is to be completely filled with medium during operation. All vessel parts are autoclavable.
[0069] As for the rotator base unit, for operation, the vessel is mounted on the motor shaft. An air pump delivers filtered air to the back of the vessel where gas exchange occurs across the silicone membrane.
[0070] Below is an exemplary and preferred procedure for preparing the bioreactor for use, adding substrate, and collecting metabolites. It is understood by those of skill in the art the procedures and reagents described below may be modified by the user in accordance with conventional procedures and knowledge in the art of cell culture and drug metabolism. For example, if using a larger HARV, volumes, cell numbers, reagent concentrations, times, etc., may be subject to a range of modifications without materially changing the nature of the present invention.
Basic Startup Procedure
[0071] 1. Autoclave a 10-mL HARV according to the manufacturer's instructions, with peripheral screws loosened and foil covering the syringe ports.
2. Assemble the vessel inside a sterile hood. Using an Allen wrench, tighten the six peripheral screws. Remove the foil covering the two syringe ports and install a sterile one-way stopcock valve onto each. Set the vessel aside.
3. Obtain the cells to be inoculated in the form of hepatocyte spheroids prepared in flat surface culture vessels, preferably 100 mm petri dishes, from the incubator and transfer to the sterile hood.
4. Remove 8 to 9 mL of medium from each dish using a pipet. Cells may be concentrated from the pre-aggregation cultures by gravity sedimentation (at 1×g) or velocity sedimentation. Simple centrifugation to concentrate the cells is preferably avoided.
5. Remove the cells from several (typically 5 to 10) dishes using a single 10-mL syringe. Attach the syringe onto one of the HARV ports and inoculate the cells into the vessel. Commonly, about 5×10 7 cells are added to each 10-mL HARV. During inoculation of the HARV, it is important that the aggregates/spheroids be handled gently with minimization of shear forces.
6. Discard the inoculation syringe. Fill a new 10-mL syringe with medium, and attach it to one valve port. Add medium to the vessel until nearly full while manipulating air bubbles underneath the second open port.
7. To remove remaining air bubbles, attach a 5-mL syringe to the other port and position the vessel so that the bubbles move directly under that port. Push on the 10-mL inoculating syringe to force the bubbles to escape via the other port and into the 5 mL syringe.
8. Once the bubbles have been removed close the valve, remove and discard the 5-mL syringe, but leave the 10-mL syringe, with some medium remaining, attached.
9. Wipe the open port with, e.g., an alcohol or other antiseptic pad, and attach an end cap.
10. The vessel can now be placed onto its rotator base inside a 37° C. incubator having a 5% CO 2 atmosphere. The vessel is typically rotated at a speed of approximately 29 rpm. The precise speed is optional and is governed by the need to maintain the spheroids in gentle suspension. As aggregates increase in size over time, the rotational speed may be increased manually.
Modified Procedure for Adding Substrate
[0072] Following Step 6, above:
[0000] 7A. Remove the one-way stopcock valve from the empty syringe port, keeping it sterile.
8A. Add the desired substrate using a micropipettor with sterile tip. Preferably, add no more than 1% (v/v) of any nonaqueous solvent with the substrate. Insert the micropipettor tip directly inside the HARV syringe port and add the substrate to the vessel contents. Place the one-way stopcock back onto this port.
9A. Attach a 5-mL syringe onto this valve port and remove the 10-mL syringe from the other side, keeping it sterile. With the 5-mL syringe, gently remove 25 to 50% of the medium, keeping the cells relatively undisturbed. Then, gently push these contents back into the vessel. This step insures that the contents are well mixed. Note that a modified mixing method may be equally effective.
10A. Re-attach the 10-mL syringe. Use the 5-mL syringe to withdraw an initial sample of about 0.5 mL, replacing that volume with fresh medium from the 10-mL syringe. Store the initial sample frozen until ready to analyze (e.g., by HPLC).
11A. From this point, follow steps 7 through 10 above.
Collecting Metabolites from the Bioreactor
1. Remove the HARV from its rotating base. Dispose of any extra medium in the attached 10-mL syringe.
2. Using a 10-mL syringe; remove contents (medium plus-cells) from the vessel and place into a conical centrifuge tube. At this point, cell viability can be determined using a small sample of the cells.
3. Add an equal volume of “stopping” solution to the conical tube and mix. The “stopping” solution may be (i) methanol; (ii) a 1:1 methanol/0.1 M Tris acetate mixture, or some other solvent, depending on the properties of a particular substrate.
4. Add 5 mL of “stopping” solution to the HARV and mix it around to contact-all surfaces. Withdraw this solution and save it separately as the extraction sample. This step is included to increase yield of substrate and/or metabolites, as some compounds have become adsorbed to the vessel surfaces.
5. With the vessel contents mixed with solvent from step 3, centrifuge at 1000 rpm (250×g) or any gravitational force that pellets the cells without disrupting them, e.g., from about 150-400×g, for approximately 5 minutes.
6. Transfer samples of the supernatant to HPLC vials of, alternatively, store frozen until analysis time. The concentrations of substrate and metabolites derived from HPLC analysis must be corrected for dilution by the solvent in step 3.
7. The cell pellet from step 5 should be processed to (1) recover the intracellular fraction of metabolite and (2) analyze total protein. Resuspend the cell pellet in 0.1 M Tris acetate. Homogenize on ice. To an aliquot of this homogenate, add an equal volume of “stopping” solution. Place briefly on ice and then centrifuge. Sample the supernatant and analyze for metabolite by HPLC. The remaining cell homogenate may be stored frozen until a convenient time to perform protein analysis.
Modified Procedure for Collection of Metabolites from Continuous Bioreactor Culture
[0073] The above procedure describes harvest of the entire contents of the bioreactor. For continuous production of a secreted metabolite, the procedure may be modified to harvest only a fraction of the bioreactor contents. The same cell culture may then be maintained for an extended period and medium sampled repeatedly to test metabolite levels. The procedure is essentially as detailed below for changing medium in the RWV. Up to 75% of the conditioned medium may be conveniently removed and replaced with fresh medium. The conditioned medium may be processed by immediate freezing, adding solvent, etc., depending on the characteristics of the metabolite of interest and the chosen method for purification and analysis of the metabolite:
Changing Medium in RWV
[0074] The following procedure should be performed on the first day following startup and every 2 to 6 days afterwards, preferably about every third day.
[0000] 1. Remove the vessel from rotator base and transfer to a sterile hood.
2. Discard the medium in the attached 10-mL syringe. Reattach this syringe to the valve port. Remove the cap from the second valve port, placing it aside on a sterile alcohol pad, and open the valve.
3. Tilt the vessel slightly to allow the cells to settle away from both syringe ports. Aggregates settle quickly.
4. Pull gently on the 10-mL syringe to remove approximately 25 to 75% of conditioned medium from the vessel (about 2:5 to 7.5 mL). During this removal process, the vessel position will need to be adjusted slightly in order to keep the syringe pot in contact with the medium. Discard the syringe and its contents or save supernatant sample for any desired measurements.
5. Fill a new 10-mL syringe with medium. Attach this to the syringe port, and gently push fresh medium into the vessel except for the last 2 to 3 mL remaining in the syringe.
6. Attach a 5-mL syringe to the second valve port. Maneuver the vessel so that air bubbles are positioned directly underneath this port. Push on the 10-mL syringe to allow bubbles to escape into the 5-mL syringe.
7. Close the valve before removing the 5-mL syringe. Swab this port with an alcohol pad and recap it. Wipe any media spills from the surface of the vessel with an alcohol pad. The 10-mL syringe stays on the vessel with the valve open. Place the vessel back on its rotator-base inside the 37° C. incubator.
[0075] Having now generally described the invention, the same will be more readily understood through reference to the following examples which are provided by way of illustration, and are not intended to be limiting of the present invention, unless specified.
Example I
Cell Viability and Morphology
[0076] As shown in FIG. 2A-2B , HARV cultures of hepatocyte spheroids produce even larger spheroid aggregates with high viability. The inventors examined the relative sizes of spheroids cultured in HARVs versus those cultured in Petri dishes. From 50 random measurements, the average HARV spheroids were 2.3 times larger than dish spheroids. Only a small number of peripheral cells are non-viable, as shown in FIG. 2A-2B by their uptake of trypan blue stain (seen as black spots in these photos). Also visible under the microscope is tan to brown pigmentation in the cells (seen here as dark gray patches), presumably reflecting the presence of the bile pigment bilirubin. In the present inventors' experience, such pigmentation is correlated with spheroid viability. Transmission electron micrographs of cultures according to this invention show characteristics of hepatocytes that are seen in vivo.
[0077] In particular, FIG. 3 shows copious rough endoplasmic reticulum, mitochondria, membrane junctions with interdigitations, lysosomes, Golgi apparatus, and storage vesicles (possibly lipid droplets). In other micrographs (not shown here), structures resembling bile canaliculi with luminal microvilli were observed.
Example II
Long-Term Maintenance of Hepatocytes
[0078] FIG. 2 shows evidence of the capability of the present bioreactor and culture system to maintain hepatocyte viability for several weeks. Hepatocyte spheroids have been viably maintained, with activity of liver enzymes preserved, for over one month. This distinguishes the present invention from all other in vitro systems for simulating metabolism of a live mammal with an intact liver.
[0079] The first example of preservation of enzyme activity is shown in Table 1. Here, the activity of the cytochrome P450 enzyme 2B1/2 has been measured via the Pentoxyresorufin O-dealkylation (PROD) assay on disrupted and homogenized rat hepatocytes cultured in a HARV, as dish spheroids (SP), as monolayers (ML), and compared to freshly isolated cell suspensions (FS).
[0080] Freshly isolated rat liver cells exhibited a PROD activity of approximately 50 pmol/mg protein. Cells from this same isolation were maintained as monolayer, dish spheroid, and HARV spheroid cultures for many days and the PROD activity was measured periodically on small cell samples from these cultures. For monolayers and dish spheroids, this activity diminishes after the first day. In HARV culture, by contrast, PROD activity is maintained and even increases over a period of 39 days. Table 1 also shows the maintenance of testosterone 16β-hydroxylation, another CYP 2B1/2 activity, by HARV cultures over a period of 16 days.
[0081] In another example of preservation of enzyme activity, human hepatocytes were maintained in the HARV for 30 days and then “challenged” with a dose of 100 μM phenacetin. Within 6 hours of dosing, the metabolites acetaminophen and acetaminophen sulfate were measured at concentrations of approximately 250 and 50 nmoles per mg protein, respectively.
[0000]
TABLE 1
Day
FS
ML
SP
HARV
PROD activity (pmol/mg protein)
0
48.6
N/A
N/A
N/A
1
N/A
11.4
25.0
25.0
4
N/A
0.0
1.9
25.3
7
N/A
0.15
0.0
31.6
16
N/A
nd
nd
53.5
39
N/A
nd
nd
61.1
TST 16β-OH activity (pmol/mg protein)
0
590
N/A
N/A
N/A
1
N/A
300
300
nd
4
N/A
80
0
190
7
N/A
180
0
350
16
N/A
Nd
nd
840
N/A = Not applicable
nd = not determined
Example III
Whole-Cell Drug Metabolism
[0082] It is well known in the art that many of the liver-specific enzyme functions disappear following cultivation of hepatocytes in vitro. The present invention provides an important improvement over the prior art. Table 2 summarizes the metabolism of a variety of drug substrates tested on viable whole liver cells (rat and human hepatocyte cultures from HARV, spheroids cultured in Petri dishes (SP), and freshly isolated cell suspensions (FS)) using the present bioreactor system. Activity of multiple Cytochrome P450 (CYP) and Phase II conjugation enzymes was examined. Substrates were added at a concentration of 100 μM, with the exception of tolbutamide (1 mM), and 7-Hydroxycoumarin (10 μM). Activity is measured on whole live cells in culture and analyzed by HPLC of the culture medium.
[0000]
TABLE 2
nmoles/mg protein/24 hr
Metabolites
1-day
7-day
1-day
7-day
Substrate
measured
Enzyme
FS
SP
SP
HARV
HARV
Tolbutamide
4-OH-
2B; 2C
4
50
18
14
31
tolbutamide
Warfarin
4-OH-warfarin
3A
2.3
43
13
15
2.4
6-OH-warfarin
1A; 2C
0.44
0.0
2.5
0.05
1.1
7-OH-warfarin
2C
0.05
0.4
0.77
0.0
0.45
Chlorzoxazone
6-OH-
2E; 1A
4.7
2.7
2.9
1.3
1.1
chlorzoxazone
Dextromethorphan
dextrorphan
2D
5.6
1.5
0.85
0.63
0.33
3-methoxy-
3A
5.5
7.9
2.7
1.7
9.2
morphinan
3-hydroxy-
2D; 3A
0.99
1.6
0.3
0.61
1.0
morphinan
7-Hydroxycoumarin
7-HC sulfate
GST*
0.41
2.3
1.8
5.8
5.0
(7-HC)
7-HC
UDP-GT*
2.1
2.1
8.3
11
30
glucuronide
Midazolam
1-OH-midazolam
3A
10
7.3
8.6
1.4
4.5
4-OH-midazolam
3A
33
10
15
2.6
17
Acetaminophen (a)
a. sulfate
GST
7.5
250
130
4.2
30
a. glucuronide
UDP-GT
0.87
41
52
11
33
Phenacetin
Acetaminophen
1A
0.37
9.2
54
11
50
a. sulfate
GST
6.0
34
17
10
6.4
a. glucuronide
UDP-GT
0.0
0.0
0.0
0.0
0.0
Phenacetin †
Acetaminophen
1A
nd
200
21
44
70
*Phase II metabolism enzymes: GST = glutathione-S-transferase; UDP-GT = uridine diphosphate glucuronyltransferase
† Second group of phenacetin data applies to metabolism by human hepatocytes. Note that in a separate experiment with human hepatocytes in the HARV, a secondary metabolite, acetaminophen sulfate was detected.
[0083] This drug metabolism is shown in comparison to that measured for hepatocyte spheroids in Petri dishes and freshly isolated hepatocytes in suspension. Table 2 shows the metabolites thus far identified by HPLC assay and the amount produced per day per milligram of cellular protein. These metabolites are the result of action by CYP enzymes, with several distinct Phase I oxidation activities measured, and/or conjugation by Phase II enzymes.
[0084] With reference to Table 2, each “suspension culture” consisted of freshly isolated liver cells added to “adherent” 24-well plates to form partially attached cell monolayers over the 24 hour period during which metabolism was measured. Spheroid aggregates of fresh cells were formed in mixed Petri dishes. At the end of this formation period, spheroids were considered “fully developed” and were designated “1-day old.” At this time, spheroids were either combined at a higher concentration in a fresh Petri dish or were transferred to a HARV for further culture and assay of metabolite production. Separate and parallel cultures of spheroids in dishes and spheroids in HARVs were maintained and fed for 7 days prior to the final assay of drug metabolite production.
[0085] In each study represented in Table 2, hepatocytes were “challenged” by adding a drug substrate to the cultures. Metabolites were measured after 24 hours incubation. Comparisons were made between (1) freshly isolated cells; (2) 1-day and 7-day-old spheroids in dishes; and (3) 1-day and 7-day-old spheroids in HARVs.
[0086] In more than 60% of the cases for HARV spheroids, 7-day-old cultures generated more metabolite than did 1-day-old cultures. This was truce in only 0.40% of cases for spheroids cultured in Petri dishes. This pattern is not surprising given the increase over time in PROD and testosterone 16-β-hydroxylation activities documented in Example II for the hepatocyte bioreactor cultures. Like the data in Example II, CYP 2B activity is seen again here as well preserved in HARV cultures.
[0087] There was an indication of reduced recovery of some substrate and metabolite compounds from the HARVs, compared with the other culture modes. This could potentially be due to the following: (1) reduced availability through adsorption to the bioreactor surfaces or diffusion limitations due to the larger size of spheroids in the HARV; (2) inadequate recovery of the intracellular fraction of the drug; (3) loss of cellular protein on harvest or feeding. Regardless, the present system exhibits consistent and continuous production of metabolites from many important drug substrates, as shown. Coupled with the greatly enhanced longevity of these HARV cultures, the present hepatocyte bioreactor system promises to be an excellent tool for drug metabolism studies.
Example IV
Protein and Urea Production
[0088] The production of albumin, an important plasma protein synthesized in the liver, was measured in HARV cultures compared to spheroids in Petri dishes ( FIG. 4 ) over the course of several days. Albumin production was, on average, 30% higher in the HARV cultures and was maintained for at least 11 days.
[0089] The inventors measured endogenous urea production by rat hepatocytes as spheroid cultures in HARVs, spheroids in dishes, and monolayers. The average production rates over 11 days in culture were:
[0090] Monolayer 35±11 μg urea/1 mg protein/day
[0091] Dish spheroids 41±13 μg urea/mg protein/day
[0092] HARV spheroids 59±6 μg urea/1 mg protein/day
[0000] The formation of urea from an exogenous source of ammonia was measured using porcine hepatocytes in a perfused RWV, a vessel related to, although different from, the HARV. Approximately 80 μmoles of urea was formed overnight in culture from 170 μmoles of NH 4 Cl added.
Example V
Propagation of Hepatitis C Virus and Drug Testing
[0093] To test the ability of the present hepatocyte bioreactor system to support infection and propagation of Hepatitis C virus, a culture of primary hepatocytes is first established in HARV bioreactors. Hepatitis C virus is introduced in the form of infectious serum (from an HCV-infected subject).
[0094] The establishment and progress of HCV infection is monitored with regular sampling of cells and/or medium from the bioreactor. A successful outcome is demonstrated by (i) presence of HCV negative-strand RNA; (ii) long-term production of HCV positive-strand RNA; and (iii) transmission of infection to cells of a fresh hepatocyte culture.
[0095] Quantification of viremia is accomplished by detecting viral core antigen by fluorescent enzyme immunoassay (Tanaka, T et al., 1995 , J. Hepatology 23:742-745) by measuring HCV RNA using the Amplicor HCV Monitor test (Roche Molecular Systems, Pleasanton, Calif.) or the Quantiplex HCV RNA 2.0 assay (bDNA; Chiron, Emeryville, Calif.).
[0096] Total RNA is purified using the RNAqueous® kit (Ambion, Austin, Tex.) or High Pure RNA Isolation kit (Boehringer Mannheim, Germany).
[0097] Production of the negative RNA strand is measured by the method of tagged RT-PCR amplification (Lanford, R E et al., 1994 , Virology 202: 606-614), followed by Southern blot hybridization.
[0098] Human infectious serum and human hepatocytes are obtained from reliable sources, with donor consent.
[0099] A form of positive control is the passage of viral infection from the supernatant of one bioreactor to a naïve culture. As a negative control, normal non-infectious human serum is added to identical bioreactor cultures.
[0100] The following parameters are varied in these studies: (1) initial number of hepatocytes in the bioreactor between 5×10 6 and 5×10 8 cells: (2) hepatocyte source: primary or cryopreserved hepatocytes from human adults or fetuses or from chimpanzees; (3) age of hepatocyte culture (e.g., 1-10 days in bioreactor prior to infection); (4) HCV titer of infectious serum, between about 5×10 6 and about 10 equivalents/mL; and (5) other properties of the serum including titers of anti-HCV antibodies that are specific for HCV proteins.
[0101] Bioreactor cultures will be started, initially using the preferred cell concentration of 5×10 6 cells/mL. Hepatitis C virus will be seeded into HARV cultures between days 1 to 10, at titers of 0.25 to 2.5×10 5 copies/mL (Rumin, S. et al., 1999 , J. Gen. Virol. 80:3007-3018; Fournier, C. et al., 1998 , J. Gen. Virol. 79:2367-2374). Infection is sustained, along with the hepatocyte culture, for an extended period, ranging between about 7 and about 30 days, to reach a titer of 0.5 to 5×10 6 copies/mL.
[0102] Proof that HCV was successfully propagated is obtained by measuring increased viral RNA content and by transmission of virus from an infected culture to a naïve HARV culture where it again propagates.
[0103] The ultimate test of successful production of competent infectious particles is by infection and Hepatitis C disease induction in a chimpanzee model using virus generated in the present bioreactor culture. Using culture supernatants that are positive by in vitro infectivity, quantities equivalent to 10 4 to 10 6.2 50% chimpanzee infective doses (CID 50 ) will be administered i.v. to chimpanzees (Feinstone, S M et al., 1983 , Infect. Immun. 41:816-821; Shimizu, Y K et al., 1990 , Proc. Nat. Acad. Sci. 87:6441-6444). Clinical signs of acute hepatitis C will appear in 80% of the recipients within 6 to 15 weeks. These signs include elevated serum alanine aminotransferase levels, anti-HCV antibodies, serum viral RNA measurable by qualitative PCR, and/or ultrastructural changes seen on liver biopsy.
[0104] The foregoing Hepatitis C model is used to test the effect of a therapeutic candidate, whether small molecule, peptide or biological macromolecule. Different concentrations of the candidate in parallel with a negative control, are added to cultures established under selected conditions determined as above. The cultures are monitored for a decrease in viral load or a static effect on viral growth in comparison with the negative control. As a positive control, an agent or regimen with known anti-HCV activity can be run concurrently, for example, the nucleoside analogue Ribavirin (e.g., Virazole®, Rebetol®), interferon-α, preferably interferon α-2b (e.g., Roferon-A®, Intron-A®) (which is the FDA-approved-standard treatment of HCV infection), or the combination of Ribavirin and interferon-α.
[0105] The present bioreactor system may be used as a model for infectious diseases other than Hepatitis C, wherein the pathogenic organism replicates in hepatocytes, with minor modifications to the protocol that are tailored to the pathogenic organism of interest.
[0106] The references cited above are all incorporated by reference herein, whether specifically incorporated or not.
[0107] Having now fully described this invention, it will be appreciated by those skilled in the art that the same can be performed within a wide range of equivalent parameters, concentrations, and conditions without departing from the spirit and scope of the invention and without undue experimentation. | A rotating wall vessel is used as a culture vessel and bioreactor for the cultivation of hepatocytes in the form of spheroids to generate a culture with many properties of the intact liver. These properties include enzyme activity comparable to fresh cells and long-term maintenance of viability and cellular function for periods on the order of months. The cultures may be used to produce hepatocyte products, evaluate metabolism of an agent, propagate Hepatitis C virus and test agents as inhibitors of this virus. Thus, the culture system disclosed herein makes long term functional cultivation of human hepatocytes feasible. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a compound having an oxime moiety or a pharmaceutically acceptable salt, hydrate or solvate thereof and its use for inhibiting semicarbazide-sensitive amine oxidase (SSAO), also known as vascular adhesion protein-1 (VAP-1), a pharmaceutical composition comprising the compound or a salt, hydrate or solvate thereof as an active ingredient, a method for the prevention or the treatment of a SSAO/VAP-1 related disease, said diseases including acute or chronic inflammatory diseases, diseases related to carbohydrate metabolism, diabetes-associated complications, diabetic retinopathy and macular oedema, diseases related to adipocyte or smooth muscle dysfunctions, neurodegenerative diseases and vascular diseases.
BACKGROUND OF THE RELATED ART
[0002] Semicarbazide sensitive amine oxidase (SSAO)/vascular adhesion protein-1 (VAP-1) is a membrane protein with a dual function. On the one hand, SSAO [EC 1.4.3.6.] belongs to the family of copper-containing amine oxidases, its name deriving from its sensitivity to inhibition by the carbonyl reagent, semicarbazide (Lyles G A, Int. J. Biochem. Cell. Biol., 1996, 28, 259-274). SSAO catalyzes the oxidative deamination of primary aliphatic and aromatic amines with the following reaction pathway.
[0000] RNH 2 +O 2 +H 2 O→RCHO+H 2 O 2 +NH 3
[0003] The enzymatic reaction of the amine results in the formation of the corresponding aldehyde, H 2 O 2 and ammonia; the products formed in the reaction being generally more cytotoxic than the substrates themselves. For the human enzyme, aminoacetone and methylamine have been identified as endogenous physiological substrates.
[0004] On the other hand, analysis of the genetic encoding of an adhesion protein revealed the identity of SSAO and human vascular adhesion protein-1 (VAP-1) (Smith D J et al, J. Exp. Med., 1998, 188, 17-27). VAP-1 is a cell adhesion molecule with some special features distinguishing it from other adhesion molecules related to inflammation, such as the monoamine oxidase activity and a restricted expression pattern (Salmi M et al, Science, 1992, 257, 1407-1409; Smith D J et al, J. Exp. Med., 1998, 188, 17-27). The level of VAP-1 is upregulated in the vasculature at sites of inflammation.
[0005] Although the substrate specificity of SSAO/VAP-1 partly overlaps with that of monoamine oxidases (MAOs), SSAO/VAP-1 differs from MAO A and MAO B with respect to cofactor (2,4,5-trihydroxy-phenylalanyl quinone (TPQ) for SSAO/VAP-1), biological function, substrates, inhibitors and subcellular distribution. Products of SSAO/VAP-1, such as formaldehyde are mainly extracellular. The absence of formaldehyde dehydrogenase from the blood plasma, where SSAO/VAP-1 products are formed, may amplify the potential toxic effects of formaldehyde towards blood vessels.
[0006] SSAO/VAP-1 exists as a membrane-bound and as a soluble form in the plasma, its activity displaying a wide tissue distribution. It has been hypothesized that the soluble form is generated via proteolytic cleavage from the membrane-bound form. The major sources of the enzyme are the endothelial cells, smooth muscle cells and adipocytes. Because expression of SSAO is particularly remarkable in the endothelium and the plasma, cytotoxic effects associated with the enzyme may be increased in the highly vascularised tissues, such as the eyes and kidneys, partially explaining late-diabetic complications (Ekblom J. et al, Pharmacol. Res., 1998, 37, 87-92).
[0007] SSAO/VAP-1 has a role in the metabolism of biogenic and xenobiotic amines. Products formed in the enzyme reaction (formaldehyde, methylglyoxal and H 2 O 2 for the endogenous substrates) may be involved in processes such as protein cross-linking, formation of advanced-glycation end products or increase of oxidative stress. Higher concentrations of the physiological substrates in diabetes together with the higher enzyme activity observed may lead to a higher production of the cytotoxic agents, therefore may lead to diabetes-associated complications. Treatment of diabetes-associated vasculopathies such as retinopathy, neuropathy and nephropathy with enzyme inhibitors has been proposed.
[0008] SSAO/VAP-1 expression is induced during adipogenesis (Fontana E et al, Biochem. J., 2001, 356, 769-777; Moldes M et al, J. Biol. Chem., 1999, 274, 9515-9523), therefore a role for SSAO/VAP-1 in the adipogenic gene program has been suggested. Due to its special features in adipose tissue, SSAO/VAP-1 has been proposed as potential target for the treatment of obesity (Bour S et al, Biochimie, 2007, 89, 916-925).
[0009] SSAO/VAP-1 as an adhesion molecule plays a role in leukocyte trafficking and is involved in an adhesive cascade leading to the transmigration of leukocytes into inflamed tissues from the circulation. In the adhesion cascade both the amine oxidase and the adhesive function of SSAO/VAP-1 take part (Salmi M et al, Immunity, 2001, 14, 265-276), a direct interaction with a leukocyte surface substrate mediating the leukocyte-SSAO/VAP-1 interaction has been proposed. Products of the enzyme reaction of SSAO/VAP-1, such as H 2 O 2 , a signalling molecule itself, via the upregulation of other adhesion molecules leading to enhanced leukocyte trafficking may contribute to the escalation of the inflammatory process. Therefore, inhibitors of the enzymatic activity may serve as useful antiinflammatory agents.
[0010] SSAO/VAP-1 inhibitors could reduce leukocyte trafficking at sites of inflammation and therefore reduce the inflammatory process as proved by several animal studies (for example: ulcerative colitis—Salter-Cid L M et al, J. Pharm. Exp. Ther., 2005, 315, 553-562; arthritis—Marttila-Ichihara F et al, Arthritis Rheum., 2006, 54, 2852-282862; multiple sclerosis—Wang E Y et al, J. Med. Chem., 2006, 49, 2166-2173; uveitis—Noda K et al, FASEB J., 2008, 22, 1094-1103). As translocation of VAP-1 to the endothelial cell surface occurs at sites of inflammation, modulation of the normal immune system could be avoided by the use of SSAO/VAP-1 as a novel anti-inflammatory target.
[0011] In healthy humans, the plasma SSAO/VAP-1 activity is rather constant. Elevated SSAO/VAP-1 levels or overexpression of the enzyme have been observed in various pathological conditions or diseases, such as diabetes (both type I and type II), particularly in the presence of diabetic complications (Boomsma F et al, Biochim Biophys. Acta, 2003, 1647, 48-54; Boomsma F, Clin. Sci., 1995, 88, 675-679; Garpenstrand H et al, Diabetic. Med., 1999, 16, 514-521; Meszaros Z et al, Metab. Clin. Exp., 1999, 48, 113-117; Boomsma F et al, Diabetologia, 1999, 42, 233-237; Salmi M et al, Am. J. Pathol., 2002, 161, 2255-2262), congestive heart failure (Boomsma F et al, Cardiovasc. Res., 1997, 33, 387-391), obesity (Meszaros Z et al, Metab. Clin. Exp., 1999, 48, 113-117; Weiss H G et al, Metab. Clin. Exp., 2003, 52, 688-692), end-stage renal disease (Kurkijarvi R et al, Eur. J. Immunol., 2001, 31, 2876-2884), multiple sclerosis (Airas L et al, J. Neuroimmunol., 2006, 177, 132-135), inflammatory liver diseases (Kurkijarvi R et al, J. Immunol., 1998, 161, 1549-1557), psoriasis (Madej A et al, J. Eur. Acad. Dermatol. Venereol., 2007, 21, 72-78), Alzheimer's disease (del Mar Hernandez M et al, Neurosci. Lett., 2005, 384, 183-187; Ferrer I et al, Neurosci. Lett., 2002, 321, 21-24) and myopathies (Olive M et al, Muscle Nerve, 2004, 29, 261-266). A role for SSAO/VAP-1 in apoptosis, possibly leading to vascular tissue damage and atherogenesis has been implicated.
[0012] An oxime prodrug approach for ketone drugs, the nonsteroidal antiinflammatory drugs ketoprofen and nabumetone has been reported recently (Kumpulainen H, J. Med. Chem., 2006, 49, 1207-1211). The oxime structure was activated to the ketone with simultaneous release of nitric oxide (NO).
[0013] Because of its proposed involvement in a number of inflammatory processes and various pathologies, there is a great demand for inhibitors of SSAO/VAP-1 that can have therapeutic value in the prevention or the treatment of disorders or diseases associated with an elevated level or overexpression of SSAO/VAP-1, said diseases involving acute and chronic inflammations, diseases related to carbohydrate metabolism, diabetes-associated complications, diabetic retinopathy and macular oedema, diseases related to adipocyte or smooth muscle dysfunctions, neurodegenerative diseases and vascular diseases.
[0014] Several small-molecule inhibitors of SSAO/VAP-1 have been identified: hydrazine derivatives, phenylallylhydrazines (WO2006/094201, WO2005/014530), hydrazino alcohols and hydrazino indanes (WO2002/0202090, WO2003/006003, WO2005/080319), arylalkylamines, propenyl- and propargylamines, oxazolidinones, haloalkylamines, 1,3,4-oxadiazines (WO2002/0202541), 4,5,6,7-tetrahydroimidazo[4,5-c]pyridines (WO2002/0238153), thiocarbamoyl derivatives, carboxamides and sulfonamides (WO2006/013209, US2007/066646), thiazole derivatives (WO2004/087138, WO2004/067521, WO2006/028269, WO2006/011631), compounds disclosed in WO2005/082343; (compounds reviewed in: Matyus P et al, Curr. Med. Chem., 2004, 11, 1285-1298; Dunkel P et al, Curr. Med. Chem., 2008, 15, 1827-1839). Further relevant documents are mentioned in “Disclosure of the Invention” part hereinbelow.
[0015] We now found that a special class of compounds, containing an oxime group and an unsaturated ring system joining to the carbon atom of the oxime group, optionally through an alkylene moiety, exhibit SSAO/VAP-1 inhibitory and antiinflammatory effects. Some of the compounds are novel.
DISCLOSURE OF THE INVENTION
[0016] The present invention relates to a compound of general formula of Ar—(CH 2 ) n —CR 1 ═N—OR 2 (I) or salt, hydrate or solvate thereof, wherein
[0017] Ar is a group of the formula:
[0000]
[0018] R 1 is H or lower alkyl;
[0019] R 2 is H, lower alkyl, benzyl, —(CH 2 ) k —COOR 13 , —(CH 2 ) m —N(R 14 R 15 ) or —CO—NH—R 16 ,
wherein R 13 is lower alkyl, k is 1, 2 or 3, preferably 1; m is 1, 2 or 3; preferably 2; R 14 and R 15 are independently from each other lower alkyl, or R 14 and R 15 together with the nitrogen they are attached form a 5 to 7 membered heteroring, optionally containing 1 to 3 further heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, R 16 is phenyl, optionally substituted with one or more group selected from halogen, lower alkyl and lower alkoxy;
[0025] R 3 and R 4 together with the carbons they are attached to form a 5 to 7 membered heteroring containing one or two oxygen(s), preferably 1,3-dioxolane, optionally substituted with lower alkyl, preferably with methyl; or
[0026] R 3 is H, halogen, lower alkyl or OR 17 , wherein R 17 is H, lower alkyl, lower alkenyl, optionally substituted with phenyl;
[0027] R 4 is H or OR 19 , wherein R 19 is lower alkyl;
[0028] R 5 is H or halogen;
[0029] R 6 is H or halogen;
[0030] R 7 is H, halogen, OH, OR 20 or a phenyl substituted with Z,
[0031] wherein R 20 is lower alkyl or lower alkenyl, and Z is —CH═N—OH or halogen;
provided that if Ar is substituted phenyl of group (a), then the phenyl ring has at least one halogen and one allyloxy substituent, excluding the following substitution patterns of the phenyl ring: if n=0, R 2 ═H and R 1 ═H: 2-allyloxy-4-bromo (see in WO2001074760), 2-allyloxy-5-bromo (see in JP2009132675), 2-allyloxy-5-chloro (see in Synth. Comm., 1996, 26(17), 3201-3215), 4-allyloxy-3-chloro, commercially available; or if n=0, R 2 ═H and R 1 ═CH 3 : 2-allyloxy-5-chloro (see in Tetrahedron Lett., 1998, 39(16), 2389-2390); or the phenyl ring has at least one methyl and one alkoxy substituent, excluding the following substitution patterns of the phenyl ring: if n=0, R 2 ═H and R 1 ═H: 2-methoxy-6-methyl, commercially available; or if n=0, R 2 ═CH 3 and R 1 ═H: 2-methoxy-6-methyl (see in Org. Lett., 2006, 8(6), 1141-1144); or the phenyl ring has one (2-phenylprop-2-ene-1-yl)oxy substituent;
[0036] X is a 5 to 7 membered heteroring containing 1 or 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms;
[0037] Y is SR 21 , OR 22 , 5 to 7 membered heteroring containing 1 to 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, optionally substituted with phenyl or a (lower alkenyl)amino, optionally N-substituted with lower alkyl; wherein R 21 is lower alkyl or phenyl and R 22 is lower alkyl;
[0038] R 8 is lower alkyl or optionally substituted benzyl, wherein the substituent is 1 or 2 lower alkoxy, preferably methoxy;
[0039] R 9 is H or phenyl;
[0040] R 10 is di(lower alkyl)amino, preferably dimethylamino, 5 to 7 membered heteroring containing 1 or 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, optionally substituted with one or more group selected from lower alkyl, lower alkenyl and phenyl;
[0041] or R 9 and R 10 together with the attached carbon atoms form an optionally substituted 5 to 8 membered heteroring containing 1 or 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, optionally substituted with one or more group selected from lower alkyl and benzyl, and optionally together with lower alkylene form a fused bicyclic group;
[0042] W is a bond or a phenylene group, preferably 1,2-phenylene group;
[0043] R 11 is lower alkyl;
[0044] R 12 is phenyl, optionally substituted with halogen; preferably with chloro;
[0045] n is integer of 0 to 4, preferably 0, 1 or 2;
[0046] Ar 2 and Ar 2 are the same or different and stand for phenyl, optionally substituted with one or more group selected from halogen, lower alkyl and lower alkoxy, preferably both are phenyl;
[0047] with the proviso that:
when n=0, R 1 ═H, R 2 ═H and Ar=2,4-dichlorophenyl, then Z is not 4-fluoro (see in EP0038061); and when n=0, R 1 ═H, R 2 ═H, R 3 +R 4 =—O—CH 2 —O—, then one of R 5 , R 6 and R 7 is not H (see in Angew. Chem., 2002, 41(16), 2983-2986); and when R 1 ═CH 3 , R 2 ═H, R 4 +R 3 =—O—CH 2 —O— and R 6 ═R 7 ═H, then R 5 is not methoxy (see in J. Chem. Soc., 1938, 372-5);
[0051] and any stereoisomer, mixture of stereoisomers, E or Z forms, mixture of E and Z forms, prodrug, metabolite, crystalline form, non-crystalline form thereof.
[0052] The above compounds are useful for inhibiting SSAO enzyme activity and/or for inhibiting binding to VAP-1.
[0053] Preferred compounds are the following ones:
Those compounds of general formula (I), wherein R 14 and R 15 are methyl, or R 14 and R 15 together with the nitrogen they are attached to form a pyrrolidine ring. Those compounds of general formula (I), wherein R 3 is methyl, allyloxy or (2-phenylprop-2-ene-1-yl)oxy. Those compounds of general formula (I), wherein Y is phenylpiperazino or a (lower alkenyl)-amino N-substituted with lower alkyl, preferably allyl(methyl)amino. Those compounds of general formula (I), wherein R 16 is pyrrolidino, piperidino, morpholino or piperazino substituted with methyl or phenyl. Those compounds of general formula (I), wherein R 9 and R 10 together with the attached carbon atoms form an 6-7 membered heteroring, preferably a 1,4-oxazine or 1,4-oxazepine, or optionally substituted with one or more group selected from methyl and benzyl, optionally fused with C 3 alkylene to form a bicyclic group. Preferred compounds are the following ones: 3-methoxy-2-methylbenzaldehyde oxime; 8-Pyrrolidino-1-naphthaldehyde oxime; 5-Hydroxy-1,3-benzodioxole-4-carbaldehyde oxime; 5-Ethoxy-1,3-benzodioxole-4-carbaldehyde oxime; 5-(Allyloxy)-1,3-benzodioxole-4-carbaldehyde oxime; 5-Bromo-1,3-benzodioxole-4-carbaldehyde oxime; 5-{2-[(Hydroxyimino)methyl]phenyl}-1,3-benzodioxole-4-carbaldehyde oxime; 6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 6-Methoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 1,3-Dimethyl-2,4-dioxo-6-propoxy-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde-O-methyloxime; 1,3-Dimethyl-2,4-dioxo-6-(propylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 1,3-Dimethyl-6-(methylthio)-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 1,3-Dimethyl-2,4-dioxo-6-(phenylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde-O-methyloxime; 6-[Allyl(methyl)amino]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime; 3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal oxime (more preferred compound) and 1-(4-Chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde oxime (more preferred compound),
[0079] or any stereoisomer, mixture of stereoisomers, E or Z forms, mixture of E and Z forms, prodrug, metabolite, crystalline form, non-crystalline form, hydrate, solvate or salt thereof.
[0080] The present invention also relates to compounds of general formula (I) or a pharmaceutically acceptable salt thereof for use as medicament.
[0081] In a specially advantageous embodiment of the invention the compound of general formula (I) possessing SSAO/VAP-1 inhibitory activity is a prodrug of another active ingredient, i.e. the compounds of general (I) can be converted through metabolism into molecules having another type therapeutical activity under in vivo conditions. Preferred embodiment of this SSAO/VAP-1 inhibitor oxime prodrug approach is the use of oxime derivatives that can be metabolized in vivo to molecules exhibiting antiinflammatory effects. Moreover, SSAO/VAP-1-inhibiting oxime compounds can display other valuable biological activities, such as NO donor properties. In this preferred embodiment both the compound of general formula (I) and metabolite of it have valuable therapeutical activity which activities are advantageous in case of the disease to be treated.
[0082] For example 3-(4,5-diphenyl-1,3-oxazol-2-yl)propanal oxime and 1-(4-chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde oxime were prepared to utilize, besides their valuable SSAO inhibitory and possible NO donor properties, also the antiinflammatory effects of their carboxylic acid analogs. Namely, 3-(4,5-diphenyl-1,3-oxazol-2-yl)propionic acid and 1-(4-chlorobenzoyl)-2-methyl-1H-indole-3-carboxylic acid, possessing excellent known antiinflammatory activities, can be formed from 3-(4,5-diphenyl-1,3-oxazol-2-yl)propanal oxime and 1-(4-chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde oxime, respectively, under in vivo conditions via known metabolic processes including hydrolysis and subsequent oxidation of the carbaldehyde formed to carboxylic acid (accordingly, these compounds are especially preferred compounds).
[0083] The present invention also provides pharmaceutical composition, which comprises, as an active ingredient, one or more compound(s) of general formula (I) or a pharmaceutically acceptable salt thereof in admixture with one or more pharmaceutically acceptable auxiliary/auxiliaries.
[0084] The pharmaceutical compositions of the invention comprise a therapeutically effective amount of one or more of the compounds of formula (I) and a pharmaceutically acceptable carrier, preferably in human unit dosages.
[0085] The present invention also relates to the use of a compound of general formula of Ar—(CH 2 ) n —CR 1 ═N—OR 2 (I′) or salt, hydrate or solvate thereof—wherein
[0086] Ar is a group of the formula:
[0000]
[0087] R 1 is H or lower alkyl;
[0088] R 2 is H, lower alkyl, benzyl, —(CH 2 ) k —COOR 13 , —(CH 2 ) m —N(R 14 R 15 ) or —CO—NH—R 16 ,
wherein R 13 is lower alkyl, k is 1, 2 or 3, preferably 1; m is 1, 2 or 3; preferably 2; R 14 and R 15 are independently from each other lower alkyl, or R 14 and R 15 together with the nitrogen they are attached form a 5 to 7 membered heteroring, optionally containing 1 to 3 further heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, R 16 is phenyl, optionally substituted with one or more group selected from halogen, lower alkyl and lower alkoxy;
[0094] R 3 and R 4 together with the carbons they are attached to form a 5 to 7 membered heteroring containing one or two oxygen(s), preferably 1,3-dioxolane, optionally substituted with lower alkyl, preferably with methyl; or
[0095] R 3 is H, halogen, lower alkyl or OR 17 , wherein R 17 is H, lower alkyl, lower alkenyl, optionally substituted with phenyl;
[0096] R 4 is H or OR 19 , wherein R 19 is lower alkyl;
[0097] R 5 is H or halogen;
[0098] R 6 is H or halogen;
[0099] R 7 is H, halogen, OH, OR 20 or a phenyl substituted with Z
[0100] wherein R 20 is lower alkyl or lower alkenyl, and Z is —CH═N—OH or halogen;
[0101] X is a 5 to 7 membered heteroring containing 1 or 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms;
[0102] Y is SR 21 , OR 22 , 5 to 7 membered heteroring containing 1 to 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, optionally substituted with phenyl or a (lower alkenyl)amino, optionally N-substituted with lower alkyl; wherein R 21 is lower alkyl or phenyl and R 22 is lower alkyl;
[0103] R 8 is lower alkyl or optionally substituted benzyl, wherein the substituent is 1 or 2 lower alkoxy, preferably methoxy;
[0104] R 9 is H or phenyl;
[0105] R 10 is di(lower alkylamino, preferably dimethylamino, 5 to 7 membered heteroring containing 1 or 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, optionally substituted with one or more group selected from lower alkyl, lower alkenyl and phenyl;
[0106] or R 9 and R 19 together with the attached carbon atoms form an optionally substituted 5 to 8 membered heteroring containing 1 or 3 heteroatom(s) selected from nitrogen, oxygen and sulfur atoms, optionally substituted with one or more group selected from lower alkyl and benzyl, and optionally together with lower alkylene form a fused bicyclic group;
[0107] W is a bond or a phenylene group, preferably 1,2-phenylene group;
[0108] R 11 is lower alkyl;
[0109] R 12 is phenyl, optionally substituted with halogen; preferably with chloro;
[0110] n is integer of 0 to 4, preferably 0, 1 or 2;
[0111] Ar 1 and Ar 2 are the same or different and stand for phenyl, optionally substituted with one or more group selected from halogen, lower alkyl and lower alkoxy, preferably both are phenyl;
[0112] and any stereoisomer, mixture of stereoisomers, E or Z forms, mixture of E and Z forms, prodrug, metabolite, crystalline form, non-crystalline form thereof—in the preparation of medicament or pharmaceutical composition for the prevention or treatment of a SSAO/VAP-1 related disease.
[0113] The reference to all the possible E- and Z-isomers (and the mixtures thereof) and the preferred compounds are the same as defined hereinbefore for compounds of general formula (I).
[0114] The present invention also relates to compounds of general formula (I′) for use in the treatment or prevention of a SSAO/VAP-1 related disease.
[0115] The present invention also relates to method of treatment or prevention of a SSAO/VAP-1 related disease comprising administering a therapeutically effective amount of one or more compound(s) of general formula (I′) or a pharmaceutically acceptable salt thereof to a mammal in the need thereof.
[0116] The above compounds, use and method of prevention and treatment may be therapeutically beneficial in inflammatory diseases and conditions and in various other pathologies, including diseases related to carbohydrate metabolism, diabetes-associated complications, diabetic retinopathy, macular oedema, diseases related to adipocyte or smooth muscle dysfunctions, neurodegenerative diseases and vascular diseases.
[0117] With other words, the present invention relates to a method for the prevention or the treatment of diseases related to elevated levels of SSAO/VAP-1, by administering compounds to inhibit SSAO/VAP-1 enzyme activity and/or to inhibit binding to SSAO/VAP-1 in a therapeutically effective amount or by administering a therapeutically effective combination of SSAO/VAP-1 inhibitors.
[0118] In a preferred embodiment, the invention relates to a method of using the compounds provided in the invention for inhibiting SSAO/VAP-1 enzyme activity and/or inhibiting binding to SSAO/VAP-1 in vitro.
[0119] In another preferred embodiment, the invention relates to a method of using the compounds provided in the invention for inhibiting SSAO/VAP-1 enzyme activity and/or inhibiting binding to SSAO/VAP-1 in vivo, e.g. in an assay.
DETAILED DESCRIPTION OF THE INVENTION
[0120] The term “halogen” as used herein refers to the Group VIIa elements and includes Cl, Br, F and I substituents. Preferred halogen substituents are Cl and F.
[0121] The term “lower alkyl” in the meaning of an alkyl group refers to aliphatic and alicyclic groups including straight-chain (linear), branched-chain or cyclic groups having up to 6, preferably 4 carbon atoms; methyl and ethyl are more preferred.
[0122] The term “lower alkenyl” refers to unsaturated aliphatic and alicyclic groups including straight-chain (linear), branched-chain, cyclic groups, and combinations thereof, having up to 6, preferably 4 carbon atoms, which contain at least one double bond (—C═C—). Preferred example of alkenyl group is the allyl group (—CH 2 —CH═CH 2 ).
[0123] The term “lower alkoxy” refers to a “(lower alkyl)-O—” group (where the “lower alkyl” has the above-defined meaning). Examples of alkoxy groups include, but are not limited to, groups such as methoxy, ethoxy, propyloxy (either n-propoxy or i-propoxy), and butoxy (either n-butoxy, i-butoxy, sec-butoxy, or tert-butoxy). A particularly preferred alkoxy substituent is methoxy.
[0124] The definition of “5 to 7” (or 5 to 8) membered heteroring, optionally containing 1 to 3 further heteroatom(s) selected from nitrogen, oxygen and sulfur atoms” relates to any saturated or unsaturated 5 to 7 (or 5 to 8) membered heteroring, optionally containing 1 to 3 further heteroatom(s) selected from nitrogen, oxygen and sulfur atoms. In a preferred embodiment the heteroring is saturated, and stands for preferably 5 or 6 ring atoms, wherein 1 or 2 ring members are selected from the group consisting of O, S and N and the remaining atoms are carbon. However, when R 9 and R 10 together with the attached carbon atoms form a ring, the 7-membered 1,4-oxazepine is also preferred. Non-limiting examples of the preferred rings are piperidine, pyrrolidine, piperazine, oxazine, preferably 1,4-oxazine (morpholine), oxazepine, preferably 1,4-oxazepine, thiomorpholine, thiazolidine, dioxolane, tetrahydrofurane, tetrahydrothiophene and tetrahydrothiopyrane.
[0125] The definition of “5 to 7” membered heteroring containing one or two oxygen(s)” relates to any saturated or unsaturated 5 to 7 membered heteroring containing one or two oxygen(s). In a preferred embodiment the heteroring is saturated and stands for 1,3-dioxolane.
[0126] In preferred embodiments the 5-7- and 5-8-membered heterorings contain 2 heteroatoms, more preferably selected from N and O.
[0127] The definition of “phenylene group” means 1,2-phenylene group, 1,3-phenylene group or 1,4-phenylene group, preferably 1,2-phenylene group
[0128] The more preferred embodiments of the substituents and above general phrases are given in the examples.
[0129] The compounds of general formula (I) have at least one double bond (since there is a double bond in the oxime moiety, but further double bond can be present in an optional substituent, too). The invention relates to all possible E- and Z-isomers of compounds of general formula (I), with respect to every double bond being in the molecule, and to any mixtures of these isomers. In one preferred embodiment, the compounds of formula (I) are in the E configuration of the double bond of the oxime moiety. In another preferred embodiment, the compounds of formula (I) are in the Z configuration of the double bond of the oxime moiety. The compounds of general formula (I) may also have further stereoisomers, due, e.g., to the presence of stereogenic centers. The invention relates to all possible stereoisomers.
[0130] The invention also includes all solvates of the compounds referred to in the above formulas, including all hydrates of the compounds referred to in the above formulas. The invention also includes all polymorphs, including crystalline and noncrystalline forms of the compounds referred to in the above formulas. The invention also includes all salts of the compounds referred to in the above formulas, particularly pharmaceutically-acceptable salts. In all uses of the compounds of the above formulas disclosed herein, the invention also includes use of any or all of the stereochemical, E or Z forms, solvates, hydrates, polymorphic, crystalline, non-crystalline, salt, pharmaceutically acceptable salt variations of the compounds described.
[0131] If the stereochemistry is not indicated explicitly in a chemical structure or a chemical name, the chemical structure or chemical name is intended to embrace all possible stereoisomers of the given compound.
[0132] Pharmaceutical compositions suitable for use include compositions wherein the active ingredients are contained in an effective amount to achieve their intended purpose. A therapeutically effective amount means an amount effective to prevent development of a disease or to alleviate the existing symptoms of the subject being treated. Determination of the effective amounts is well within the capability of those skilled in the art.
[0133] For all of the compositions and methods using the compounds of the invention, the compounds according to the invention can be admixed with one or more non-toxic, pharmaceutically acceptable auxiliaries as carriers and/or diluents and/or adjuvants and/or other active ingredients. The carrier can be any of those conventionally used and is limited only by chemico-physical considerations, such as the solubility and lack of the reactivity of the compound, and by the route of administration. Pharmaceutical compositions can be prepared by methods and contain excipients which are well known in the art. A generally recognized compendium of such methods and ingredients is Remington's Pharmaceutical Sciences.
[0134] According to the invention the SSAO/VAP-1 related diseases may be: diseases or disorders related to an elevated level of SSAO/VAP-1 (where the elevated level may affect the binding function, amine oxidase function, or both), including but not limited to acute or chronic inflammatory conditions and diseases, connective tissue inflammatory conditions and diseases, rheumatoid arthritis, ankylosing spondylitis, osteoarthritis, lupus erythematosus, vasculitis, synovitis, gastrointestinal inflammatory conditions and diseases, ulcerative colitis, Crohn's disease, irritable bowel syndrome, central nervous system inflammatory conditions and diseases, Alzheimer's disease, multiple sclerosis, chronic multiple sclerosis, pulmonary inflammatory conditions and diseases, asthma, inflammatory skin conditions, psoriasis, atopic eczema, contact dermatitis, atopic dermatitis, liver inflammatory conditions and diseases, inflammatory eye conditions, uveitis, conjunctivitis, corneal angiogenesis, age-related macular degeneration, diseases related to carbohydrate metabolism, type I and/or type II diabetes, complications of diabetes, vascular complications and/or neuropathy and/or retinopathy and/or nephropathy related to diabetes, diabetic retinopathy and macular oedema, diseases related to adipocyte dysfunction, diseases related to smooth muscle cell dysfunction, atherosclerosis, obesity, vascular diseases, ischemic heart disease, arteriosclerosis, Raynaud's disease, stroke and/or complications thereof, cancer or cancer metastasis.
[0135] A compound of formula (I) can be administered per se in a therapeutically effective amount, or with one or more additional compounds of formula I. When administered in combination, the compounds can either be administered in amounts that would be therapeutically effective were the compounds to be administered per se, or in amounts that would not be therapeutically effective were the compounds to be administered per se, but which are therapeutically effective in combination. One or more compounds of formula (I) can also be administered with other compounds exhibiting therapeutically useful effect not included in formula I; the compounds can either be administered in amounts that would be therapeutically effective were the compounds to be administered per se, or in amounts that would not be therapeutically effective were the compounds to be administered per se, but which are therapeutically effective in combination.
[0136] The method of the present invention can involve the co-administration of other pharmaceutically active compound(s), co-administration meaning administration of other pharmaceutically active compound(s) before, concurrently with, e.g., in combination with an SSAO/VAP-1 inhibitor in the same formulation or in separate formulations, or after administration of the SSAO/VAP-1 inhibitor. Other pharmaceutically active compounds can be corticosteroids and non-corticosteroidal anti-inflammatory compounds. Further compounds to be co-administered can be vitamins, minerals, antioxidants and micronutrients.
[0137] The pharmaceutical compositions of the present invention can be administered to humans and any animal that can experience the beneficial effects of the compounds of the invention. Foremost among them are humans, although the invention is not intended to be so limited.
[0138] The pharmaceutical compositions of the present invention can be administered by any means that achieve their intended purpose. The mode of administration can be selected to maximize delivery to a desired target site in the body. Routes of administration of the compounds of the present invention can be, for example, parenteral, subcutaneous, intravenous, intraarticular, intrathecal, intramuscular, intraperitoneal, intradermal, intramuscular, subconjunctival, parabulbar, retrobulbar, subtenon, intracameral, intravitreal and other injections, transdermal, buccal, oromucosal, ocular, via inhalation or oral. The manner in which the SSAO/VAP-1 inhibitor is administered is dependent, in part, upon whether the treatment of an SSAO/VAP-1 associated disease is prophylactic or therapeutic.
[0139] The dosage administered will be dependent upon a variety of factors, including the strength of the particular SSAO/VAP-1 inhibitor to be employed, species, the age, health, weight of the recipient, kind of concurrent treatment, if any, frequency of treatment, degree of the SSAO/VAP-1 associated disease and the nature of the effect desired. The exact formulation, route of administration and dosage can be chosen by the individual physician in view of the patient's condition. The desired dose may be presented in single dose or as divided doses administered at appropriate intervals.
[0140] The “prevention or treatment of diseases related to elevated levels of SSAO/VAP-1” or “prevention or treatment of SSAO/VAP-1 related disease” is intended to include administration of a compound having SSAO/VAP-1 inhibitory activity (i.e. SSAO/VAP-1 inhibitor) to a subject for therapeutic purposes, which may include propylaxis, amelioration, prevention and cure of the above described SSAO/VAP-1 related disease. As used herein, by the term “subject” is meant a target of the administration of SSAO/VAP-1 inhibitor in the present invention, such as mammal, especially human. The therapeutic method comprises administration of an SSAO/VAP-1 inhibitor in an amount sufficient to treat the SSAO/VAP-1 related disease. Any SSAO/VAP-1 inhibitor can be used in the method of the present invention as long as it is safe and effective.
[0141] Of course, in the above detailed compounds of general formula (I′), use, pharmaceutical compositions, method of prevention and treatment it is advisable to apply the above-discussed preferred compounds of general formula (I).
[0142] Compounds for use in the invention can be assayed for SSAO/VAP-1 inhibitory activity by the protocol in the examples below.
[0143] Synthetic Methods
[0144] The compounds of the present invention may be prepared according to known methods with use of starting materials that are commercially available or can be prepared following known procedures.
[0145] Compounds of the general formula Ar—(CH 2 ) n —CR 1 ═N—OR 2 are prepared in accordance with, but not limited to, the following procedures.
[0146] Procedure A
[0147] A method of synthesizing the appropriate oximes (Scheme 1) which can be adapted for the synthesis of the compounds covered in the present invention is based on conditions well known in the art by reacting the aldehydes with (O-alkyl)hydroxylamine hydrochloride in the presence of e.g. sodium acetate in e.g. ethanol/water at room temperature/under reflux. Products thus obtained can be isolated or purified by known separation or purification methods, such as concentration in vacuo, solvent extraction, crystallization, recrystallization, chromatography and the like.
[0000]
[0148] Some of the methods used for the synthesis of starting aldehydes not commercially available are exemplified in the procedures below. The reactions given below are made with preferred starting compounds and preferred reagents, among preferred reaction conditions. Compounds being similar to the products of the reaction schemes (i.e. structural analogues) can be prepared by the choice of the corresponding starting materials, reagents and reaction conditions. Such modification of the reactions given above and below to prepare the desired structural analogues is within the knowledge of a person skilled in synthetic organic chemistry.
[0149] Procedure B
[0150] The appropriate pen substituted naphtaldehydes can be synthesized from the corresponding amine as exemplified in the synthesis of 8-pyrrolidino-1-naphthaldehyde, which is shown below in Scheme 2:
[0000]
[0151] A solution of 1-(1-naphthyl)pyrrolidine in ether was cooled and treated stepwise with n-butyllithium and N,N-dimethylformamide to afford the aldehyde.
[0152] Procedure C
[0153] Benzodioxole aldehydes can be synthesized by one of the methods exemplified below.
[0154] A method for synthesizing 5-alkoxy derivatives of 1,3-benzodioxole-4-carbaldehyde from the corresponding alcohol is exemplified in the synthesis of 5-ethoxy-1,3-benzodioxole-4-carbaldehyde, which is shown below in Scheme 3:
[0000]
[0155] A solution of 5-hydroxy-1,3-benzodioxole-4-carbaldehyde and K 2 CO 3 in N,N-dimethylformamide was treated with ethyl-bromide at room temperature to provide the corresponding 5-ethoxy derivative.
[0156] A method of synthesizing 1,3-benzodioxole-4-carbaldehyde compounds having a 2-substituted phenyl substituent at 5 position is exemplified in the synthesis of 5-(2-formylphenyl)-1,3-benzodioxole-4-carbaldehyde shown in Scheme 4:
[0000]
[0157] Suzuki reaction of 5-bromo-1,3-benzodioxole-4-carbaldehyde with 2-formylphenylboronic acid in dimethoxyethane, using Pd(PPh 3 ) 4 as catalyst and 2M Na 2 CO 3 as base afforded the appropriate 5-(2-formylphenyl) product.
[0158] Procedure D
[0159] Synthesis of 1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine carbaldehydes is exemplified in the methods below.
[0160] A method for the synthesis of O-alkyl derivatives of 6-chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde is exemplified in the synthesis of 6-methoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde, which is shown in Scheme 5:
[0000]
[0161] Carbaldehyde was added to a stirred solution of sodium in dry alcohol to afford the appropriate alkoxycarbaldehyde derivative.
[0162] A method for the synthesis of S-alkyl or S-aryl derivatives of 6-chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde is exemplified in the synthesis of 6-(ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde, which is shown in Scheme 6:
[0000]
[0163] 6-Chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde was added to a stirred solution of ethanethiol in 1,4-dioxane and sodium hydride while cooling the mixture and stirred at room temperature to afford the appropriate 6-ethylthio derivative.
[0164] Derivatives substituted with a N-containing cycle at position 6 can be synthesized by the method exemplified by the synthesis of 1,3-dimethyl-2,4-dioxo-6-(4-phenylpiperazin-1-yl)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde, which is shown in Scheme 7:
[0000]
[0165] A solution of the carbaldehyde in dichloromethane in the presence of triethylamine was cooled and treated with N-phenylpiperazine to afford the appropriate 6-(4-phenylpiperazin-1-yl) derivative.
[0166] Procedure E
[0167] Pyridazinone carbaldehydes can be synthesized by one of the methods exemplified below.
[0168] Derivatives substituted with a N-containing cycle at position 5 can be synthesized by the method exemplified by the synthesis of 2-methyl-5-(4-methylpiperazino)-3-oxo-2,3-dihydropyridazine-4-carbaldehyde, which is shown in Scheme 8:
[0000]
[0169] The title product was obtained starting from 4,5-dichloro-2-methylpyridazin-3(2H)-one in 3 steps, first by treating it with 1-methylpiperazine in water under reflux, in the second step by removal of the 4-chloro substituent by treatment with ammonium formate in methanol in the presence of Pd/C, and in the last step by Vilsmeier formylation.
[0170] Pyridazino benzaldehydes can be synthesized by the method exemplified in the synthesis of 2-[5-(dimethylamino)-2-methyl-3-oxo-2,3-dihydropyridazin-4-yl]benzaldehyde, which is shown in Scheme 9:
[0000]
[0171] Suzuki reaction of 4-chloro-5-(dimethylamino)-2-methylpyridazin-3(2H)-one with 2-formylphenylboronic acid in dimethoxyethane, using Pd(PPh 3 ) 4 as catalyst and 2M Na 2 CO 3 as base afforded the title compound.
[0172] The following examples are provided for the purpose of illustration and are not intended to limit the scope of the present invention. The present invention is not to be limited in scope by the exemplified embodiments, which are intended as illustrations of individual aspects of the invention. Indeed, various modifications of the invention in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description and accompanying drawings. Such modifications are intended to fall within the scope of the appended claims.
EXAMPLES
[0173] All melting points were determined on a Büchi apparatus or on a Kofler hot-stage microscope and are uncorrected. The 1 H NMR spectra were recorded at ambient temperature in the solvent indicated, using the 2 H signal of the solvent as the lock and tetramethylsilane or the residual undeuterated solvent as the internal standard. Chemical shifts (δ) are given in parts per million and all coupling constants (J) in hertz. Varian Mercury Plus spectrometer at 400 MHz or a Varian Unity Plus spectrometer at 300 MHz were used. Flash column chromatography was performed on Kieselgel 60 (Merck, 0.040-0.063 mm). The elemental analyses have been carried out with an Elementar Vario EL III apparatus. For TLC analysis Silica gel 60 F 254 (Merck) plates were applied. Solvent mixtures used for chromatography are always given in a vol/vol ratio. The reagents were obtained from commercial sources and used as received. Solvents were dried and distilled prior to use.
[0174] The synthesis of the compounds are depicted in Schemes 1-9 above, as well as in the following examples, which are not to be construed as limitative.
I. Type 1 of Production Examples
Synthesis of Benzaldehyde Oximes (Procedure A)
1.1: Example 1
3-Methoxy-2-methylbenzaldehyde oxime (compound 1)
[0175]
Step 1: 3-Methoxy-2-methylbenzaldehyde
[0176] The preparation of 3-methoxy-2-methylbenzaldehyde starting from m-anisaldehyde is described by Comins D. L. et al., J. Org. Chem., 54(15), 3730 (1989).
[0177] Yield: 0.390 g (44%), pale yellow oil.
[0178] 1 H NMR (CDCl 3 ): 2.54 (s, 3H, Ar—CH 3 ); 3.90 (s, 3H, O—CH 3 ); 7.08 (dd, 1H, Ar); 7.31 (t, 1H, Ar); 7.43 (dd, 1H, Ar); 10.32 (s, 1H, CHO).
Step 2: 3-Methoxy-2-methylbenzaldehyde oxime (Method A, as a preferred embodiment of Procedure A, Scheme 1) (compound 1)
[0179] To an ice-cooled and stirred suspension of 3-methoxy-2-methylbenzaldehyde (0.269 g, 1.8 mmol) in ethanol (15 ml) a solution of NaOAc.3H 2 O (1.3 eq) and NH 2 OH.HCl (1.3 eq) in water (5 ml) was added dropwise within 5 minutes. The resulting suspension was stirred at room temperature until the starting material was consumed (monitored by TLC). After evaporation of the ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of chloroform:ethyl acetate (95:5) as the eluent.
[0180] Yield: 0.218 g (74%), white crystals. Mp.: 110° C.
[0181] 1 H NMR (CDCl 3 ): 2.29 (s, 3H, Ar—CH 3 ); 3.84 (s, 3H, N—CH 3 ); 6.88 (d, 1H, Ar); 7.18 (t, 1H, Ar); 7.30 (d, 1H, Ar); 8.42 (s, 1H, CH); 8.47 (s, 1H, N—OH).
[0182] Analysis calculated for C 9 H 11 NO 2 (165.19): C, 65.44%; H, 6.71%; N, 8.48%. Found: C, 65.45%; H, 6.64%; N, 8.45%.
I.2: Example 2
1-[2-(Allyloxy)-4-bromophenyl]ethanone oxime (compound 2)
[0183]
[0184] The process described in Method A was followed. 1-[2-(Allyloxy)-4-bromophenyl]ethanone (0.088 g, 0.34 mmol, see in Bioorg. Med. Chem., 2007, 15(12), 4048-4056) was used to obtain the title compound.
[0185] Work-up/purification: after evaporation of the ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0186] Yield: 0.074 g (79%), white crystals. Mp.: 115° C.
[0187] 1 H NMR (DMSO-d 6 ): 2.05 (s, 3H, CH 3 ); 4.65 (d, 2H, O—CH 2 ); 5.27 and 5.37 (dd, 2H, ═CH 2 ); 6.02 (m, 1H, CH); 7.15 (m, 2H, Ar); 7.25 (m, 1H, Ar); 11.13 (s, 1H, N—OH).
[0188] Analysis calculated for C 11 H 12 BrNO 2 (270.12): C, 48.91%; H, 4.48%; N, 5.19%. Found: C, 48.44%; H, 4.22%; N, 5.11%.
I.3: Example 3
1-[2-(Allyloxy)-5-bromophenyl]ethanone oxime (compound 3)
[0189]
[0190] The process described in Method A was followed. 1-[2-(Allyloxy)-5-bromophenyl]ethanone (0.090 g, 0.35 mmol, see in Bioorg. Med. Chem., 2007, 15(12), 4048-4056) was used to obtain the title compound.
[0191] Work-up/purification: after evaporation of the ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0192] Yield: 0.082 g (87%), white crystals. Mp.: 110-111° C.
[0193] 1 H NMR (DMSO-d 6 ): 2.06 (s, 3H, CH 3 ); 4.61 (d, 2H, O—CH 2 ); 5.26 and 5.37 (dd, 2H, ═CH 2 ); 6.02 (m, 1H, CH); 7.03 (d, 1H, Ar); 7.32 (d, 1H, Ar); 7.50 (dd, 1H, Ar); 11.18 (s, 1H, N—OH).
[0194] Analysis calculated for C 11 H 12 BrNO 2 (270.12): C, 48.91%; H, 4.48%; N, 5.19%. Found: C, 48.81%; H, 4.16%; N, 5.13%.
I.4: Example 4
2-[(2-Phenylprop-2-en-1-yl)oxy]benzaldehyde oxime (compound 4)
[0195]
Step 1: 2-[(2-Phenylprop-2-en-1-yl)oxy]benzaldehyde
[0196] A suspension of 0.763 g (6.25 mmol) 2-hydroxybenzaldehyde, 1.009 g (5.12 mmol)
[0197] [1-(bromomethyl)vinyl]benzene and 0.850 g (6.15 mmol) K 2 CO 3 in 20 ml acetone was stirred at room temperature for 48 h. After evaporation to dryness, 20 ml water and 20 ml dichloromethane was added to the residue. After separation of the phases, the aqueous phase was extracted with a further 2×20 ml of dichloromethane and the combined organic phases were dried over MgSO 4 and evaporated to dryness. The crude product obtained was purified by column chromatography with chloroform as the eluent.
[0198] Yield: 0.102 g (8%), pale yellow oil.
[0199] 1 H NMR (CDCl 3 ): 5.02 (t, 2H, OCH 2 , J=0.9); 5.48 and 5.63 (q, 1H, ═CH 2 , J 1 =J 2 =0.9); 7.00-7.86 (m, 9H, Ar); 10.39 (s, 1H, CHO).
Step 2: 2-[(2-Phenylprop-2-en-1-yl)oxy]benzaldehyde oxime (compound 4)
[0200] The process described in Method A was followed. 2-[(2-Phenylprop-2-en-1-yl)oxy]benzaldehyde (0.102 g, 0.43 mmol) was used to obtain the title compound.
[0201] Work-up/purification: after evaporation of the ethanol in vacuo, water was added to the residue. The aqueous phase was extracted with dichloromethane. The combined organic phases were dried over MgSO 4 and evaporated to dryness. The crude product was purified by column chromatography with a mixture of chloroform:ethyl acetate (1:1) as the eluent.
[0202] Yield: 0.09 g (83%), white crystals. Mp.: 61-62° C.
[0203] 1 H NMR (CDCl 3 ): 9.95 (bs, 2H, OCH 2 ); 5.45 and 5.60 (bs, 1H, ═CH 2 ); 6.92-7.76 (m, 9H, Ar); 8.24 (s, 1H, NOH); 8.45 (s, 1H, CHN).
II. Type 2 of Production Examples
Synthesis of Naphtaldehyde Oximes (Procedure B)
II.1: Example 5
8-Pyrrolidino-1-naphthaldehyde oxime (compound 5)
[0204]
Step 1: 8-Pyrrolidino-1-naphthaldehyde
[0205] n-Butyllithium (14.7 ml of a 1.7 M solution in hexane) was added dropwise to a stirred solution of 1-(1-naphthyl)pyrrolidine (25.00 mmol, 5.00 g) in dry ether (50 ml) at −20° C. under argon. After 48 hours a solution of dry N,N-dimethylformamide (6.2 ml, 75.00 mmol) in ether (10 ml) was added dropwise at −78° C. to the reaction mixture. The mixture was allowed to warm to −20° C. over 4 hours, then quenched with a solution of methanol (15 ml) and allowed to warm to room temperature. The reaction mixture was diluted with ether (100 ml), washed with water (3×150 ml) and with brine (150 ml), dried over MgSO 4 and evaporated under reduced pressure. The residue was purified by column chromatography using dichloromethane as eluent to afford the aldehyde which was crystallized from hexane.
[0206] Yield: 3.54 g (63%), yellow crystals. Mp.: 44.1-44.5° C.
[0207] 1 H NMR (CDCl 3 ): 1.96 (s, 4H, H-3, H-4 pyrrolidine); 2.65-3.45 (br, 4H, H-2, H-5 pyrrolidine); 7.32 (d, 1H, H-7 Ar, J=7.4); 7.42-7.58 (m, 3H, H-3, H-5, H-6 Ar); 7.62 (d, 1H, H-4 Ar, J=8.2); 7.88 (d, 1H, H-2 Ar, J=8.2); 10.63 (s, 1H, CHO).
[0208] Analysis calculated for C 16 H 13 N 3 (225.28): C, 79.97%; H, 6.71%; N, 6.22%. Found: C, 79.77%; H, 6.72%, N, 6.14%.
Step 2: 8-Pyrrolidino-1-naphthaldehyde oxime (compound 5)
[0209] The process described in Method A was followed. 8-Pyrrolidin-1-yl-1-naphthaldehyde (0.500 g, 2.20 mmol) was used to obtain the title compound.
[0210] Work-up/purification: the precipitated product was filtered off and washed with water and ethanol. The crude product was purified by crystallization from 95% ethanol.
[0211] Yield: 0.344 g (65%), yellow crystals. Mp.: 187.4-188.5° C.
[0212] 1 H NMR (DMSO-d 6 ): 1.88 (bs, 4H, CH 2 —CH 2 pyrrolidine); 2.70 and 3.24 (bs, 2H and bs, 2H, N(CH 2 ) 2 pyrrolidine); 7.21-7.23 (m, 1H, H-7); 7.39-7.47 (m, 2H, H-2, H-6); 7.56-7.60 (m, 2H, H-3, H-5); 7.86-7.88 (m, 1H, H-4); 9.08 (s, 1H, HO—N═C—H); 10.81 (1H, s, OH).
[0213] Analysis calculated for C 15 H 16 N 2 O (240.30): C, 74.97%; H, 6.71%; N, 11.66%. Found: C, 75.09%; H, 6.66%; N, 11.49%.
III. Type 3 of Production Examples
Synthesis of Benzodioxole Oximes (Procedure C)
III.1: Example 6
5-Hydroxy-1,3-benzodioxole-4-carbaldehyde oxime (compound 6)
[0214]
Step 1: 5-Hydroxy-1,3-benzodioxole-4-carbaldehyde
[0215] The preparation of 5-hydroxy-1,3-benzodioxole-4-carbaldehyde starting from 1,3-benzodioxol-5-ol is described by Birch A. M. et al., WO1998/9840386.
[0216] Yield: 1.00 g (56%), pale yellow crystals. Mp.: 112-115° C.
[0217] 1 H NMR (CDCl 3 ): 6.07 (s, 2H, O—CH 2 —O); 6.37 (d, 1H, Ar); 6.97 (d, 1H, Ar); 10.14 (s, 1H, Ar—OH); 10.42 (s, 1H, CHO).
[0218] Analysis calculated for C 8 H 6 O 4 (166.13): C, 57.84%; H, 3.64%. Found: C, 57.88%; H, 3.39%.
Step 2: 5-Hydroxy-1,3-benzodioxole-4-carbaldehyde oxime (compound 6)
[0219] The process described in Method A was followed. 5-Hydroxy-1,3-benzodioxole-4-carbaldehyde (0.249 g, 1.50 mmol) was used to obtain the title compound.
[0220] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0221] Yield: 0.231 g (88%), pale yellow crystals. Mp.: 161-162° C.
[0222] 1 H NMR (DMSO-d 6 ): 5.97 (s, 2H, O—CH 2 —O); 6.29 (d, 1H, Ar); 6.75 (d, 1H, Ar); 8.18 (s, 1H, CH); 9.60 (s, 1H, Ar—OH); 11.45 (s, 1H, N—OH).
[0223] Analysis calculated for C 8 H 7 NO 4 (181.15): C, 53.04%; H, 3.89%; N, 7.73%. Found: C, 53.09%; H, 3.80%; N, 7.78%.
III.2: Example 7
5-Ethoxy-1,3-benzodioxole-4-carbaldehyde oxime (compound 7)
[0224]
Step 1: 5-Ethoxy-1,3-benzodioxole-4-carbaldehyde
[0225] Under argon to a stirred solution of 5-hydroxy-1,3-benzodioxole-4-carbaldehyde (0.151 g, 0.91 mmol) and K 2 CO 3 (1 eq) in dry N,N-dimethylformamide (2 ml) ethyl-bromide (1 eq) was added. The mixture was stirred at room temperature for 18 h until the starting material had been consumed (monitored by TLC). Then the mixture was poured onto ice water (15 ml). This aqueous phase was extracted with ethyl acetate (1×40 ml, then 2×15 ml) and the combined organic phases were washed with water and dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo, and the crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (4:1) as the eluent.
[0226] Yield: 0.071 g (40%), pale yellow crystals. Mp.: 155-156° C.
[0227] 1 H NMR (CDCl 3 ): 1.44 (t, 3H, CH 3 ); 4.06 (q, 2H, O—CH 2 ); 6.08 (s, 2H, O—CH 2 —O); 6.32 (d, 1H, Ar); 6.89 (d, 1H, Ar); 10.40 (s, 1H, CHO).
[0228] Analysis calculated for C 10 H 10 O 4 (194.18): C, 61.85%; H, 5.19%. Found: C, 61.61%; H, 5.49%.
Step 2: 5-Ethoxy-1,3-benzodioxole-4-carbaldehyde oxime (compound 7)
[0229] The process described in Method A was followed. 5-Ethoxy-1,3-benzodioxole-4-carbaldehyde (0.090 mg, 0.46 mmol) was used to obtain the title compound.
[0230] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0231] Yield: 0.075 g (77%), yellow crystals. Mp.: 161-164° C.
[0232] 1 H NMR (CDCl 3 ): 1.40 (t, 3H, CH 3 ); 3.98 (q, 2H, O—CH 2 ); 6.04 (s, 2H, O—CH 2 —O); 6.31 (d, 1H, Ar); 6.73 (d, 1H, Ar); 8.47 (s, 1H, CH); 9.62 (s, 1H, N—OH).
[0233] Analysis calculated for C 10 H 11 NO 4 (209.19): C, 57.41%; H, 5.30%; N, 6.70%. Found: C, 57.30%; H, 4.93%; N, 6.69%.
III.3: Example 8
5-(Allyloxy)-1,3-benzodioxole-4-carbaldehyde oxime (compound 8)
[0234]
Step 1: 5-(Allyloxy)-1,3-benzodioxole-4-carbaldehyde
[0235] To a stirred solution of 5-hydroxy-1,3-benzodioxole-4-carbaldehyde (0.166 g, 1.00 mmol) and K 2 CO 3 (1.00 mmol) in dry N,N-dimethylformamide (2 ml) was added allylbromide (1.00 mmol) under argon. The mixture was stirred at room temperature for 18 h until the starting material was consumed (monitored by TLC). Then the mixture was poured onto ice-water (15 ml). The aqueous phase was filtered off, the precipitated product was washed with water and n-heptane and dried to give analytically pure crystals.
[0236] Yield: 0.148 g (80%), pale yellow crystals. Mp.: 102-103° C.
[0237] 1 H NMR (CDCl 3 ): 4.57 (dt, 2H, OCH 2 ); 5.32 (dq, 1H, ═CH 2 cis); 5.43 (dq, 1H, ═CH 2 trans); 6.06 (ddt, 1H, CH); 6.10 (s, 2H, OCH 2 O); 6.34 (d, 1H, Ar); 6.90 (d, 1H, Ar); 10.42 (s, 1H, CHO).
[0238] Analysis calculated for C 11 H 10 O 4 (206.19): C, 64.07%; H, 4.89%. Found: C, 64.20%; H, 5.23%.
Step 2: 5-(Allyloxy)-1,3-benzodioxole-4-carbaldehyde oxime (compound 8)
[0239] The process described in Method A was followed. 5-(Allyloxy)-1,3-benzodioxole-4-carbaldehyde (0.090 mg, 0.43 mmol) was used to obtain the title compound.
[0240] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (2:1) as the eluent.
[0241] Yield: 0.078 g (81%), yellow crystals. Mp.: 166-167° C.
[0242] 1 H NMR (CDCl 3 ): 4.50 (dt, 2H, OCH 2 ); 5.29 (dq, 1H, ═CH 2 cis); 5.40 (dq, 1H, ═CH 2 trans); 6.03 (ddt, 1H, CH); 6.05 (s, 2H, OCH 2 O); 6.33 (d, 1H, Ar); 6.73 (d, 1H, Ar); 8.49 (s, 1H, NCH); 9.60 (s, 1H, N—OH).
[0243] Analysis calculated for C 11 H 11 NO 4 (221.21): C, 59.73%; H, 5.01%; N, 6.33%. Found: C, 59.80%; H, 4.78%; N, 6.21%.
III.4: Example 9
5-Bromo-1,3-benzodioxole-4-carbaldehyde oxime (compound 9)
[0244]
[0245] The process described in Method A was followed. 5-Bromo-1,3-benzodioxole-4-carbaldehyde (2.00 g, 8.50 mmol, commercially available, e.g. from Aldrich) was used to obtain the title compound.
[0246] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water.
[0247] Yield: 2.02 g (95%), white crystals. Mp.: 239-240° C.
[0248] 1 H NMR (DMSO-d 6 ): 6.13 (s, 2H, OCH 2 O); 6.90 and 7.15 (d, 2H, aromatic protons, J=8.2); 8.18 (s, 1H, CHN); 11.73 (s, 1H, NOH).
[0249] Analysis calculated for C 8 H 6 BrNO 3 (244.04): C, 39.37%; H, 2.48%; N, 5.74%. Found: C, 39.37%; H, 2.25%; N, 5.65%.
III.5: Example 10
5-Bromo-2-methyl-1,3-benzodioxole-4-carbaldehyde oxime (compound 10)
[0250]
Step 1: (R,S)-5-Bromo-2-methyl-1,3-benzodioxole
[0251] The preparation of 5-bromo-2-methyl-1,3-benzodioxole starting from catechol is described by Lynch G. S. et al., WO1994/9402475.
5-Bromo-2-methyl-1,3-benzodioxole-4-carbaldehyde
[0252] The (R,S)-5-bromo-2-methyl-1,3-benzodioxole (5.00 g, 23.25 mmol) was added dropwise under argon to a −78° C. stirred solution of lithium diisopropylamide (13 ml, 2M in THF/heptane/ethylbenzene) in dry THF (70 ml) at such a rate that the temperature remained below −70° C. The resulting solution was stirred for 15 min at −78° C., and then N,N-dimethylformamide (2.25 ml, 29.06 mmol) was added to the solution. Then it was stirred for 15 min, and the −78° C. cooling bath was removed. The reaction mixture was allowed to warm to room temperature and it was stirred for 30 min at ambient temperature. Then in a small portion water (20 ml) was added to the reaction mixture. The organic phase was separated, washed with 1M HCl (2×50 ml) and with saturated Na 2 CO 3 solution (2×50 ml). The organic layer was dried over anhydrous Na 2 SO 4 . The solvent was evaporated in vacuo, and the crude product was purified by crystallization from n-hexane.
[0253] Yield: 0.890 g (16%), yellow crystals. Mp.: 81.8-85.1° C.
[0254] 1 H NMR (CDCl 3 ): 1.76 (d, 3H, CH 3 , J=4.8); 6.47 (q, 1H, H-2); 6.79 (d, 1H, H-7, J=8.4); 7.07 (d, 1H, H-6, J=8.4); 10.28 (s, 1H, CHO).
[0255] Analysis calculated for C 9 H 7 BrO 3 (243.05): C, 44.47%; H, 2.90%. Found: C, 44.20%; H, 2.66%.
Step 2: 5-Bromo-2-methyl-1,3-benzodioxole-4-carbaldehyde oxime (compound 10)
[0256] The process described in Method A was followed. 5-Bromo-2-methyl-1,3-benzodioxole-4-carbaldehyde (0.500 g, 2.05 mmol) was used to obtain the title compound.
[0257] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by crystallization from a mixture of acetone and water (2:1).
[0258] Yield: 0.289 g (55%), white crystals. Mp.: 208.0-208.9° C.
[0259] 1 H NMR (DMSO-d 6 ): 1.62 (d, 3H, CH 3 , J=5.1); 6.47 (q, 1H, H-2); 6.84 (d, 1H, H-7, J=8.4); 7.12 (d, 1H, H-6, J=8.4); 8.18 (s, 1H, HO—N═C—H); 11.77 (1H, s, OH).
[0260] Analysis calculated for C 9 H 8 BrNO 3 (258.07): C, 41.89%; H, 3.12%; N, 5.43%. Found: C, 41.37%; H, 2.76%; N, 5.42%.
III.6: Example 11
1-(5-bromo-1,3-benzodioxol-4-yl)-N-[2-(pyrrolidin-1-yl)ethoxy]methanimine (compound 11)
[0261]
[0262] To a stirred solution of 5-bromo-1,3-benzodioxole-4-carbaldehyde oxime (0.244 g, 1 mmol) in dry DMF (15 ml), 1-(2-chloroethyl)pyrrolidine hydrochloride (0.207 g, 1.22 mmol) and NaH (0.138 g, 3.45 mmol, 60% dispersion in oil) were added. The reaction mixture was stirred at ambient temperature for 5 minutes and then heated at 80° C. overnight. Then the reaction mixture was cooled to ambient temperature and quenched with methanol (4 ml). After evaporation of the solvent in vacuo, water (25 ml) was added to the residue, and the mixture was extracted with dichloromethane (2×25 ml). The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo, and the residue was purified by column chromatography with a mixture of chloroform:ethyl acetate (10:1) as the eluent. After the isolation of the unreacted starting material, the eluent was changed to ethyl acetate:isopropanol:cc. NH 3 (9:1:0.5). The crude product was digerated with water.
[0263] Yield: 0.083 g (24%), brownish white powder. Mp. 68.5-70.0° C.
[0264] 1 H NMR (CDCl 3 ): 1.82 (m, 4H); 2.64 (m, 4H); 2.87 (t, 2H); 4.39 (t, 2H); 6.09 (s, 2H); 6.67 (d, 1H); 7.06 (d, 1H); 8.43 (s, 1H).
[0265] Analysis calculated for C 14 H 17 BrN 2 O 3 (341.20): C, 49.28%; H, 5.02%; N, 8.21%. Found: C, 49.16%; H, 4.91%; N, 8.11%.
III.7: Example 12
5-{2-[(hydroxyimino)methyl]phenyl}-1,3-benzodioxole-4-carbaldehyde oxime (compound 12)
Step 1: 5-(2-Formylphenyl)-1,3-benzodioxole-4-carbaldehyde (Method B, as a preferred embodiment of Procedure C, Scheme 4)
[0266]
[0267] To a solution of 5-bromo-1,3-benzodioxole-4-carbaldehyde (0.458 g, 2.00 mmol) in dry dimethoxy-ethane were added Pd(PPh 3 ) 4 (5 mol %, 0.10 mmol), 2.5 ml 2M Na 2 CO 3 and 2-formylphenylboronic acid (0.450 g, 3.00 mmol) under argon. The reaction mixture was heated under reflux until the starting material was consumed (monitored by TLC). Then the mixture was poured onto ice-water (30 ml) and the aqueous phase was extracted with dichloromethane (3×30 ml). The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo and the crude product was purified by column chromatography with a mixture of hexane:ethyl acetate (9:1) as the eluent.
[0268] Yield: 0.400 g (79%), pink crystals. Mp.: 76-78° C.
[0269] 1 H NMR (CDCl 3 ): 6.24 (AB, 2H, CH 2 , J=1.1); 6.76 (d, 1H, Ar, J=7.8); 7.05 (d, 1H, Ar, J=7.8); 7.31-7.34 (m, 1H, Ar); 7.54-7.59 (m, 1H, Ar); 7.61-7.67 (m, 1H, Ar); 8.00-8.05 (m, 1H, Ar); 9.80 (s, 1H, CHO); 9.90 (s, 1H, CHO).
[0270] Analysis calculated for C 15 H 10 O 4 (254.24): C, 70.86%; H, 3.96%. Found: C, 70.87%; H, 3.92%.
Step 2: 5-{2-[(Hydroxyimino)methyl]phenyl}-1,3-benzodioxole-4-carbaldehyde oxime (compound 12)
[0271] The process described in Method A was followed. 5-(2-Formylphenyl)-1,3-benzodioxole-4-carbaldehyde (0.350 g, 1.38 mmol) was used to obtain the title compound.
[0272] Work-up/purification: the reaction mixture was evaporated in vacuo to dryness, to the residue water was added and the aqueous phase was extracted with ethyl acetate. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization (two times) from a mixture of ethanol and water (4:1).
[0273] Yield: 0.114 g (29%), pink crystals. Mp.: 227-229° C.
[0274] 1 H NMR (DMSO-d 6 ): 6.15+6.17 (AB, 2H, CH 2 , J=1.0); 6.67 (d, 1H, Ar, J=8.0); 6.99 (d, 1H, Ar, J=8.0); 7.17-7.23 (m, 1H, Ar); 7.40-7.45 (m, 2H, Ar); 7.46 (s, 1H, OH—N═C—H); 7.64 (s, 1H, OH—NH═C—H); 7.83-7.88 (m, 1H, Ar); 11.30 (s, 1H, OH); 11.39 (s, 1H, OH).
[0275] Analysis calculated for C 15 H 12 N 2 O 4 (284.27): C, 63.38%; H, 4.25%; N, 9.85%. Found: C, 63.30%; H, 4.14%; N, 9.73%.
III.8: Example 13
5-(2-Fluorophenyl)-1,3-benzodioxole-4-carbaldehyde oxime (compound 13)
[0276]
Step 1: 5-(2-Fluorophenyl)-1,3-benzodioxole-4-carbaldehyde
[0277] The process described in Method B was followed. 5-Bromo-1,3-benzodioxole-4-carbaldehyde (0.458 g, 2.00 mmol) and 2-fluorophenylboronic acid (0.420 g, 3.00 mmol) were used to obtain the title compound. The crude product was purified by column chromatography with a mixture of hexane:ethyl acetate (4:1) as the eluent.
[0278] Yield: 0.453 g (93%), yellow crystals. Mp.: 84-86° C.
[0279] 1 H NMR (CDCl 3 ): 6.20 (s, 2H, CH 2 ); 6.83 (d, 1H, Ar, J=8.0); 7.05 (d, 1H, Ar, J=8.0); 7.11-7.17 (m, 1H, Ar); 7.20-7.33 (m, 2H, Ar); 7.36-7.43 (m, 1H, Ar); 9.82 (d, 1H, CHO, J=2.9).
[0280] Analysis calculated for C 14 H 9 FO 3 (244.22): C, 68.85%; H, 3.71%. Found: C, 68.91%; H, 3.53%.
Step 2: 5-(2-Fluorophenyl)-1,3-benzodioxole-4-carbaldehyde oxime (compound 13)
[0281] The process described in Method A was followed. 5-(2-Fluorophenyl)-1,3-benzodioxole-4-carbaldehyde (0.350 g, 1.43 mmol) was used to obtain the title compound.
[0282] Work-up/purification: the reaction mixture was evaporated in vacuo to dryness, to the residue water was added and the aqueous phase was extracted with ethyl acetate. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization (two times) from a mixture of ethanol and water (4:1).
[0283] Yield: 0.180 g (49%), white crystals. Mp.: 197-198° C.
[0284] 1 H NMR (DMSO-d 6 ): 6.15 (s, 2H, CH 2 ); 6.78 (d, 1H, Ar, J=8.0); 7.00 (d, 1H, Ar, J=8.0); 7.24-7.34 (m, 3H, Ar); 7.42-7.49 (m, 1H, Ar); 7.66 (d, 1H, OH—N═C—H, J=2.2); 11.38 (s, 1H, OH).
[0285] Analysis calculated for C 14 H 10 FNO 3 (259.23): C, 64.87%; H, 3.89%; N, 5.40%. Found: C, 64.82%; H, 3.65%; N, 5.34%.
III.9: Example 14
5-(2-Chlorophenyl)-1,3-benzodioxole-4-carbaldehyde oxime (compound 14)
[0286]
Step 1: 5-(2-Chlorophenyl)-1,3-benzodioxole-4-carbaldehyde
[0287] The process described in Method B was followed. 5-Bromo-1,3-benzodioxole-4-carbaldehyde (0.458 g, 2.00 mmol) and 2-chlorophenylboronic acid (0.469 g, 3.00 mmol) were used to obtain the title compound. The crude product was purified by column chromatography with a mixture of hexane:ethyl acetate (4:1) as the eluent.
[0288] Yield: 0.420 g (81%), yellow crystals. Mp.: 84-86° C.
[0289] 1 H NMR (CDCl 3 ): 6.20 (AB, 2H, CH 2 , J=1.2); 6.76 (d, 1H, Ar, J=8.0); 7.04 (d, 1H, Ar, J=8.0); 7.28-7.40 (m, 3H, Ar); 7.44-7.49 (m, 1H, Ar); 9.69 (s, 1H, CHO).
[0290] Analysis calculated for C 14 H 9 ClO 3 (260.67): C, 64.51%; H, 3.48%. Found: C, 64.37%; H, 3.30%.
Step 2: 5-(2-Chlorophenyl)-1,3-benzodioxole-4-carbaldehyde oxime (compound 14)
[0291] The process described in Method A was followed. 5-(2-Chlorophenyl)-1,3-benzodioxole-4-carbaldehyde (0.350 g, 1.34 mmol) was used to obtain the title compound.
[0292] Work-up/purification: the reaction mixture was evaporated in vacuo to dryness, to the residue water was added and the aqueous phase was extracted with ethyl acetate. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization (two times) from a mixture of ethanol and water (4:1).
[0293] Yield: 0.079 g (21%), white crystals. Mp.: 182-183° C.
[0294] 1 H NMR (DMSO-d 6 ): 6.15 (AB, 2H, CH 2 , J=1.0); 6.69 (d, 1H, Ar, J=7.8); 7.00 (d, 1H, Ar, J=7.8); 7.29-7.33 (m, 1H, Ar); 7.39-7.46 (m, 2H, Ar); 7.51 (s, 1H, OH—N═C—H); 7.53-7.57 (m, 1H, Ar); 11.37 (s, 1H, OH).
[0295] Analysis calculated for C 14 H 10 ClNO 3 (275.69): C, 60.99%; H, 3.66%; N, 5.08%. Found: C, 61.41%; H, 3.42%; N, 5.03%.
III.10: Example 15
5-(2-Bromophenyl)-1,3-benzodioxole-4-carbaldehyde oxime (compound 15)
[0296]
Step 1: 5-(2-Bromophenyl)-1,3-benzodioxole-4-carbaldehyde
[0297] The process described in Method B was followed. 5-Bromo-1,3-benzodioxole-4-carbaldehyde (1.15 g, 5.00 mmol) and 2-bromophenylboronic acid (1.10 g, 5.50 mmol) were used to obtain the title compound. The crude product was purified by column chromatography with a mixture of hexane:ethyl acetate (9:1) as the eluent.
[0298] Yield: 0.900 g (59%), yellow crystals. Mp.: 89-91° C.
[0299] 1 H NMR (CDCl 3 ): 6.21 (AB, 2H, CH 2 , J=1.4); 6.73 (d, 1H, Ar, J=8.0); 7.04 (d, 1H, Ar, J=8.0); 7.25-7.33 (m, 2H, Ar); 7.36-7.41 (m, 1H, Ar); 7.63-7.69 (m, 1H); 9.68 (s, 1H, CHO).
[0300] Analysis calculated for C 14 H 9 BrO 3 (305.12): C, 55.11%; H, 2.97%. Found: C, 56.53%; H, 2.85%.
Step 2: 5-(2-Bromophenyl)-1,3-benzodioxole-4-carbaldehyde oxime (compound 15)
[0301] The process described in Method A was followed. 5-(2-Bromophenyl)-1,3-benzodioxole-4-carbaldehyde (0.350 g, 1.15 mmol) was used to obtain the title compound.
[0302] Work-up/purification: the reaction mixture was evaporated in vacuo to dryness, to the residue water was added and the aqueous phase was extracted with ethyl acetate. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization (two times) from a mixture of ethanol and water (4:1).
[0303] Yield: 0.139 g (38%), yellow crystals. Mp.: 168-169° C.
[0304] 1 H NMR (DMSO-d 6 ): 6.15 (AB, 2H, CH 2 , J=7.4, 1.0); 6.66 (d, 1H, Ar, J=8.0); 6.99 (d, 1H, Ar, J=8.0); 7.28-7.33 (m, 1H, Ar); 7.33-7.37 (m, 1H, Ar); 7.43-7.48 (m, 1H, Ar); 7.49 (s, 1H, OH—N═C—H); 7.70-7.74 (m, 1H, Ar); 11.37 (s, 1H, OH).
[0305] Analysis calculated for C 14 H 16 BrNO 3 (320.14): C, 52.52%; H, 3.15%; N, 4.38%. Found: C, 52.66%; H, 2.97%; N, 4.35%.
IV. Type 4 of Production Examples
Synthesis of 1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine oximes (Procedure D)
IV.1: Example 16
6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 16)
[0306]
Step 1: 6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (Method C, as a preferred embodiment of Procedure D, Scheme 5)
[0307] To a stirred solution of sodium (3.82 mmol) in ethanol (3.8 ml) under argon at 5-7° C., 6-chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (2.67 mmol) (Tetrahedron Lett., 1993, 34(51), 8213-8216) was added. The resulting mixture was stirred at room temperature under argon for 1 h. Then it was evaporated to dryness in vacuo and the residue was stirred in a mixture of ice-water (40 ml) and ethyl acetate (20 ml). After separation of the phases, the aqueous phase was extracted with ethyl acetate (20 ml). The combined organic phases were washed with water, brine and dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo, and the crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (1:1) as the eluent.
[0308] Yield: 0.203 g (36%), white crystals. Mp.: 110-111° C.
[0309] 1 H NMR (CDCl 3 ): 1.50 (t, 3H, CH 3 ); 3.38 (s, 3H, N—CH 3 ); 3.44 (s, 3H, N—CH 3 ); 4.54 (s, 2H, O—CH 2 ); 10.08 (s, 1H, CHO).
[0310] Analysis calculated for C 9 H 12 N 2 O 4 (212.20): C, 50.94%; H, 5.70%; N, 13.20%. Found: C, 49.89%; H, 5.30%; N, 13.14%.
Step 2: 6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 16)
[0311] The process described in Method A was followed. 6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.386 g, 1.82 mmol) was used to obtain the title compound.
[0312] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0313] Yield: 0.256 g (62%), white crystals. Mp.: 115° C.
[0314] 1 H NMR (DMSO-d 6 ): 1.34 (t, 3H, CH 3 ); 3.17 (s, 3H, N—CH 3 ); 3.29 (s, 3H, N—CH 3 ); 4.20 (q, 2H, CH 2 ); 7.89 (s, 1H, CH); 11.02 (s, 1H, N—OH).
[0315] Analysis calculated for C 9 H 13 N 3 O 4 (227.22): C, 47.57%; H, 5.77%; N, 18.49%. Found: C, 47.49%; H, 5.66%; N, 18.34%.
IV.2: Example 17
[0316]
Step 1: 6-Methoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde
[0317] The process described in Method C was followed. 6-Chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.270 g, 1.33 mmol) and methanol were used to obtain the title compound. The crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (4:1) as the eluent.
[0318] Yield: 0.089 g (34%), white crystals. Mp.: 105-107° C.
[0319] 1 H NMR (CDCl 3 ): 3.38 (s, 3H, N—CH 3 ); 3.44 (s, 3H, N—CH 3 ); 4.25 (s, 3H, O—CH 3 ); 10.08 (s, 1H, CHO).
[0320] Analysis calculated for C 8 H 10 N 2 O 4 (198.18): C, 48.48%; H, 5.09%; N, 14.14%. Found: C, 48.43%; H, 5.40%; N, 13.93%.
Step 2: 6-Methoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 17)
[0321] The process described in Method A was followed. 6-Methoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.125 g, 0.63 mmol) was used to obtain the title compound.
[0322] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of chloroform:methanol (95:5) as the eluent.
[0323] Yield: 0.090 g (67%), white crystals. Mp.: 127-128° C.
[0324] 1 H NMR (DMSO-d 6 ): 3.17 (s, 3H, N—CH 3 ); 3.29 (s, 3H, N—CH 3 ); 3.93 (s, 3H, O—CH 3 ); 7.90 (s, 1H, CH); 11.09 (s, 1H, N—OH).
[0325] Analysis calculated for C 8 H 11 N 3 O 4 (213.19): C, 45.07%; H, 5.20%; N, 19.71%. Found: C, 44.46%; H, 5.07%; N, 19.20%.
IV.3: Example 18
1,3-Dimethyl-2,4-dioxo-6-propoxy-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 18)
[0326]
Step 1: 1,3-Dimethyl-2,4-dioxo-6-propoxy-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde
[0327] The process described in Method C was followed. 6-Chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.270 g, 1.33 mmol) and propanol were used to obtain the title compound. The crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (1:1) as the eluent.
[0328] Yield: 0.118 g (40%), white crystals. Mp.: 57-58° C.
[0329] 1 H NMR (CDCl 3 ): 1.04 (t, 3H, CH 3 ); 1.88 (sx, 2H, CH 2 ); 3.38 (s, 3H, N—CH 3 ); 3.45 (s, 3H, N—CH 3 ); 4.43 (t, 2H, O—CH 2 ); 10.06 (s, 1H, CHO).
[0330] Analysis calculated for C 10 H 14 N 2 O 4 (226.23): C, 53.09%; H, 6.24%; N, 12.38%. Found: C, 53.04%; H, 7.02%; N, 12.42%.
Step 2: 1,3-Dimethyl-2,4-dioxo-6-propoxy-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 18)
[0331] The process described in Method A was followed. 1,3-Dimethyl-2,4-dioxo-6-propoxy-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.110 g, 0.48 mmol) was used to obtain the title compound.
[0332] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of chloroform:methanol (9:1) as the eluent.
[0333] Yield: 0.086 g (73%), white crystals. Mp.: 119-120° C.
[0334] 1 H NMR (DMSO-d 6 ): 0.95 (t, 3H, CH 3 ); 1.76 (sx, 2H, CH 2 ); 3.17 (s, 3H, N—CH 3 ); 3.30 (s, 3H, N—CH 3 ); 4.10 (t, 2H, O—CH 2 ); 7.88 (s, 1H, CH); 11.05 (s, 1H, N—OH).
[0335] Analysis calculated for C 10 H 15 N 3 O 4 (241.24): C, 49.79%; H, 6.27%; N, 17.42%. Found: C, 49.33%; H, 6.10%; N, 17.08%.
IV.4: Example 19
6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde O-methyloxime (compound 19)
[0336]
[0337] The process described in Method A was followed. 6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (Example 16, Step 1) (0.168 g, 0.79 mmol) and methoxyamine hydrochloride (0.087 g, 1.04 mmol) were used to obtain the title compound.
[0338] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (1:1) as the eluent.
[0339] Yield: 0.154 g (81%), white crystals. Mp.: 108-109° C.
[0340] 1 H NMR (DMSO-d 6 ): 1.38 (t, 3H, CH 3 ); 3.17 (s, 3H, N—CH 3 ); 3.31 (s, 3H, N—CH 3 ); 3.83 (s, 3H, O—CH 3 ); 4.22 (q, 2H, O—CH 2 ); 7.97 (s, 1H, CH).
[0341] Analysis calculated for C 10 H 15 N 3 O 4 (241.24): C, 49.79%; H, 6.27%; N, 17.42%. Found: C, 49.99%; H, 6.34%; N, 17.47%.
IV.5: Example 20
6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde O-benzyloxime (compound 20)
[0342]
[0343] The process described in Method A was followed. 6-Ethoxy-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.074 mg, 0.35 mmol) (Example 16, Step 1) and O-benzyl-hydroxyl-amine hydrochloride (0.073 mg, 0.46 mmol) were used to obtain the title compound.
[0344] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0345] Yield: 0.102 g (93%), white crystals. Mp.: 93-94° C.
[0346] 1 H NMR (DMSO-d 6 ): 1.21 (t, 3H, CH 3 ); 3.16 (s, 3H, N—CH 3 ); 3.27 (s, 3H, N—CH 3 ); 4.05 (q, 2H, O—CH 2 ); 5.10 (s, 2H, N—CH—Ar); 7.27-7.39 (m, 5H, Ar); 8.06 (s, 1H, CH).
[0347] Analysis calculated for C 16 H 19 N 3 O 4 (317.34): C, 60.56%; H, 6.03%; N, 13.24%. Found: C, 60.07%; H, 5.86%; N, 13.10%.
IV.6: Example 21
1,3-Dimethyl-2,4-dioxo-6-(propylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 21)
[0348]
Step 1: 1,3-Dimethyl-2,4-dioxo-6-(propylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (Method D, as a preferred embodiment of Procedure D, Scheme 6)
[0349] To a stirred solution of propane-1-thiol (2.30 mmol) in dry 1,4-dioxane (4 ml), NaH (2.30 mmol) was added under argon. To the mixture, a solution of 6-chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (2 mmol) in dry 1,4-dioxane (8 ml) was added at 5-8° C. in one portion. The mixture was stirred at room temperature until the starting material was consumed (monitored by TLC). Then the mixture was poured onto ice water (50 ml) and the aqueous phase was extracted with ethyl acetate (3×30 ml). The combined organic phases were washed with water and dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo and the crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (1:1) as the eluent.
[0350] Yield: 0.160 g (39%), pale yellow crystals. Mp.: 53-55° C.
[0351] 1 H NMR (CDCl 3 ): 1.02 (t, 3H, CH 3 ); 1.69 (sx, 2H, CH 2 ); 3.02 (t, 2H, S—CH 2 ); 3.40 (s, 3H, N—CH 3 ); 3.72 (s, 3H, N—CH 3 ); 10.19 (s, 1H, CHO).
[0352] Analysis calculated for C 10 H 14 N 2 O 3 S (242.29): C, 49.57%; H, 5.82%; N, 11.56%. Found: C, 49.22%; H, 6.33%; N, 11.72%.
Step 2: 1,3-Dimethyl-2,4-dioxo-6-(propylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 21)
[0353] The process described in Method A was followed. 1,3-Dimethyl-2,4-dioxo-6-(propylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.144 g, 0.60 mmol) was used to obtain the title compound.
[0354] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0355] Yield: 0.106 g (69%), white crystals. Mp.: 161-162° C.
[0356] 1 H NMR (DMSO-d 6 ): 0.92 (t, 3H, CH 3 ); 1.54 (sx, 2H, CH 2 ); 2.89 (t, 2H, S—CH 2 ); 3.19 (s, 3H, N—CH 3 ); 3.58 (s, 3H, N—CH 3 ); 8.00 (s, 1H, CH); 11.29 (s, 1H, N—OH).
[0357] Analysis calculated for C 10 H 15 N 3 O 3 S (257.31): C, 46.68%; H, 5.88%; N, 16.33%. Found: C, 46.49%; H, 5.54%; N, 16.32%.
IV.7: Example 22
1,3-Dimethyl-6-(methylthio)-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 22)
[0358]
Step 1: 1,3-Dimethyl-6-(methylthio)-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde
[0359] The process described in Method D was followed. 6-Chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.404 g, 2.00 mmol) and sodium thiomethoxide (0.154 g, 2.20 mmol in 4 ml 1,4-dioxane) were used to obtain the title compound. The crude product was purified by washing with n-pentane.
[0360] Yield: 0.302 g (70%), pale yellow crystals. Mp.: 104° C.
[0361] 1 H NMR (CDCl 3 ): 2.58 (s, 3H, S—CH 3 ); 3.38 (s, 3H, N—CH 3 ); 3.69 (s, 3H, N—CH 3 ); 10.16 (s, 1H, CHO).
[0362] Analysis calculated for C 8 H 10 N 2 O 3 S (214.24): C, 44.85%; H, 4.70%; N, 13.08%. Found: C, 44.80%; H, 4.82%; N, 13.05%.
Step 2: 1,3-Dimethyl-6-(methylthio)-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 22)
[0363] The process described in Method A was followed. 1,3-Dimethyl-6-(methylthio)-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.546 g, 2.55 mmol) was used to obtain the title compound.
[0364] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of chloroform:methanol (9:1) as the eluent.
[0365] Yield: 0.443 g (76%), white crystals. Mp.: 165° C.
[0366] 1 H NMR (DMSO-d 6 ): 2.43 (s, 3H, S—CH 3 ); 3.19 (s, 3H, N—CH 3 ); 3.58 (s, 3H, N—CH 3 ); 7.98 (s, 1H, CH); 11.29 (s, 1H, N—OH).
[0367] Analysis calculated for C 8 H 11 N 3 O 3 S (229.26): C, 41.91%; H, 4.84%; N, 18.33%. Found: C, 41.55%; H, 4.83%; N, 18.00%.
IV.8: Example 23
6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 23)
[0368]
Step 1: 6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde
[0369] The process described in Method D was followed. 6-Chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.303 g, 1.50 mmol) and ethanethiol were used to obtain the title compound. The crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (1:1) as the eluent.
[0370] Yield: 0.102 g (30%), white crystals. Mp.: 72° C.
[0371] 1 H NMR (CDCl 3 ): 1.32 (t, 3H, CH 3 ); 3.06 (q, 2H, CH 2 ); 3.38 (s, 3H, N—CH 3 ); 3.69 (s, 3H, N—CH 3 ); 10.18 (s, 1H, CHO).
[0372] Analysis calculated for C 9 H 12 N 2 O 3 S (228.27): C, 47.36%; H, 5.30%; N, 12.27%. Found: C, 47.24%; H, 5.35%; N, 12.20%.
Step 2: 6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 23)
[0373] The process described in Method A was followed. 6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.200 g, 0.87 mmol) was used to obtain the title compound.
[0374] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off and washed with water and n-pentane.
[0375] Yield: 0.097 g (40%), white crystals. Mp.: 161-163° C.
[0376] 1 H NMR (DMSO-d 6 ): 1.19 (t, 3H, CH 3 ); 2.93 (q, 2H, S—CH 2 ); 3.19 (s, 3H, N—CH 3 ); 3.58 (s, 3H, N—CH 3 ); 8.00 (s, 1H, CH); 11.29 (s, 1H, N—OH).
[0377] Analysis calculated for C 9 H 13 N 3 O 3 S (243.28): C, 44.43%; H, 5.39%; N, 17.27%. Found: C, 44.18%; H, 5.24%; N, 16.93%.
IV.9: Example 24
1,3-Dimethyl-2,4-dioxo-6-(phenylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 24)
[0378]
Step 1: 1,3-Dimethyl-2,4-dioxo-6-(phenylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde
[0379] The process described in Method D was followed. 6-Chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (1.50 g, 7.40 mmol) and benzenethiol were used to obtain the title compound.
[0380] Work-up/purification: the reaction mixture was evaporated to dryness and to the residue ethyl acetate (40 ml) was added. The organic phase was washed with water (3×40 ml) and dried over anhydrous MgSO 4 . The crude product was purified by crystallization from a mixture of ethanol and diethyl ether (1:1).
[0381] Yield: 0.612 g (30%), beige crystals. Mp.: 132.4-133.5° C. (dec).
[0382] 1 H NMR (DMSO-d 6 ): 3.21 (s, 3H, N—CH 3 ); 3.27 (s, 3H, N—CH 3 ); 7.30-7.55 (m, 5H, phenyl); 10.02 (s, 1H, CHO).
[0383] Analysis calculated for C 13 H 12 N 2 O 3 S (276.31): C, 56.51%; H, 4.38%; N, 10.14%. Found: C, 56.30%; H, 4.07%; N, 10.08%.
Step 2: 1,3-Dimethyl-2,4-dioxo-6-(phenylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 24)
[0384] The process described in Method A was followed. 1,3-Dimethyl-2,4-dioxo-6-(phenylthio)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.400 g, 1.44 mmol) was used to obtain the title compound.
[0385] Work-up/purification: the precipitated crystals were filtered off and washed with water and ethanol. The crude product was purified by crystallization from a mixture of isopropyl alcohol and water (20:1).
[0386] Yield: 0.195 g (45%), pale yellow crystals. Mp.: 151.7-152.5° C.
[0387] 1 H NMR (DMSO-d 6 ): 3.22 (s, 3H, N—CH 3 ); 3.24 (s, 3H, N—CH 3 ); 7.45-7.30 (m, 5H, phenyl); 7.99 (s, 1H, HO—N═C—H); 11.45 (1H, s, OH).
[0388] Analysis calculated for C 13 H 13 N 3 O 3 S (291.32): C, 53.60%; H, 4.50%; N, 14.42%. Found: C, 53.57%; H, 4.21%; N, 14.37%.
IV.10: Example 25
6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde O-methyloxime (compound 25)
[0389]
[0390] The process described in Method A was followed. 6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (Example 23, Step 1) (0.148 mg, 0.65 mmol) and methoxyamine hydrochloride (0.072 mg, 0.86 mmol) were used to obtain the title compound.
[0391] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (1:1) as the eluent.
[0392] Yield: 0.130 g (78%), white crystals. Mp.: 74-75° C. 1 H NMR (DMSO-d 6 ): 1.20 (t, 3H, CH 3 ); 2.94 (q, 2H, CH 2 ); 3.19 (s, 3H, N—CH 3 ); 3.58 (s, 3H, N—CH 3 ); 3.84 (s, 3H, O—CH 3 ); 8.08 (s, 1H, CH).
[0393] Analysis calculated for C 10 H 15 N 3 O 3 S (257.31): C, 46.68%; H, 5.88%; N, 16.33%. Found: C, 46.81%; H, 5.80%; N, 16.32%.
IV.11: Example 26
6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde O-benzyloxime (compound 26)
[0394]
[0395] The process described in Method A was followed. 6-(Ethylthio)-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (Example 23, Step 1) (0.070 mg, 0.30 mmol) and O-benzyl-hydroxylamine hydrochloride (0.063 mg, 0.40 mmol) were used to obtain the title compound.
[0396] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of n-hexane:ethyl acetate (1:1) as the eluent.
[0397] Yield: 0.079 g (78%), white crystals. Mp.: 76° C.
[0398] 1 H NMR (DMSO-d 6 ): 1.13 (t, 3H, CH 3 ); 2.86 (q, 2H, S—CH 2 ); 3.18 (s, 3H, N—CH 3 ); 3.56 (s, 3H, N—CH 3 ); 5.12 (s, 2H, O—CH 2 —Ar); 7.28-7.43 (m, 5H, Ar); 8.15 (s, 1H, CH).
[0399] Analysis calculated for C 16 H 19 N 3 O 3 S (333.41): C, 57.64%; H, 5.74%; N, 12.60%. Found: C, 57.62%; H, 5.48%; N, 12.61%.
IV.12: Example 27
6-[Allyl(methyl)amino]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 27)
[0400]
Step 1: 6-[Allyl(methyl)amino]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde
[0401] To a stirred solution of 6-chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.500 g, 2.47 mmol) and triethyl-amine (0.52 ml, 3.71 mmol) in dry ethanol (10 ml), N-methylprop-2-en-1-amine (0.36 ml, 3.71 mmol) was added under argon. The resulting mixture was stirred at room temperature under argon overnight. After evaporation of the solvent in vacuo, water (15 ml) was added to the yellow oily residue, and the mixture was extracted with dichloromethane (4×15 ml). The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo, and the crude product was purified by crystallization from a mixture of cyclohexane:isopropyl alcohol (4:1).
[0402] Yield: 0.330 g (55%), beige crystals. Mp.: 81.6-83.5° C.
[0403] 1 H NMR (CDCl 3 ): 2.89 (s, 3H, N(6)CH 3 ); 3.35 (s, 3H, N—CH 3 ); 3.41 (s, 3H, N—CH 3 ); 3.78 (d, 2H, N—CH 2 —CH═CH 2 , J=3.4); 5.20-5.40 (m, 2H, N—CH 2 —CH═CH 2 ); 5.65-5.75 (m, 1H, N—CH 2 —CH═CH 2 ); 9.95 (s, 1H, CHO).
[0404] Analysis calculated for C 11 H 15 N 3 O 3 (237.25): C, 55.69%; H, 6.37%; N, 17.71%. Found: C, 55.58%; H, 6.09%; N, 17.65%.
Step 2: 6-[Allyl(methyl)amino]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 27)
[0405] The process described in Method A was followed. 6-[Allyl(methyl)amino]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.120 g, 0.50 mmol) was used to obtain the title compound.
[0406] Work-up/purification: the precipitated crystals were filtered off. The crude product was purified by crystallization from a mixture of ethanol and water (2:1).
[0407] Yield: 0.022 g (55%), white crystals. Mp.: 95.5-97.1° C.
[0408] 1 H NMR (DMSO-d 6 ): 2.61 (s, 3H, N(6)CH 3 ); 3.16 (s, 3H, N—CH 3 ); 3.32 (s, 3H, N—CH 3 ); 3.54 (d, 2H, N—CH 2 —CH═CH 2 , J=6.4); 5.05-5.15 (m, 2H, N—CH 2 —CH═CH 2 ); 5.70-5.90 (m, 1H, N—CH 2 —CH═CH 2 ); 7.88 (s, 1H, HO—N═C—H); 10.98 (s, 1H, OH).
[0409] Analysis calculated for C 11 H 16 N 4 O 3 ×0.5 H 2 O (261.27): C, 50.57%; H, 6.56%; N, 21.44%. Found: C, 49.83%; H, 7.12%; N, 21.02%.
IV.13: Example 28
1,3-Dimethyl-2,4-dioxo-6-(4-phenylpiperazin-1-yl)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 28)
[0410]
Step 1: 1,3-Dimethyl-2,4-dioxo-6-(4-phenylpiperazin-1-yl)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde
[0411] To an ice-cooled, stirred solution of 6-chloro-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.600 g, 2.96 mmol) and triethyl-amine (0.45 ml, 3.26 mmol) in dichloromethane (20 ml), a solution of N-phenylpiperazine (0.49 ml, 3.26 mmol) in dichloromethane (10 ml) was added dropwise. The resulting suspension was stirred at room temperature until the starting material was consumed (3.5 h, monitored by TLC). Then the reaction mixture was washed with water (3×10 ml), and the organic phase was dried over 20, anhydrous MgSO 4 . The solvent was evaporated in vacuo, and the brown oily crude product was purified by column chromatography with a mixture of dichloromethane:ethyl acetate (1:1) as the eluent and crystallized from ethanol.
[0412] Yield: 0.710 g (73%), orange crystals. Mp.: 167.2-168.5° C.
[0413] 1 H NMR (CDCl 3 ): 3.33-3.35 (m, 4H, N—(CH 2 ) 2 ); 3.36 (s, 3H, N—CH 3 ); 3.43-3.45 (m, 4H, N—(CH 2 ) 2 ); 3.51 (s, 3H, N—CH 3 ); 6.94-6.97 (m, 3H, Ar); 7.28-7.33 (m, 2H, Ar); 10.0 (s, 1H, CHO).
[0414] Analysis calculated for C 17 H 20 N 4 O 3 (328.36): C, 62.18%; H, 6.14%; N, 17.06%. Found: C, 61.93%; H, 6.02%; N, 16.95%.
Step 2: 1,3-Dimethyl-2,4-dioxo-6-(4-phenylpiperazin-1-yl)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde oxime (compound 28)
[0415] The process described in Method A was followed. 1,3-Dimethyl-2,4-dioxo-6-(4-phenylpiperazin-1-yl)-1,2,3,4-tetrahydropyrimidine-5-carbaldehyde (0.400 g, 1.20 mmol) was used as starting material.
[0416] Work-up/purification: the precipitated crystals were filtered off and washed with water and ethanol. The crude product was purified by crystallization from a mixture of ethanol and water (4:1).
[0417] Yield: 0.153 g (37%), white crystals. Mp.: 173.4-174.3° C.
[0418] 1 H NMR (DMSO-d 6 ): 3.07-3.14 (m, 4H, N(CH 2 ) 2 ); 3.16 (s, 3H, N—CH 3 ); 3.30-3.37 (m, 4H, N(CH 2 ) 2 ); 6.75-6.83 (m, 1H, H-4 phenyl); 6.90-7.10 (m, 2H, H-2, H-6 phenyl); 7.20-7.30 (m, 2H, H-3, H-5 phenyl); 7.92 (s, 1H, HO—N═C—H); 11.10 (1H, s, OH).
[0419] Analysis calculated for C 17 H 21 N 5 O 3 (343.38): C, 59.46%; H, 6.16%; N, 20.40%. Found: C, 59.11%; H, 5.97%; N, 20.13%.
V. Type 5 of Production Examples
Synthesis of Pyridazinone Oximes (Procedure E)
V.1: Example 29
E-2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 29)
[0420]
Step 1: 2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazine-4-carbaldehyde
[0421] A solution of 2-methyl-5-(piperidin-1-yl)pyridazin-3(2H)-one [F. Farina, M. V. Martin and A. Tito, An. Quim., 77, 188-195 (1981)] (1.35 g, 7 mmol) in dry DMF (23.3 ml) was cooled to 5° C., then a solution of POCl 3 (1.44 ml, 15.4 mmol) in dry DMF (3.5 ml) was added dropwise. The cooling bath was removed and the mixture was stirred at room temperature for 30 min. Then, the temperature was raised to 70° C. and stirring was continued for 75 min. After cooling, the volatile components were removed under reduced pressure and the residue was treated with crushed ice (15 g). The mixture was adjusted to pH 7-8 with aqueous NaOH. Then it was extracted with dichloromethane (4×40 ml) and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. Residual volatile material was removed at 10 −2 mbar to leave an oily residue which slowly solidified on storage in a refrigerator.
[0422] Yield: 1.35 g (87%), yellow-orange wax-like material. Mp.: 78-79° C.
[0423] 1 H NMR (300 MHz, CDCl 3 ): 1.70-1.74 (m, 6H, CH 2 ); 3.39-3.42 (m, 4H, NCH 2 ); 3.64 (s, 3H, NCH 3 ); 7.69 (s, 1H, H-6); 10.16 (s, 1H, CHO).
[0424] Analysis calculated for C 11 H 15 N 3 O 2 (221.26): C, 59.71%; H, 6.83%; N, 18.99%. Found: C, 59.80%; H, 6.83%; N, 18.81%.
Step 2: E-2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 29)
[0425] The process described in Method A was followed. 2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazine-4-carbaldehyde (663 mg, 3.00 mmol) was used to obtain the title compound. The reaction mixture was refluxed until the starting material was completely consumed (approx. 3 h; TLC monitoring: dichloromethane:methanol (9:1)).
[0426] Work-up/purification: the reaction mixture was evaporated to dryness under reduced pressure. After addition of water, the pH was adjusted to 7-8 with ammonia. The mixture was exhaustively extracted with dichloromethane and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product (containing an E/Z mixture) was recrystallized from ethyl acetate to afford the pure E isomer.
[0427] Yield: 326 mg (46%), pale yellow crystals. Mp.: 170-171° C.
[0428] 1 H NMR (300 MHz, CDCl 3 ): 1.60-1.70 (m, 6H, CH 2 ); 3.18-3.23 (m, 4H, NCH 2 ); 3.73 (s, 3H, NCH 3 ); 7.65 (s, 1H, H-6); 8.06 (s, 1H, HO—N═C—H; shows NOE on irradiation at 11.31 ppm); 11.31 (br s, 1H, N—OH).
[0429] Analysis calculated for C 11 H 16 N 4 O 2 (236.28): C, 55.92%; H, 6.83%; N, 23.71%. Found: C, 56.12%; H, 6.80%; N, 23.68%.
V.2: Example 30
E-2-Methyl-5-(4-methylpiperazin-1-yl)-3-oxo-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 30)
[0430]
Step 1: 4-Chloro-2-methyl-5-(4-methylpiperazin-1-yl)pyridazin-3(2H)-one
[0431] A mixture of 4,5-dichloro-2-methylpyridazin-3(2H)-one [S.-F. Chen and R. P. Panzica, J. Org. Chem., 46, 2467-2473 (1981)] (8.95 g, 50 mmol) and 1-methylpiperazine (12.5 g, 125 mmol) in water (150 ml) was refluxed for 30 h. After cooling, about two thirds of the solvent was removed under reduced pressure and the mixture was adjusted to pH 7-8 by addition of aqueous NaHCO 3 . It was then extracted with dichloromethane (4×40 ml) and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product was purified by recrystallization from ethanol (95%).
[0432] Yield: 7.97 g (66%), colorless crystals. Mp.: 132-133° C.
[0433] 1 H NMR (300 MHz, CDCl 3 ): 2.31 (s, 3H, piperazine NCH 3 ); 2.50-2.53 (m, 4H, CH 2 ); 3.36-3.39 (m, 4H, CH 2 ); 3.72 (s, 3H, pyridazine NCH 3 ); 7.55 (s, 1H, H-6).
[0434] Analysis calculated for C 10 H 15 ClN 4 O (242.71): C, 49.49%; H, 6.23%; N, 23.08%. Found: C, 49.63%; H, 6.33%; N, 22.84%.
Step 2: 2-Methyl-5-(4-methylpiperazin-1-yl)pyridazin-3(2H)-one
[0435] To a mixture of 4-chloro-2-methyl-5-(4-methylpiperazin-1-yl)pyridazin-3(2H)-one (4.85 g, 20 mmol) and 10% Pd/C catalyst (1.14 g) in methanol (100 ml) was added ammonium formate (2.90 g, 46 mmol), and the mixture was refluxed under argon with TLC monitoring (dichloromethane:methanol (9:1)). Further portions of ammonium formate were added until the starting material was completely consumed. The catalyst was filtered off and washed with methanol, then the solvent was evaporated under reduced pressure. The residue was taken up in water (30 ml) and extracted with dichloromethane (4×40 ml). The combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product was purified by recrystallization from ethyl acetate:light petroleum.
[0436] Yield: 2.57 g (62%), colorless crystals. Mp.: 127-128° C.
[0437] 1 H NMR (300 MHz, CDCl 3 ): 2.31 (s, 3H, piperazine NCH 3 ); 2.46-2.49 (m, 4H, CH 2 ); 3.26-3.30 (m, 4H, CH 2 ); 3.66 (s, 3H, pyridazine NCH 3 ); 5.88 (d, 1H, H-4, J=2.7); 7.60 (d, 1H, H-6, J=2.7).
[0438] Analysis calculated for C 10 H 16 N 4 O (208.27): C, 57.67%; H, 7.74%; N, 26.90%. Found: C, 57.88%; H, 7.94%; N, 26.85%.
Step 3: 2-Methyl-5-(4-methylpiperazino)-3-oxo-2,3-dihydropyridazine-4-carbaldehyde
[0439] A solution of 2-methyl-5-(4-methylpiperazin-1-yl)pyridazin-3(2H)-one (416 mg, 2 mmol) in dry DMF (6.7 ml) was cooled to 5° C., then a solution of POCl 3 (0.41 ml, 4.4 mmol) in dry DMF (1 ml) was added dropwise. The cooling bath was removed and the mixture was stirred at room temperature for 10 min. Then, the temperature was raised to 70° C. and stirring was continued for 75 min. After cooling, the volatile components were removed under reduced pressure and the residue was treated with crushed ice (15 g). The mixture was adjusted to pH 7-8 with aqueous NaOH. Then it was extracted with dichloromethane (4×40 ml) and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. Residual volatile material was removed at 10 −2 mbar to leave an oily residue which slowly solidified on storage in a refrigerator.
[0440] Yield: 376 mg (80%), yellowish wax-like material. Mp.: 85-102° C.
[0441] 1 H NMR (300 MHz, CDCl 3 ): 2.32 (s, 3H, piperazine NCH 3 ); 2.55-2.59 (m, 4H, CH 2 ); 3.47-3.50 (m, 4H, CH 2 ); 3.67 (s, 3H, pyridazine NCH 3 ); 7.69 (s, 1H, H-6), 11.20 (s, 1H, CHO).
[0442] Analysis calculated for C 11 H 16 N 4 O 2 (236.28): C, 55.92%; H, 6.83%; N, 23.71%. Found: C, 55.91%; H, 6.97%; N, 23.30%.
Step 4: E-2-Methyl-5-(4-methylpiperazin-1-yl)-3-oxo-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 30)
[0443] The process described in Method A was followed. 2-Methyl-5-(4-methylpiperazino)-3-oxo-2,3-dihydropyridazine-4-carbaldehyde (472 mg, 2.00 mmol) was used to obtain the title compound. The reaction mixture was refluxed until the starting material was completely consumed (approx. 3 h; TLC monitoring: dichloromethane:methanol (9:1)).
[0444] Work-up/purification: the reaction mixture was evaporated in vacuo to dryness. After addition of water; the pH was adjusted to 7-8 with ammonia. The mixture was exhaustively extracted with dichloromethane and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product (containing an E/Z mixture) was recrystallized from ethyl acetate to afford the pure E isomer.
[0445] Yield: 240 mg (48%), colorless crystals. Mp.: 168-169° C.
[0446] 1 H NMR (300 MHz, CDCl 3 ): 2.35 (s, 3H, piperazine NCH 3 ); 2.54-2.57 (m, 4H, CH 2 ); 3.33-3.36 (m, 4H, CH 2 ); 3.72 (s, 3H, pyridazine NCH 3 ); 7.65 (s, 1H, H-6); 8.25 (s, 1H, HO—N═C—H; shows NOE on irradiation at 11.65 ppm); 11.65 (br s, 1H, N—OH).
[0447] Analysis calculated for C 11 H 17 N 5 O 2 (251.29): C, 52.58%; H, 6.82%; N, 27.87%. Found: C, 52.67%; H, 6.72%; N, 27.73%.
V.3: Example 31
E-2-Methyl-5-morpholino-3-oxo-6-phenyl-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 31)
[0448]
Step 1: 2-Methyl-5-morpholino-3-oxo-6-phenyl-2,3-dihydropyridazine-4-carbaldehyde
[0449] The preparation of 2-methyl-5-morpholino-3-oxo-6-phenyl-2,3-dihydropyridazine-4-carbaldehyde starting from 5-chloro-2-methyl-6-phenylpyridazin-3(2H)-one is described by Dajka-Halász B. et al., ARKIVOC 2008 (iii), 102-126.
Step 2: 2-Methyl-5-morpholino-3-oxo-6-phenyl-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 31)
[0450] The process described in Method A was followed. 2-Methyl-5-morpholino-3-oxo-6-phenyl-2,3-dihydropyridazine-4-carbaldehyde (0.500 g, 1.67 mmol) was used to obtain the title compound. The reaction mixture was heated under reflux for 17 h.
[0451] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with dichloromethane. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization from 95% ethanol.
[0452] Yield: 0.208 g (35%), yellow crystals. Mp.: 182.4-183.2° C. 1 H NMR (DMSO-d 6 ): 2.72 (t, 4H, N—(CH 2 ) 2 morpholino, J=4.8); 3.36 (t, 4H, O—(CH 2 ) 2 morpholino, J=5.2); 3.61 (s, 3H, N(2)CH 3 ); 7.55-7.40 (m, 3H, Ar); 7.63-7.59 (m, 2H, Ar); 8.12 (s, 1H, HO—N═C—H); 11.59 (s, 1H, OH).
[0453] Analysis calculated for C 16 H 18 N 4 O 3 (314.34): C, 61.13%; H, 5.77%; N, 17.82%. Found: C, 61.03%; H, 5.73%; N, 17.66%.
V.4: Example 32
E-2-(4-Methoxybenzyl)-5-morpholino-3-oxo-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 32)
[0454]
Step 1: 4-Chloro-2-(4-methoxybenzyl)-5-morpholinopyridazin-3(2H)-one
[0455] A mixture of 4,5-dichloro-2-(4-methoxybenzyl)pyridazin-3(2H)-one [P. Matyus, Gy. Rabloczky, L. Jaszlits, J. Kosary, M. Kurthy, A. Papp Behr, D. Zara, E. Karpati, A. Kovacs, WO1992/9212137] (10.15 g, 35.61 mmol) and morpholine (7.66 g, 87.92 mmol) in water (200 ml) was refluxed for 18 h. After cooling, the mixture was extracted with dichloromethane (4×40 ml) and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product was purified by recrystallization from ethanol (95%).
[0456] Yield: 8.66 g (72%), colorless crystals. Mp.: 125-127° C.
[0457] 1 H NMR (300 MHz, DMSO-d 6 ): 3.35-3.38 (m, 4H, morpholine-CH 2 ); 3.66-3.69 (m, 4H, morpholine-CH 2 ); 3.71 (s, 3H, OCH 3 ); 5.13 (s, 2H, benzyl-CH 2 ); 6.86-6.88 (AA′ part of an AA′BB′ system, 2H, phenyl-H); 7.22-7.25 (BB′ part of an AA′BB′ system, 2H, phenyl-H); 7.91 (s, 1H, H-6).
[0458] Analysis calculated for C 16 H 18 ClN 3 O 3 (335.79): C, 57.23%; H, 5.40%; N, 12.51%. Found: C, 57.03%; H, 5.42%; N, 12.59%.
Step 2: 2-(4-Methoxybenzyl)-5-morpholinopyridazin-3(2H)-one
[0459] To a mixture of 4-chloro-2-(4-methoxybenzyl)-5-(morpholin-4-yl)pyridazin-3(2H)-one (8.56 g, 25.50 mmol) and 10% Pd/C catalyst (1.45 g) in methanol (105 ml) was added ammonium formate (3.70 g, 58.7 mmol), and the mixture was refluxed under argon with TLC monitoring (ethyl acetate). Further portions of ammonium formate were added until the starting material was completely consumed. The catalyst was filtered off and washed with methanol, then the solvent was evaporated under reduced pressure. The residue was taken up in water (30 ml) and extracted with dichloromethane (4×40 ml). The combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product was purified by crystallization from ethanol (95%).
[0460] Yield: 4.25 g (85%), colorless crystals. Mp.: 132-133° C.
[0461] 1 H NMR (300 MHz, DMSO-d 6 ): 3.26-3.29 (m, 4H, morpholine-CH 2 ); 3.64-3.67 (m, 4H, morpholine-CH 2 ); 3.71 (s, 3H, OCH 3 ); 5.05 (s, 2H, benzyl-CH 2 ); 5.85 (d, 1H, H-4, J=2.7 Hz); 6.84-6.87 (AA′ part of an AA′BB′ system, 2H, phenyl-H); 7.18-7.21 (BB′ part of an AA′BB′ system, 2H, phenyl-H); 7.96 (d, 1H, H-6, J=2.7 Hz).
[0462] Analysis calculated for C 16 H 19 N 3 O 3 (301.35): C, 63.77%; H, 6.36%; N, 13.94%. Found: C, 63.79%; H, 6.38%; N, 14.11%.
Step 3: 2-(4-Methoxybenzyl)-5-morpholino-3-oxo-2,3-dihydropyridazine-4-carbaldehyde
[0463] A solution of 2-(4-methoxybenzyl)-5-(morpholin-4-yl)pyridazin-3(2H)-one (6.22 g, 20.60 mmol) in dry DMF (60 ml) was cooled to 5° C., then a solution of POCl 3 (4.21 ml, 45.1 mmol) in dry DMF (12 ml) was added dropwise. The cooling bath was removed and the mixture was stirred at room temperature for 30 min. Then, the temperature was raised to 70° C. and stirring was continued for 80 min. After cooling, the volatile components were removed under reduced pressure and the residue was treated with crushed ice (70 g). The mixture was adjusted to pH 7-8 with aqueous NaOH. Then it was extracted with ethyl acetate (2×60 ml) and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product was purified by crystallization from ethanol (95%).
[0464] Yield: 6.09 g (90%), yellow crystals. Mp.: 130-132° C.
[0465] 1 H NMR (300 MHz, DMSO-d 6 ): 3.44-3.47 (m, 4H, morpholine-CH 2 ); 3.70-3.73 (m, 7H, OCH 3 , morpholine-CH 2 ); 5.07 (s, 2H, benzyl-CH 2 Ph); 6.86-6.89 (AA′ part of an AA′BB′ system, 2H, phenyl-H); 7.23-7.27 (BB′ part of an AA′BB′ system, 2H, phenyl-H); 8.10 (s, 1H, H-6); 10.00 (s, 1H, CHO).
[0466] Analysis calculated for C 17 H 19 N 3 O 4 (329.36): C, 62.00%; H, 5.81%; N, 12.76%. Found: C, 61.71%; H, 5.83%; N, 12.82%.
Step 4: E-2-(4-Methoxybenzyl)-5-morpholino-3-oxo-2,3-dihydropyridazine-4-carbaldehyde oxime (compound 32)
[0467] The process described in Method A was followed. 2-(4-Methoxybenzyl)-5-(morpholin-4-yl)-3-oxo-2,3-dihydro-pyridazine-4-carbaldehyde (1.69 g, 5.1 mmol) was used to obtain the title compound. The reaction mixture was refluxed until the starting material was completely consumed (approx. 3 h; TLC monitoring: ethyl acetate:methanol (19:1)).
[0468] Work-up/purification: the reaction mixture was evaporated in vacuo to dryness. After addition of water, the pH was adjusted to 7-8 with ammonia. The mixture was exhaustively extracted with dichloromethane and the combined extracts were washed with water, dried (Na 2 SO 4 ) and evaporated. The crude product (containing an E/Z mixture) was recrystallized from ethanol (95%) to afford the pure E isomer.
[0469] Yield: 755 mg (43%), almost colorless crystals. Mp.: 166-168° C.
[0470] 1 H NMR (300 MHz, DMSO-d 6 ): 3.20-3.24 (m, 4H, morpholine-CH 2 ); 3.63-3.67 (m, 4H, morpholine-CH 2 ); 3.71 (s, 3H, OCH 3 ); 5.08 (s, 2H, benzyl-CH 2 ); 6.85-6.88 (AA′ part of an AA′BB′ system, 2H, phenyl-H); 7.21-7.25 (BB′ part of an AA′BB′ system, 2H, phenyl-H); 7.94 (s, 1H, H-6); 8.17 (s, 1H, HO—N═C—H; shows NOE on irradiation at 11.34 ppm); 11.34 (br s, 1H, N—OH).
[0471] Analysis calculated for C 17 H 20 N 4 O 4 (344.37): C, 59.25%; H, 5.85%; N, 16.27%. Found: C, 59.27%; H, 5.83%; N, 16.27%.
V.5: Example 33
2,5-Dimethyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde oxime (compound 33)
[0472]
Step 1: 2,5-Dimethyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde
[0473] 2,5-Dimethyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde can be synthesized by the method described by Elias O. et al THEOCHEM, 666-667, 625 (2003).
Step 2: 2,5-Dimethyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde oxime (compound 33)
[0474] The process described in Method A was followed. 2,5-Dimethyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde (0.800 g, 3.80 mmol) was used to obtain the title compound.
[0475] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with dichloromethane. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization from 95% ethanol.
[0476] Yield: 0.270 g (31%), beige crystals. Mp.: 200.7-202.8° C. (dec).
[0477] 1 H NMR (DMSO-d 6 ): 2.81 (s, 3H, N(5)CH 3 ); 3.38 (s, 3H, N(2)CH 3 ); 3.51 (t, 2H, H 2 -6, J=4.8); 4.26 (t, 2H, H 2 -7, J=4.8); 8.14 (s, 1H, HO—N═C—H); 11.12 (s, 1H, OH).
[0478] Analysis calculated for C 9 H 12 N 4 O 3 (224.22): C, 48.21%; H, 5.39%; N, 24.99%. Found: C, 47.96%; H, 5.38%; N, 24.36%.
V.6: Example 34
5-Benzyl-2-methyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde oxime (compound 34)
[0479]
Step 1: 5-Benzyl-2-methyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde
[0480] The preparation of 5-benzyl-2-methyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde is described by Elias O. et al THEOCHEM, 666-667, 625 (2003).
Step 2: 5-Benzyl-2-methyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde oxime (compound 34)
[0481] The process described in Method A was followed. 5-Benzyl-2-methyl-3-oxo-3,5,6,7-tetrahydro-2H-pyridazino[3,4-b][1,4]oxazine-4-carbaldehyde (1.00 g, 3.50 mmol) was used to obtain the title compound.
[0482] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with dichloromethane. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization from 95% ethanol.
[0483] Yield: 0.550 g (53%), white crystals. Mp.: 225.0-228.2° C. (dec).
[0484] 1 H NMR (DMSO-d 6 ): 3.35 (s, 3H, N(2)CH 3 ); 3.61 (t, 2H, H 2 -6, J=5.2); 4.31 (t, 2H, H 2 -7, J=5.2); 4.69 (s, 2H, CH 2 —Ar); 7.00-7.15 (m, 2H, Ar); 7.20-7.40 (m, 3H, Ar); 7.74 (1H, s, HO—N═C—H); 11.29 (1H, s, OH).
[0485] Analysis calculated for C 15 H 16 N 4 O 3 (300.31): C, 59.99%; H, 5.37%; N, 18.66%. Found: C, 59.66%; H, 5.21%; N, 18.53%.
V.7: Example 35
3-Methyl-2-oxo-2,3,6a,7,8,9-hexahydro-6H-pyridazino[3,4-b]pyrrolo[1,2-d][1,4]oxazine-1-carbaldehyde oxime (compound 35)
[0486]
Step 1: 3-Methyl-2-oxo-2,3,6a,7,8,9-hexahydro-6H-pyridazino[3,4-b]pyrrolo[1,2-d][1,4]oxazine-1-carbaldehyde
[0487] The preparation of 3-methyl-2-oxo-2,3,6a,7,8,9-hexahydro-6H-pyridazino[3,4-b]pyrrolo[1,2-d][1,4]oxazine-1-carbaldehyde is described by Elias O. et al THEOCHEM, 666-667, 625 (2003).
Step 2: 3-Methyl-2-oxo-2,3,6a,7,8,9-hexahydro-6H-pyridazino[3,4-b]pyrrolo[1,2-d][1,4]oxazine-1-carbaldehyde oxime (compound 35)
[0488] The process described in Method A was followed. 3-Methyl-2-oxo-2,3,6a,7,8,9-hexahydro-6H-pyridazino[3,4-b]pyrrolo[1,2-d][1,4]oxazine-1-carbaldehyde (0.235 g, 1.00 mmol) was used to obtain the title compound.
[0489] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with dichloromethane. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization from 95% ethanol.
[0490] Yield: 0.193 g (77%), beige crystals. Mp.: 195-198° C. (dec).
[0491] 1 H NMR (DMSO-d 6 ): δ 1.04-2.06 (m, 4H, CH 2 ); 3.02-3.44 (m, 1H, NCH 2 ); 3.40 (s, 3H, NCH 3 ); 3.64-3.85 (m, 2H, OCH 2a and NCH); 4.47-4.57 (m, 1H, OCH 2b ); 8.05 (s, 1H, CHN); 11.13 (s, 1H, NOH).
[0492] Analysis calculated for C 11 H 14 N 4 O 3 (250.25): C, 52.79%; H, 5.64%; N, 22.39%. Found: C, 52.72%; H, 5.52%; N, 22.38%.
V.8: Example 36
5-Benzyl-2-methyl-3-oxo-2,3,5,6,7,8-hexahydropyridazino[3,4-b][1,4]oxazepine-4-carbaldehyde oxime (compound 36)
[0493]
Step 1: 5-Benzyl-2-methyl-3-oxo-2,3,5,6,7,8-hexahydropyridazino[3,4-b][1,4]oxazepine-4-carbaldehyde
[0494] The preparation of 5-benzyl-2-methyl-3-oxo-2,3,5,6,7,8-hexahydropyridazino[3,4-b][1,4]oxazepine-4-carbaldehyde is described by Elias O. et al THEOCHEM, 666-667, 625 (2003).
Step 2: 5-Benzyl-2-methyl-3-oxo-2,3,5,6,7,8-hexahydropyridazino[3,4-b][1,4]oxazepine-4-carbaldehyde oxime (compound 36)
[0495] The process described in Method A was followed. 5-Benzyl-2-methyl-3-oxo-2,3,5,6,7,8-hexahydropyridazino[3,4-b][1,4]oxazepine-4-carbaldehyde (1.00 g, 3.34 mmol) was used to obtain the title compound.
[0496] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with dichloromethane. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization from 95% ethanol.
[0497] Yield: 0.690 g (67%), pale yellow crystals. Mp.: 178.7-180.6° C. (dec).
[0498] 1 H NMR (DMSO-d 6 ): 1.91 (t, 2H, H 2 -7, J=5.4); 3.26 (t, 2H, H 2 -6, J=5.2); 3.43 (s, 3H, N(2)CH 3 ); 4.09 (t, 2H, H 2 -8, J=6.0); 4.18 (s, 2H, CH 2 —Ar); 7.35-7.15 (m, 5H, Ar); 8.03 (s, 1H, HO—N═C—H); 11.50 (s, 1H, OH).
[0499] Analysis calculated for C 16 H 18 N 4 O 3 (314.34): C, 61.13%; H, 5.77%; N, 17.82%. Found: C, 61.13%; H, 6.62%; N, 17.72%.
V.9: Example 37
2-[5-(Dimethylamino)-2-methyl-3-oxo-2,3-dihydropyridazin-4-yl]benzaldehyde oxime (compound 37)
[0500]
Step 1: 2-[5-(Dimethylamino)-2-methyl-3-oxo-2,3-dihydropyridazin-4-yl]benzaldehyde (Method E)
[0501] 4-Chloro-5-(dimethylamino)-2-methylpyridazin-3(2H)-one (50.00 mmol) was dissolved in dimethoxyethane (155 ml), and Pd(PPh 3 ) 4 (1.60 g, 1.38 mmol) was added under argon. After stirring at room temperature for 10 min, 2-formylbenzeneboronic acid (10.50 g, 70.00 mmol) and 2M Na 2 CO 3 solution (49.5 ml) were added. Subsequently, the reaction mixture was refluxed (oil bath temperature: 110° C.) for 15 h. The reaction was followed by TLC (eluent: chloroform:acetone (9:1)). Upon cooling the reaction mixture was poured onto ice (375 g), filtered over Celite and washed with chloroform (130 ml). The two layers were separated and the aqueous phase was extracted with chloroform (3×380 ml). The combined organic layers were washed with water (1×100 ml), dried over MgSO 4 , filtered and purified by flash column chromatography with a mixture of diisopropyl ether and acetone (8:1) as the eluent and crystallized from a mixture of ethyl acetate and hexane (2.3:1).
[0502] Yield: 8.75 g (68%); yellow crystals. Mp.: 153-154° C.
[0503] 1 H NMR (CDCl 3 ): 2.69 (s, 6H, N(CH 3 ) 2 ); 3.73 (s, 3H, NCH 3 ); 7.31 (dm, 1H, H-11, J=7.6); 7.46 (tm, 1H, H-13, J=7.6); 7.60 (tm, 1H, H-12, J=7.6); 7.74 (s, 1H, H-5); 7.96 (dm, 1H, H-14, J=7.6); 9.90 (d, 1H, CHO, J=0.7).
[0504] Analysis calculated for C 14 H 15 N 3 O 2 (257.29): C, 65.35%; H, 5.88%; N, 16.33%. Found: C, 65.27%; H, 5.90%; N, 16.29%.
Step 2: 2-[5-(Dimethylamino)-2-methyl-3-oxo-2,3-dihydropyridazin-4-yl]benzaldehyde oxime (compound 37)
[0505] The process described in Method A was followed. 2-[5-(Dimethylamino)-2-methyl-3-oxo-2,3-dihydropyridazin-4-yl]benzaldehyde (1.00 g, 3.89 mmol) was used to obtain the title compound.
[0506] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with dichloromethane. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization from 99% ethanol.
[0507] Yield: 1.01 g (96%), white crystals. Mp.: 202-203° C.
[0508] 1 H NMR (DMSO-d 6 ): 2.60 (s, 6H, N(CH 3 ) 2 ); 3.57 (s, 3H, NCH 3 ); 7.11-7.15 (m, 1H, H-11); 7.30-7.40 (m, 2H, H-12, -13); 7.78 (dd, 1H, H-14, J=7.5, 1.9); 7.79 (s, 1H, H-16); 7.90 (s, 1H, H-5); 11.18 (s, 1H, H-18).
[0509] Analysis calculated for C 14 H 16 N 4 O 2 (272.30): C, 61.75%; H, 5.92%; N, 20.58%. Found: C, 61.52%; H, 6.35%; N, 20.50%.
V.10: Example 38
2-(2-Methyl-3-oxo-5-pyrrolidino-2,3-dihydropyridazin-4-yl)benzaldehyde oxime (compound 38)
[0510]
Step 1: 2-(2-Methyl-3-oxo-5-pyrrolidino-2,3-dihydropyridazin-4-yl)benzaldehyde
[0511] The process described in Method E was followed. 4-Chloro-2-methyl-5-pyrrolidin-1-ylpyridazin-3(2H)-one was used to obtain the title compound.
[0512] Yield: 9.20 g (65%); yellow crystals. Mp.: 140-141° C.
[0513] 1 H NMR (CDCl 3 ): 1.67-1.90 (m, 4H, pyrrolidine CH 2 ); 2.92-3.13 (m, 4H, pyrrolidine-NCH 2 ); 3.73 (s, 3H, NCH 3 ); 7.29 (dm, 1H, H-13, J=7.7); 7.45 (tm, 1H, H-15, J=7.7); 7.56 (td, 1H, H-14, J=7.7); 7.68 (s, 1H, H-7); 7.95 (dm, 1H, H-16, J=7.7); 9.96 (d, 1H, H-18, J=0.7).
[0514] Analysis calculated for C 16 H 17 N 3 O 2 (283.33): C, 67.83%; H, 6.05%; N, 14.83%. Found: C, 67.73%; H, 6.12%; N, 14.86%.
Step 2: 2-(2-Methyl-3-oxo-5-pyrrolidino-2,3-dihydropyridazin-4-yl)benzaldehyde oxime (compound 38)
[0515] The process described in Method A was followed. 2-(2-Methyl-3-oxo-5-pyrrolidino-2,3-dihydropyridazin-4-yl)benzaldehyde (1.00 g, 3.53 mmol) was used to obtain the title compound.
[0516] Work-up/purification: the precipitated crystals were filtered off. The crude product was purified by crystallization from 99% ethanol.
[0517] Yield: 0.970 g (97%), white crystals. Mp.: 239° C.
[0518] 1 H NMR (DMSO-d 6 ): 1.57-1.76 (m, 4H, pyrrolidine-CH 2 ); 2.88-3.02 (m, 4H, pyrrolidine-NCH 2 ); 3.56 (s, 3H, NCH 3 ); 7.10-7.16 (m, 1H, H-13); 7.29-7.38 (m, 2H, H-14, -15); 7.73-7.79 (m, 1H, H-16); 7.81 (s, 1H, H-18); 7.82 (s, 1H, H-7); 11.20 (s, 1H, H-20).
[0519] Analysis calculated for C 16 H 18 N 4 O 2 .⅙ H 2 O (301.34): C, 63.77%; H, 6.13%; N, 18.59%. Found: C, 64.13%; H, 6.53%; N, 18.58%.
V.11: Example 39
2-(2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazin-4-yl)benzaldehyde oxime (compound 39)
[0520]
Step 1: 2-(2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazin-4-yl)benzaldehyde
[0521] The process described in Method E was followed. 4-Chloro-2-methyl-5-piperidin-1-ylpyridazin-3(2H)-one was used to obtain the title compound.
[0522] Yield: 9.07 g (61%), yellow crystals. Mp.: 134-135° C.
[0523] 1 H NMR (CDCl 3 ): 1.29-1.58 (m, 6H, piperidine-CH 2 ); 2.84-3.04 (m, 4H, piperidine-NCH 2 ); 3.75 (s, 3H, NCH 3 ); 7.41 (dm, 1H, H-14, J=7.8); 7.46 (tm, 1H, H-16, J=7.8); 7.64 (tm, 1H, H-15, J=7.8); 7.72 (s, 1H, H-8); 7.98 (dm, 1H, H-17, J=7.8); 9.84 (s, 1H, H-19).
[0524] Analysis calculated for C 17 H 19 N 3 O 2 (297.35): C, 68.67%; H, 6.44%; N, 14.13%. Found: C, 68.65%; H, 6.89%; N, 14.07%.
Step 2: 2-(2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazin-4-yl)benzaldehyde oxime (compound 39)
[0525] The process described in Method A was followed. 2-(2-Methyl-3-oxo-5-piperidino-2,3-dihydropyridazin-4-yl)benzaldehyde (1.00 g, 3.36 mmol) was used to obtain the title compound.
[0526] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with dichloromethane. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by crystallization from 99% ethanol.
[0527] Yield: 1.02 g (97%), white crystals. Mp.: 184-185° C.
[0528] 1 H NMR (DMSO-d 6 ): 1.23-1.33 (m, 4H, piperidine-CH 2 ); 1.34-1.43 (m, 2H, piperidine-CH 2 ); 2.81-2.98 (m, 4H, H-2, -6); 3.58 (s, 3H, NCH 3 ); 7.20 (dm, 1H, H-14, J=7.7); 7.35 (tm, 1H, H-16, J=7.7); 7.41 (td, 1H, H-15, J=7.7, 1.6); 7.75 (s, 1H, H-19); 7.82 (dm, 1H, H-17, J=7.7); 7.90 (s, 1H, H-8); 11.19 (s, 1H, H-21).
[0529] Analysis calculated for C 17 H 20 N 4 O 2 (312.37): C, 65.37%; H, 6.45%; N, 17.94%. Found: C, 65.39%; H, 6.95%; N, 17.93%.
VI. Type 6 of Production Examples
Synthesis of Oxazole Oximes
VI.1: Example 40
3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal oxime (compound 40)
[0530]
Step 1: 3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal
[0531] The synthesis of 3-(4,5-diphenyl-1,3-oxazol-2-yl)propanal is described by Pridgen L. N. et al in Tetrahedron Lett., 25(27), 2835 (1984).
Step 2: 3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal oxime (compound 40)
[0532] The process described in Method A was followed. 3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal (277 mg, 1 mmol) was used to obtain the title compound.
[0533] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. Then the precipitated crystals were filtered off. The crude product was purified by column chromatography with a mixture of chloroform:ethyl acetate (95:5) as the eluent.
[0534] Yield: 195 mg (67%), yellow amorphous.
[0535] 1 H NMR (CDCl 3 ): 2.73-2.82 (m, 2H, CH 2 ); 3.10-3.19 (m, 2H, CH 2 ); 7.28-7.42 (m, 6H, Ar & NCH); 7.52-7.68 (m, 5H, Ar); 8.56 (s, 1H, OH). Due to E/Z isomerism of the oxime, two signal sets appear in the 1 H H NMR spectrum.
[0536] Analysis calculated for C 18 H 16 N 2 O 2 (292.33): C, 73.96%; H, 5.52%; N, 9.58%. Found: C, 73.61%; H, 5.22%; N, 9.56%.
VI.2: Example 41
Ethyl({[3-(4,5-diphenyl-1,3-oxazol-2-yl)propylidene]amino}oxy)acetate (compound 41)
[0537]
[0538] To a stirred solution of 3-(4,5-diphenyl-1,3-oxazol-2-yl)propanal (500 mg, 1.71 mmol, see by Pridgen L. N. et al in Tetrahedron Lett., 25(27), 2835 (1984)) in dry methyl ethyl ketone (10 ml), anhydrous K 2 CO 3 (260 mg, 1.88 mmol) and ethyl bromoacetate (0.20 ml, 1.88 mmol) were added in one portion. The resulting suspension was stirred at reflux temperature (80° C.) until the starting material was consumed (2 h, monitored by TLC). The slurry was filtered off and the solvent was evaporated in vacuo. The brown oily crude product was purified by column chromatography with dichloromethane as eluent and crystallized from n-hexane.
[0539] Yield: 0.323 g (50%), white crystals. Mp.: 58-59.5° C.
[0540] 1 H NMR (CDCl 3 ): 1.20 (t, 3H); 2.80 (m, 2H); 3.01 (m, 2H); 4.14 (q, 2H); 4.50/4.56 (s, 2H); 6.89/7.62 (t, 1H); 7.21-7.59 (m, 10H). Due to E/Z isomerism of the oxime two signal sets appear in the 1 H NMR spectra.
[0541] Analysis calculated for C 22 H 22 N 2 O 4 (378.42): C, 69.83%; H, 5.86%; N, 7.40%. Found: C, 69.67%; H, 5.81%; N, 7.32%.
VI.3: Example 42
3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal O-(phenylcarbamoyl)oxime (compound 42)
[0542]
[0543] To a cooled (ice and water bath) and stirred solution of 3-(4,5-diphenyl-1,3-oxazol-2-yl)propanal (300 mg, 1.02 mmol, Pridgen L. N. et al in Tetrahedron Lett., 25(27), 2835 (1984)) in dry acetonitrile (10 ml), 2-3 drops of triethylamine was added. A solution of phenyl isocyanate in 2 ml of dry acetonitrile was added dropwise at such rate, that the internal temperature remained below 30° C. The resulting reaction mixture was stirred at room temperature until the starting material was consumed (19 h, monitored by TLC). The light precipitate was filtered off and the solvent was evaporated in vacuo. The yellow oily crude product was purified by column chromatography with dichloromethane as eluent and crystallized from n-hexane.
[0544] Yield: 0.193 g (45%), yellow crystals. Mp.: 117-118° C. (dec).
[0545] 1 H NMR (CDCl 3 ): 2.98/3.10 (m, 2H); 3.14/3.22 (m, 2H); 7.32/7.96 (t, 1H); 7.02-7.68 (m, 15H); 8.05/8.14 (broad s, 1H). Due to E/Z isomerism of the oxime two signal sets appear in the 1 H NMR spectra.
[0546] Analysis calculated for C 25 H 21 N 3 O 3 (411.45): C, 72.98%; H, 5.14%; N, 10.21%. Found: C, 72.61%; H, 5.06%; N, 10.03%.
VI.4: Example 43
3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal O-(2-ethylpyrrolidine)oxime (compound 43)
[0547]
[0548] To a stirred solution of 3-(4,5-diphenyl-1,3-oxazol-2-yl)propanal (0.50 g, 1.71 mmol, see Pridgen L. N. et al in Tetrahedron Lett., 25(27), 2835 (1984)) in dry methyl ethyl ketone (10 ml), anhydrous K 2 CO 3 (2.12 g, 15.39 mmol) was added and the mixture was refluxed for 1 h. Then 1-(2-chloroethyl)pyrrolidine hydrochloride (0.87 g, 5.13 mmol) and a catalytic amount of NaOH were added and the reaction mixture was refluxed until the completion of the reaction (22 h, monitored by TLC, no more change observed). The slurry was filtered off and the solvent was evaporated in vacuo. The brown oily crude product was purified by column chromatography with chloroform:methanol (90:10) as eluent. (0.177 g unreacted starting material was isolated).
[0549] Yield: 0.288 g (43%), light yellow oil.
[0550] 1 H NMR (CDCl 3 ): 1.78 (m, 4H); 2.59 (m, 4H); 2.77/2.81 (m, 2H); 2.77/2.88 (m, 2H); 3.05/3.08 (m, 2H); 4.19/4.27 (t, 2H); 6.86/7.57 (t, 1H); 7.28-7.68 (m, 10H). Due to E/Z isomerism of the oxime two signal sets appear in the 1 H NMR spectra.
VI.5: Example 44
3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal O-(2-N,N-diethylethanamine)oxime (compound 44)
[0551]
[0552] To a stirred solution of 3-(4,5-diphenyl-1,3-oxazol-2-yl)propanal (0.50 g, 1.71 mmol, see Pridgen L. N. et al in Tetrahedron Lett., 25(27), 2835 (1984)) in dry methyl ethyl ketone (10 ml), anhydrous K 2 CO 3 (2.12 g, 15.39 mmol) was added and the mixture was refluxed for 1 h. Then 2-chloro-N,N-diethylethanamine hydrochloride (0.88 g, 5.13 mmol) and a catalytical amount of NaOH were added and the reaction mixture was refluxed until the completion of the reaction (22 h, monitored by TLC, no more change observed). The slurry was filtered off and the solvent was evaporated in vacuo. The brown oily crude product was purified by column chromatography with chloroform:methanol (90:10) as eluent. (0.156 g unreacted starting material was isolated).
[0553] Yield: 0.317 g (47%), light yellow oil.
[0554] 1 H NMR (CDCl 3 ): 1.03/1.05 (m, 6H); 2.60/2.62 (m, 4H); 2.75/2.79 (m, 2H); 2.77/2.88 (m, 2H); 3.04/3.07 (m, 2H); 4.14/4.21 (t, 2H); 6.86/7.56 (t, 1H); 7.28-7.68 (m, 10H). Due to E/Z isomerism of the oxime two signal sets appear in the 1 H NMR spectra.
VI.6: Example 45
3-(4,5-Diphenyl-1,3-oxazol-2-yl)-propionaldehyde O-benzyl-oxime (compound 45)
[0555]
[0556] The process described in Method A was followed. 3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal (416 mg, 1.5 mmol, see Pridgen L. N. et al in Tetrahedron Lett., 25(27), 2835 (1984)) and O-benzylhydroxylamine hydrochloride (319 mg, 2.0 mmol) were used to obtain the title compound.
[0557] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with chloroform, dichloromethane and ethyl acetate. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by column chromatography with hexane:ethyl acetate (5:1) as eluent.
[0558] Yield: 488 mg (85%), yellow oil.
[0559] 1 H NMR (CDCl 3 ): 2.74-2.81 (m, 1H); 2.89-2.95 (m, 1H); 3.03-3.10 (m, 2H); 5.06+5.13 (AB, 2H); 6.90 (t, 1H, J=5.2); 7.27-7.39 (m, 11H); 7.55-7.66 (m, 4H).
VI.7: Example 46
3-(4,5-Diphenyl-oxazol-2-yl)-propionaldehyde O-methyl-oxime (compound 46)
[0560]
[0561] The process described in Method A was followed. 3-(4,5-Diphenyl-1,3-oxazol-2-yl)propanal (554 mg, 2.0 mmol, see Pridgen L. N. et al in Tetrahedron Lett., 25(27), 2835 (1984)) and methoxyamine hydrochloride (222 mg, 2.66 mmol) were used to obtain the title compound.
[0562] Work-up/purification: after evaporation of ethanol in vacuo, water was added to the residue. The mixture was extracted with chloroform, dichloromethane and ethyl acetate. The combined organic phases were dried over anhydrous MgSO 4 . The solvent was evaporated in vacuo. The crude product was purified by column chromatography with hexane:ethyl acetate (5:1) as eluent.
[0563] Yield: 500 mg (82%), yellow oil.
[0564] 1 H NMR (CDCl 3 ): 2.74-2.80 (m, 1H); 2.83-2.90 (m, 1H); 3.01-3.10 (m, 2H); 3.83+3.89 (s, 3H); 6.85 (t, 1H, J=5.2); 7.29-7.40 (m, 6H); 7.61-7.66 (m, 4H).
VII. Type 7 of Production Examples
Synthesis of Indole Oximes
VII.1: Example 47
1-(4-Chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde oxime (compound 47)
[0565]
Step 1: 1-(4-Chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde
[0566] 1-(4-Chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde can be prepared by an analogous method as 1-(4-chlorobenzoyl)-5-methoxy-2-methyl-1H-indole-3-carboxaldehyde, described in U.S. Pat. No. 4,981,865.
Step 2: 1-(4-Chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde oxime
[0567] The process described in Method A was followed. The 1-(4-chlorobenzoyl)-2-methyl-1H-indole-3-carbaldehyde of Step 1 (200 mg, 0.67 mmol) was used to obtain the title compound.
[0568] Work-up/purification: the precipitated crystals were filtered off, washed with water, a mixture of n-pentane:ethyl acetate (95:5) and n-hexane.
[0569] Yield: 60 mg (28%), yellow crystals. Mp.: 152° C.
[0570] 1 H NMR (CDCl 3 ): 2.51 (s, 3H, CH 3 ); 6.93 (d, 1H, Ar, J=8.3); 7.10-7.18 (m, 1H, Ar); 7.20-7.30 (m, 1H, Ar); 7.33 (br s, 1H, —CH═N—OH); 7.46-7.53 (m, 2H, Ar); 7.67-7.74 (m, 2H, Ar); 8.10 (d, 1H, Ar, J=7.8); 8.44 (s, 1H, OH).
[0571] HRMS calculated for C 17 H 13 ClN 2 O 2 +H + : 313.0743. Found: 313.0735.
Test Example 1
In Vitro Inhibition of SSAO Activity on Human Recombinant VAP-1
[0572] For determining the SSAO/VAP-1 activity, the colorimetric method described by Holt, A (Holt, A., Anal. Biochem. 244, 384, 1997) for monoamine oxidase and analogous enzymes was used. Recombinant SSAO/VAP-1 enzyme was expressed in Chinese Hamster Ovary cells (CHO). These cells and cell cultures have been described earlier (Smith, D. J. et al, J. Exp. Med. 188, 17, 1998). The cell homogenate was prepared as follows: a suspension was made of approximately 3.6×10 8 cells in 25 ml lysation buffer (150 mM NaCl, 10 mM Tris-base pH 7.2, 1.5 mM MgCl 2 , 1% NP40), that was stirred for 1 night and incubated at 4° C. The homogenate was centrifugated (18000 g). The supernatant was used directly afterwards for the measurement. SSAO/VAP-1 activity measurement was carried out as follows on 96 precisely microtitrated plates, a given amount of inhibitor was added to each. The amount of the inhibitors varied among the measurements, the final concentration being between 1 nM and 50 μM in general, in 20 μl aqueous total volume for all cases. Then 0.2 M potassium phosphate buffer (pH=7.6) was added, to obtain a total volume of 200 μl 50 μl freshly prepared chromogen solution was given, which contains 1 mM of vanillic acid, 500 μM 4-aminoantipyrin, 8 U/ml horse radish peroxidase, and such an amount of SSAO/VAP-1 containing CHO cell homogenate that causes a 0.6 A- 490 per h change, the latter being in the linear coherence scope of the method. The plates were incubated for 30 min at 37° C. and the background absorbance was measured at 490 nm by a Wallac Victor II apparatus. For starting the enzyme reaction, 20 μl 10 mM benzyl amine solution was added, the final concentration of which was therefore 1 mM. The plates were reincubated at 37° C. for 1 h. The increase in the absorbance showing the SSAO/VAP-1 activity was measured at 490 nm. The inhibition was calculated in the % of the control absorbance corrected with the background absorbance, IC 50 values were calculated using GraphPad Prism.
[0573] SSAO/VAP-1 inhibitory effects (IC 50 values or in some cases, % inhibition at a given concentration) of representative compounds according to the present invention are listed in the following table. Numbers in the table respectively correspond to the compound numbers in Production Examples described above.
[0000]
TABLE 1
IC 50 (μM) or %
Compound No.
inhibition
1
102
5
32% (50 μM)
6
4.3
7
40
8
95
9
14.9
10
35% (500 μM)
12
180
16
53
17
30
18
18
19
29
21
58
22
48
23
111
24
106
25
113
27
41
29
240
32
263
35
55% (500 μM)
38
31% (500 μM)
40
3.5
Test Example 2
Inhibition of Carrageenan-Induced Rat Paw Edema
[0574] Carrageenan-induced rat paw edema has been extensively used in the evaluation of anti-inflammatory effects of various agents and it is useful in assessing the efficacy of compounds to alleviate acute inflammation (Whiteley P E, Dalrymple S A (1998) Models of inflammation: carrageenan-induced paw edema in the rat, in Current Protocols in Pharmacology (Enna S J, Williams M, Ferkany J W, Kenakin T, Porsolt R E, Sullivan J P eds) pp 5.4.1-5.4.3, John Wiley & Sons, New York.). Edema in the paws was induced by injecting 0.1 ml of a 1% solution of carrageenan intraplantary. The size of the edema was measured with a plethysmographic (Ugo-Basil) method 3 hours after injection of carrageenan solution. Compounds of the invention were administered subcutaneously (s.c.) and orally (p.o.) 60, or 30 minutes prior to carrageenan exposure. Inhibitory effects are expressed in % values.
[0000]
TABLE 2
Compound
Dose
Inhibition of rat paw edema in %
No.
mg/kg
n
60 min
120 min
180 min
9
30
s.c.
10
54 ± 6*
40 ± 5*
50 ± 5*
15
s.c.
5
53 ± 5*
52 ± 3*
66 ± 7**
7.5
s.c.
5
63 ± 7*
62 ± 6*
66 ± 5**
30
p.o.
5
0
5 ± 1
0
16
30
s.c.
10
8 ± 1
19 ± 2
31 ± 4
22
30
s.c.
10
58 ± 7*
54 ± 5*
72 ± 8**
15
s.c.
5
60 ± 6*
63 ± 7**
65 ± 7**
7.5
s.c.
5
15 ± 2
55 ± 5*
60 ± 5*
30
p.o.
5
0
21 ± 2
21 ± 2
Indomethacin
2.5
p.o.
5
32 ± 2*
51 ± 4*
53 ± 5**
Solvent
10
0
0
10 ± 1
*p < 0.05
**p < 0.01 (ANOVA, Newmann-Keuls post hoc test)
Test Example 3
Inhibition of Acetic Acid Induced Writhing on Mice
[0575] The method described by Van der Wende (Van der Vende C, Margolin S, Fed. Proc., 15, 494, 1956) with the modifications of Witkin et al. (Witkin L B et al, J. Pharm. Exp. Ther., 133, 400, 1961) was applied. 0.2 ml of a 0.6% acetic acid solution was injected intraperitoneally, causing a typical writhing syndrome in 90% of the animals. Compounds of the invention were administered subcutaneously, 20 minutes prior to acetic acid exposure. Antianalgetic effect was determined by the formula, which is shown below, and is expressed in % values.
[0000] (number of writhings in treatment group (5′)/number of writhings in control group (5′))×100
[0000]
TABLE 3
Compound
Dose
Inhibition of writhing
No.
mg/kg
syndrome in %
9
30 s.c.
80 ± 7**
15 s.c.
84 ± 8**
16
30 s.c.
96 ± 6**
15 s.c.
86 ± 7**
22
15 s.c.
100
5 s.c.
70 ± 5**
Solvent
s.c.
10 ± 1
*p < 0.01
**p < 0.05 (ANOVA, Newmann-Keuls post hoc test), n = 5
[0576] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is apparent to those skilled in the art that certain minor changes and modifications will be practiced. Therefore, the description and examples should not be construed as limiting the scope of the invention. | The present invention relates to compounds of general formula (i) having an oxime moiety or a pharmaceutically acceptable salt, hydrate or solvate thereof and its use for inhibiting semicarbazide-sensitive amine oxidase (SSAO), also known as vascular adhesion protein-1 (VAP-1), a pharmaceutical composition comprising the compound or a salt, hydrate or solvate thereof as an active ingredient, a method for the prevention or the treatment of a SSAO/VAP-1 related disease, said diseases including acute or chronic inflammatory diseases, diseases related to carbohydrate metabolism, diabetes-associated complications, diabetic retinopathy and macular oedema, diseases related to adipocyte or smooth muscle dysfunctions, neurodegenerative diseases and vascular diseases. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Application No. 61/059,673, filed on Jun. 6, 2008, titled SELF-ADJUSTING PIPE SPINNER, which application is incorporated in its entirety by reference in this application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally concerns tooling and equipment utilized in the maintenance and servicing of oil and gas production wells, and more particularly relates to a power tong of the type utilized in conjunction with back-up tongs or wrenches to make or break threaded joints between successive tubing elements that extending through a well bore into underground deposits.
[0004] 2. Related Art
[0005] In drilling for oil and gas, it is necessary to assemble a suing of drill pipe joints. Thus, a tubular drill string may be formed from a series of connected lengths of drill pipe and suspended by an overhead derrick. These lengths of drill pipe are connected by tapered external threads (the pin) on one end of the pipe, and tapered internal threads (the box) on the other end of the pipe.
[0006] During the drilling and completion of a well, as the well is drilled deeper, additional joints of pipe are periodically added to the drill string and, as the drill bit at the end of the drill string is worn, the drill string must occasionally be pulled from the well and reinstalled for maintenance purposes. The process of pulling or installing the drill string is referred to as “tripping.” During tripping, the threaded connections between the lengths of drill pipe are connected and disconnected as needed. The connecting and disconnecting of adjacent sections of drill pipe (referred to as making or breaking the connection, respectively), involves applying torque to the connection and rotating one of the pipes relative to the other to fully engage or disengage the threads.
[0007] In modern wells, a drill string may be thousands of feet long and typically is formed from individual thirty-foot sections of drill pipe. Even if only every third connection is broken, as is common, hundreds of connections have to be made and broken during tripping. Thus, the tripping process is one of the most time consuming and labor intensive operations performed on the drilling rig.
[0008] Currently, there are a number of devices utilized to speed tripping operations by automating or mechanizing the process of making and breaking a threaded pipe connection. These devices include tools known as power tongs, iron roughnecks, and pipe spinners. Many of these devices are complex pieces of machinery that require two or more people to operate and require multiple steps, either automated or manual, to perform the desired operations. Additionally, many of these devices grip the pipe with teeth that can damage the drill pipe and often cannot be adjusted to different pipe diameters without first replacing certain pieces, or performing complex adjustment procedures.
[0009] In particular, roughnecks combine a torque wrench and a spinning wrench, simply called a spinner, to connect and disconnect drill pipe joints of the drill string. In most instances, the spinner and the torque wrench are both mounted together on a carriage. To make or break a threaded connection between adjoining joints of drill pipe, certain roughnecks have a torque wrench with two jaw levels. In these devices, an upper jaw of the torque wrench is utilized to clamp onto a portion of an upper tubular, and a lower jaw clamps onto a portion of a lower tubular (e.g., upper and lower threadedly connected pieces of drill pipe). After clamping onto the tubular, the upper and lower jaws are turned relative to each other to break or make a connection between the upper and lower tubulars. A spinner, mounted on the carriage above the torque wrench, engages the upper tubular and spins it until it is disconnected from the lower tubular (or in a connection operation, spins two tubulars together prior to final make-up by the torque wrench).
[0010] Generally, a spinner comprises four rollers, each driven by a separate hydraulic motor, that engage the outer wall of the drill pipe to spin the pipe. However, other spinners exists that use flexible belts or chains to engage and spin the pipe. An example of a chain spinner is the SPINMASTER® spinner made available from Hawk Industries. The basic function and construction of the SPINMASTER® spinner are disclosed in U.S. Pat. No. 4,843,924 (Hauk).
[0011] In particular, the Hauk '924 patent discloses a spinner that includes first and second elongate casing sections that are pivotally connected to each other at a pivot, and first and second driven sprockets mounted, respectively, on the casing sections at locations remote from the pivot. The spinner also includes a drive sprocket, mounted on the first casing section, driven by a motor-gear assembly and a continuous chain mounted around the drive sprocket, and around the first and second driven sprockets. The chain has an inverse internal portion adapted to receive and directly contact a tubular well element to be rotated. Cylinders connected between the casing sections pivot them toward and away from each other and thus, alternately clamp the inverse internal portion around the well element, and release such element from the inverse internal portion of the chain.
[0012] Some prior art spinners, such as the SPINMASTER®, are also adjustable to accommodate pipes of varying diameter. These spinners are adjusted by changing the location of the drive sprocket relative to the driven sprockets, thus the effective length of the chain is adjusted to accommodate different pipe diameters. While adjustable spinners are versatile, these spinners must be manually adjusted by the operator during use. In many instances, the operator must climb atop of the spinner, disengage fasteners or locking pins holding the drive sprocket in place, manually adjust the drive sprocket to a desired location, and re-fasten or lock the drive sprocket at its new location. Manually adjusting the spinner can therefore be consuming and dangerous.
[0013] Thus, a need exists for an automated spinner that allows the operator to change the pipe size of the spinner from a remote location to provide a safer and quicker pipe change.
SUMMARY
[0014] A self-adjusting spinner is provided that is capable of accommodating various pipe sizes without requiring the need for an operator to climb up the support mechanism and manually change the position of the drive assembly. The self-adjusting spinner includes a case having two pivotally connected members: a stationary case member and a moving case member. Upper and lower plates having gear racks are mounted on the stationary case member for moving a drive assembly horizontally across the case. The drive assembly includes a motor that drives gear sprocket through a drive shaft. The drive sprocket then drives a chain that rotates a drill pipe in an operative position relative to the case. The spinner also includes an adjusting assembly mounted on the case that moves the drive assembly along the gear rack upon the actuation of an adjustment sequence. When the adjustment sequence is initiated, the effective length of the chain is adjusted to accommodate drill pipes of varying diameters.
[0015] In another aspect of the invention, a method for operating a pipe spinner having a chain positioned inside a case is provided. The method includes the steps of receiving a pipe within the case, where the case has a stationary member and a movable arm member pivotally connected to the stationary member, pivoting a moving arm member toward the stationary member to surround the pipe with the chain, and applying tension to the chain by remotely engaging a drive assembly on the case that is moveable relative to the stationary member.
[0016] Other devices, apparatus, systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE FIGURES
[0017] The invention may be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0018] FIG. 1 is a side view of a drill pipe making and breaking apparatus that incorporates a self-adjusting pipe spinner of the invention.
[0019] FIG. 2 is a perspective view of one example of an implementation of a self-adjusting spinner of the invention.
[0020] FIG. 3 is a side view of the self-adjusting spinner of FIG. 2 .
[0021] FIG. 4 is an enlarged side view of the rear of the case of the self-adjusting spinner of FIG. 3 , illustrating the engagement of the motor clamp assembly on the rear of the case.
[0022] FIG. 5 is an exploded perspective view of the self-adjusting spinner of FIG. 2 .
[0023] FIG. 6 is a top view of the self-adjusting spinner of FIG. 2 positioned at a setting designed to receive a small diameter pipe, highlighting the position of the roller chain and the spinner motor assembly.
[0024] FIG. 7 is a top view of the self-adjusting spinner of FIG. 6 illustrated after the spinner motor assembly has been adjusted to receive a larger diameter pipe, highlighting the position of the roller chain and the spinner motor assembly after adjustment.
[0025] FIG. 8 is a top view of the self-adjusting spinner of FIG. 7 illustrated after a pipe has been inserted in the spinner and the slack in the roller chain has been removed, highlighting the position of the roller chain, pipe, and the spinner motor assembly after adjustment.
[0026] FIG. 9 is a top view of the self-adjusting spinner of FIG. 6 illustrated after the pipe has been positioned in the self-adjusting spinner and the case assembly has been closed around the pipe, highlighting the position of the roller chain and the spinner motor assembly after adjustment.
DETAILED DESCRIPTION
[0027] The present invention is directed to a chain spinner that can be a free hanging, separate stand alone unit, or part of a drill pipe making and breaking apparatus such as the T-WREX JR. 51200 apparatus, available from Hawk Industries, Inc. of Long Beach, Calif., as depicted in FIG. 1 . The apparatus, referred to herein as a roughneck 50 , includes a structural frame 52 that is moveably coupled to a vertical translator 56 via an extending arm 54 . The vertical translator 56 is configured to move the structural frame 52 up and down relative to a drill string, and the extending arm 54 is configured to move the structural frame 52 towards and away from the drill string. The structural frame 52 carries a wrench assembly that includes a top wrench 58 , a middle wrench 60 , and bottom wrench 62 , and a spinner 100 . The wrenches 58 , 60 , 62 are configured to hold a pipe section of the drill string while the spinner 100 spins an adjoining pipe section of the drill string to make or break the drill string.
[0028] FIG. 1 illustrates one implementation of an embodiment of a self-adjusting spinner 100 of the present invention. As illustrated in FIG. 1 , the self-adjusting spinner 100 includes a case assembly 200 , a moveable drive assembly 400 , a motor adjustment assembly 500 , and a continuous roller chain 302 . The case assembly 200 includes a stationary case member 210 and a moving arm case member 240 . The stationary case and moving arm case members 210 , 240 are configured to enclose the roller chain 302 .
[0029] Referring now to FIG. 4 , the stationary case member 210 includes an elongated sidewall 212 coupled between an upper gear mount plate 214 and a lower gear mount plate 216 ( FIG. 3 ). The sidewall 212 and the upper and lower gear mount plates 214 , 216 define a substantially U-shaped channel for receiving the roller chain 302 .
[0030] The upper gear and lower mount plates 214 , 216 include a corresponding pair of drill holes (not shown), corresponding elongated openings 218 that extend longitudinally along a central portion of the mount plates, and corresponding arcuate surfaces 222 and semi-circular cut-outs 224 ( FIG. 5 ) located near the front of the case assembly 200 . The elongated openings 218 are configured to receive a base portion of the drive assembly 400 , such that the drive assembly 400 may be moveable along the length of the openings 218 .
[0031] Now turning to the moving arm member 240 , this member includes an elongated sidewall 242 coupled between an upper mount plate 244 and lower mount plate 246 . The sidewall 242 and the upper and lower mount plates 244 , 246 define a substantially U-shaped channel for receiving the roller chain 302 .
[0032] The upper and lower gear mount plates 214 , 216 of the stationary case member are configured to engage the upper and lower mount plates 244 , 246 of the moving arm case member 240 as the moving arm case member 240 is rotated towards the stationary case member 210 . The upper and lower mount plates 244 , 246 include a corresponding pair of drill holes 248 , and corresponding arcuate surfaces 250 and semi-circular cut-outs 252 located near the front of the case assembly 200 .
[0033] According to an implementation of the invention, all or a portion of the casing assembly 200 may be constructed from durable metal. For example, in one implementation all or a portion of the case assembly 200 may be constructed from mild steel. Further, the case assembly may be manufactured by a variety of means. For example, in one implementation the mounting plates and sidewalls of the case assembly may be integrally formed, or laser cut, formed, and welded together on the tooling gig. Alternatively, the sidewalls may be fastened to the mounting plates by, for example, rivets, bolts, or any other suitable fasteners.
[0034] As best shown in FIG. 5 , the moving arm case member 240 is rotatably coupled to the stationary case member 210 at a pivot P ( FIG. 5 ) near the rear of the case assembly 200 , such that the moving arm case member 240 is able to move toward and away from the stationary case member 210 to engage a pipe 602 positioned in the case assembly 200 , as illustrated in FIGS. 6-8 below. The moving arm case member 240 and the stationary case member 210 are coupled together by a bolt and lock nut assembly that extends through a corresponding pair of bores 226 located at rear ends of the moving arm and stationary case members 240 , 210 .
[0035] Now turning back to FIG. 4 , the moving arm case member 240 is moved toward and away from the stationary case member 210 by an upper grip actuator 260 and a lower grip actuator 262 . In one implementation, the grip actuators 260 , 262 are linear double acting hydraulic cylinders, but it would be obvious to one skilled in the art that any suitable actuator may be applied.
[0036] In this example, the upper grip actuator 260 is rotatably mounted horizontally across the case assembly 200 at one end by an upper mounting support 270 positioned on the stationary case member 210 and, at the other end, by a second upper mounting support 274 positioned on the moving arm case member 240 . The lower grip actuator 262 is rotatably mounted horizontally across the case assembly 200 at one end by a lower mounting support 272 positioned on the underside of the stationary case member 210 and, at the other end, by a second lower mounting support 276 positioned on the underside of the moving arm case member 240 . The grip actuators 260 , 262 are mounted to the mounting supports 270 , 272 , 274 , 276 by retaining bolt and lock nut assemblies extending through the ends of the actuators. These retaining bolts also extend through idler rollers 278 positioned between the mounting supports 270 , 272 , 274 , 276 .
[0037] As will be described in more detail below, the upper and lower grip actuators 260 , 262 are generally maintained in an open (or fully extended) position to receive the pipe 602 within the case assembly 200 . Once the pipe 602 is positioned within the case assembly 200 , the grip actuators 260 , 262 are activated to move the moving arm case member 240 towards the stationary case member 210 to grip the pipe 602 .
[0038] The idler rollers 278 correspond with and are disposed between corresponding drill holes 228 in the moving arm and stationary case members 240 , 210 . The idler rollers 278 are free to rotate relative to the moving arm and stationary case members 240 , 210 and are maintained in spaced apart relation from the sidewalls 212 , 242 to form a passage for passing the chain 302 therethrough. The idler rollers 278 are adapted to slidably engage the roller chain 302 as it rotates within the case assembly 200 . In an implementation, the idler rollers 278 may be made from heat treated alloy steel or any other durable metal.
[0039] Driven roller assemblies 310 , 312 are positioned in the semi-circular cut-outs 224 , 252 at ends of the stationary and moving arm case members 210 , 240 opposite the pivot P. The driven rollers 310 , 312 attached to the stationary and moving arm case members 210 , 240 are free to rotate relative thereto. Each roller 310 , 312 includes a pair of bearing caps 320 that retain a roller sprocket 322 that is rotatably coupled between a pair of roller bearings 324 . The roller sprocket 322 includes a body carrying a series of teeth for engaging the chain 302 and driving it about the rollers 310 , 312 to spin a pipe positioned between the driven rollers 310 , 312 when the roller chain 302 is wrapped about the pipe, as illustrated in FIGS. 6-8 below.
[0040] Movement of the roller chain 302 is driven by the drive assembly 400 . The drive assembly 400 includes a gear motor 402 mounted on a planetary gear reducer 404 . In one example, the gear motor 402 may be a hydraulic motor, an air motor, or any other suitable driving mechanism. In one implementation, a gear 406 is coupled between the gear motor 402 and the rear reducer 404 to increase the torque transferred from the gear motor 402 to a drive shaft 410 coupled to the gear reducer 404 at an end opposite the motor 402 . The gear 406 is retained inside of an upper portion of the gear reducer 404 by a gear key 408 .
[0041] In this way, the gear motor 402 drives the planetary gear reducer 404 , which in turn drives a drive sprocket 412 coupled to an end of the drive shaft 410 opposite the gear reducer 404 . In one implementation, the drive sprocket 412 is secured to the drive shaft 410 by a sprocket key 414 . The drive sprocket 412 carries teeth that engage (mesh) the links of the roller chain 302 to drive the roller chain 302 through the driven rollers 310 , 312 , respectively positioned at an end of the case assembly 200 opposite the drive assembly 400 .
[0042] The upper and lower gear mount plates 214 , 216 of the stationary case member 210 are configured to movably retain the drive assembly 400 against the case assembly 200 . In one implementation, the drive assembly 400 is retained within the elongated openings 218 of the upper and lower gear mount plates 214 , 216 by a pair of gear mounts 420 , 422 that movably abut the upper and lower gear mount plates 214 , 216 . In this implementation, gear mount 420 supports the gear reducer 404 , as gear mounts 420 and 422 are coupled together by fasteners that extend through a set of spacers 424 fastened between the gear mounts 420 , 422 . The gear mounts 420 , 422 are configured to ride between a set of upper and lower fixed racks 282 , 284 axially mounted to the upper and lower gear mount plates 214 , 216 about elongated openings 218 . The fixed racks 420 , 422 may be secured to the upper and lower gear mount plates 214 , 216 by screws, bolts, rivets, or any kind of industrial fastener. In one implementation, spacers 420 , 422 may be configured such that the contact surfaces of gear mounts 420 , 422 and the upper and lower fixed racks 282 , 284 are maintained within a spaced relationship of approximately 0.050 inches. A drive shaft bearing 426 is further attached to gear mount 422 to support the drive shaft 410 of the drive assembly 400 .
[0043] The drive assembly 400 is adjustably secured to the stationary case member 210 by a motor clamp assembly 450 attached to a rear end of the drive assembly 400 . As illustrated in FIGS. 2-4 , the motor clamp assembly 450 includes a hydraulic cylinder (not shown) that activates a set of upper and lower rack clamps 452 , 456 that compliment the upper and lower fixed racks 282 , 284 . As better illustrated in FIG. 3 , each rack clamp 452 , 456 includes a set of toothed feet 454 and 458 that mesh with a complimentary set of teeth carried by the upper and lower fixed racks 282 , 284 . Thus, when the hydraulic cylinder activates the upper and lower rack clamps 452 , 456 , the rack clamps 452 , 456 may be moved towards each other to engage (mesh) the rack clamps 452 , 456 with the respective fixed racks 282 , 284 to secure the drive assembly 400 to case assembly 200 and provide a positive lock. The positive lock prevents movement of the drive assembly 400 within the elongated openings 218 .
[0044] In the alternative, the hydraulic cylinder of the motor clamp assembly 450 may cause the upper and lower gear rack clamps 452 , 456 to move away from each other to disengage the rack clamps 452 , 456 from the fixed gear racks 282 , 284 , to an unlocked position. When in the unlocked position, the drive assembly 400 is released from case assembly 200 and the drive assembly 400 may be moved relative to the fixed racks 282 , 284 to change the effective chain engagement length. (It can be slid parallel to the fixed racks 282 , 284 , within the elongated opening 218 .) When the drive assembly 400 is in the new desired position, the operator sends a signal to the hydraulic cylinder of the motor clamp assembly 450 to lock the movable gear rack clamps 452 , 456 in the new position (by the engaging the gear rack teeth). Because the gear racks 282 , 284 are securely mounted to the stationary case member 214 , the drive assembly 400 is prevented from slipping while it is in the locked position.
[0045] Referring to FIG. 5 , the motor adjustment assembly 500 is provided for adjusting the position of the drive assembly 400 along the elongated openings 218 of the case assembly 200 . The motor adjustment assembly 500 includes an adjusting actuator 502 that is secured to one end of a pivot arm 504 . In one implementation, the actuator 502 may include an air cylinder, a hydraulic cylinder, or any other suitable actuating device. The adjusting actuator 502 is secured to the case assembly 200 by a mount 503 attached to the sidewall 212 ( FIG. 1 ) of the stationary case member 210 .
[0046] The pivot arm 504 pivots about a pivot arm mount 506 attached to the upper gear mount plate 214 . The pivot arm 504 also carries an elongated slot 508 at an end opposite the adjusting actuator 502 that slidably engages a slide pin 510 coupled to a front end of the drive assembly 400 . In this configuration, the adjusting actuator 502 applies force to an end of the pivot arm 504 to rotate the arm 504 about the pivot arm mount 506 , thus generating torque about the pivot mount 506 . The torque generated by the adjusting actuator 502 is applied to the slide pin 510 to move the drive assembly 400 forwards and backwards within the elongated openings 218 . While a lever mechanism is presently described, other mechanisms and implementations may be used to adjust the position of the drive assembly 400 in accordance with the present invention.
[0047] As illustrated in FIGS. 5 through 8 , the roller chain 302 is a continuous chain that runs around the driven rollers 310 , 312 , the idler rollers 278 , the drive sprocket 412 , and around the pipe 602 (see FIGS. 6-8 ). According to one implementation, the roller chain 302 is driven by the drive sprocket 412 and configured to grip a pipe 602 without damaging its outer surface and provides sufficient friction to rotate the pipe 602 within the case assembly 200 as desired.
[0048] The length of the roller chain 302 and the position of the idler rollers 310 , 312 and their respective roller sprockets 322 result in the chain 302 having an inverse internal portion. This inverse internal portion wraps around a pipe 602 (see FIGS. 6-8 ) inserted in the front opening of the case assembly 200 when the moving case member 240 closes relative to the stationary case member 210 , thereby enabling the chain 302 to grip the circumference of the pipe 602 and spin it.
[0049] The effective length of the roller chain 300 on the pipe 602 can be adjusted by repositioning the drive assembly 400 (or more particularly the drive sprocket 412 ) relative to the pipe 602 (or the driven rollers 310 , 312 ) via the motor adjustment assembly 500 , as discussed above. The repositioning is used to accommodate pipes 602 of different diameters, to compensate for chain “stretch” as the chain wears, and to adjust the chain gripping tension on the pipe 602 . In one implementation, the roller chain 302 may be adjustable to accommodate pipes having diameters from 3 to 9½ inches and the chain may be a heavy-duty, durable roller-style chain having eight-eight links and one inch pitch.
Operation
[0050] In operation, as illustrated in FIGS. 5-8 , the moving arm case member 240 may be opened and closed relative to the stationary case member 210 . The accurate surfaces 222 , 250 of the stationary case member 210 and the moving arm case member 240 correspond to define a well 610 for receiving a section of the pipe 602 . A guide 620 mounted to the front end of the stationary case member 210 is configured to engage the drill pipe 602 if the spinner 100 is misaligned with the drill pipe 602 when the spinner 100 approaches the pipe. If the spinner is misaligned, the guide 620 will contact the pipe 602 to pivot and align the spinner 100 with the pipe 602 as the spinner 100 moves towards it.
[0051] When an operator wishes to make or break a drill string section, the operator may move a roughneck carrying the spinner 100 towards a drill string. Depending on the drill pipe diameter, the operator may desire to adjust the spinner 100 to accommodate the dimensions of the drill pipe, so the operator may initiate a self-adjusting sequence to allow the operator to change the pipe size of the spinner 100 . The sequence may be initiated remotely, for example, from an operator's console (not shown).
[0052] As shown in FIG. 5 , the self-adjusting sequence begins with the spinner 100 being set at its current pipe size. For example, in the implementation depicted in FIG. 5 , the pipe size of the spinner 100 is set at a 3 inch. pipe setting. In this setting, the drive motor assembly 400 is clamped to the stationary case member 210 at a location near the rear of the spinner 100 . In addition, the upper and lower grip actuators 260 , 260 are maintained in their open (extended) position to receive the pipe 602 .
[0053] After the self-adjusting sequence is initiated, the operator may switch a spinner adjusting switch (not shown) on, for example, the operator's remote console (not shown) to an unclamp position. When the switch is switched to this position, as shown in FIG. 6 , a first signal is sent to the motor clamping assembly 450 to disengage the upper and lower rack clamps 452 , 456 of the clamping assembly 450 from the upper and lower fixed racks 282 , 284 on the stationary case member 210 . Simultaneous to the first signal, a second signal is sent to the adjusting actuator 502 , which activates the actuator to move from an open (extended) position to a closed (retracted) position. As the adjusting actuator 502 is retracted, the drive assembly 400 is moved forward towards a front end of the elongated opening 218 and slack is created in the roller chain 302 in the back of the roller chain train.
[0054] Turning now to FIG. 7 , after the drive assembly 400 is unclamped and moved forward, the roughneck is moved forward toward the center of the oil well and the spinner 100 is pushed forward towards the drill pipe 602 by a push cylinder on its mount. As the spinner 100 is moved towards the pipe 602 , the pipe 602 engages the inverse internal portion of the roller chain 302 . As the pipe 602 engages the roller chain 603 , the slack in the chain 602 is taken up. A sensor located on the roughneck wrench head is activated when the pipe reaches a certain geometrical relationship to the wrench head. Once activated, the roughneck stops its forward movement.
[0055] When the roughneck is stopped, the operator may switch the spinner adjusting switch (not shown) to a center position, which activates the adjusting actuator 502 to move to the actuator towards its open (extended) position. As the actuator 502 is moved to towards its open position, the drive assembly 400 is pushed back along the elongated opening 218 to take up any residual slack in the roller chain 302 . After the drive assembly 400 is adjusted, the operator may switch the spinner adjusting switch (not shown) to a clamp position, which energizes the hydraulic motor on the motor clamp assembly 450 to engage the upper and lower rack clamps 452 , 456 with the upper and lower fixed racks 282 , 284 , thus locking the drive motor assembly 400 in place.
[0056] Once the drive motor assembly 400 is clamped in place and the pipe 602 has been positioned in the well 610 , the operator may engage a spin button (not shown) on the operator's remote console (not shown). As shown in FIG. 8 , once the spin button is engaged, hydraulic fluid is sent to the upper and lower grip actuators 260 , 262 , which change the direction of the actuators from a “pushing” actuation to a “pulling” actuation. As the actuators 260 , 262 retract, they move the moving arm case member 240 towards the stationary case member to encircle the pipe 602 with the inverse internal portion of the roller chain 302 . As the moving arm case member 240 moves closer towards the stationary case member 210 , the stationary and moving arm case members 210 , 240 pinch the chain 302 around the pipe 602 to generate a gripping force to hold the pipe 602 .
[0057] As the stationary and moving arm case members 210 , 240 grip the pipe 602 , hydraulic pressure is built-up in a hydraulic fluid line (not shown) coupled between the grip actuators 260 , 262 and the gear motor 402 of the drive assembly 402 . Once the hydraulic pressure reaches a certain pressure, a sequential valve (not shown) coupled in series with the hydraulic fluid line opens to send the flow of hydraulic fluid to the gear motor 402 . The hydraulic fluid starts the gear motor 402 , which in turn drives the drive sprocket 412 and the pipe 602 begins to spin.
[0058] When the operator wants to make a drill string, the operator may spin the pipe 602 until the pipe 602 “shoulders out” with the adjoining pipe section (i.e., the threaded ends of the connecting pipe sections are fully engaged). When a pipe shoulders out, the spinner 100 cannot spin the pipe anymore and the gear motor just stalls out. At that point, the operator may disengage the spin button, which cuts off the flow of hydraulic fluid going to the gear motor 402 , and the inverse flow of hydraulic fluid routed to the gear motor 402 will be routed to the grip actuators 260 , 262 to reverse the direction of the actuators back to their original open (extended) position. As the grip actuators 260 , 262 are returned back to their open position, the grip on the pipe 602 is loosened and the operator can remove the spinner from the drill string.
[0059] In the converse, when the operator wants to break a drill string, the operator may spin the pipe 602 until the operator hears a rattling of the disengaged threaded portions of the adjoining pipe sections. At that point, the operator may disengage the spin button and remove the top pipe section from the roughneck.
[0060] In one implementation of an embodiment of the present invention, a pneumatic control system may be used to send air signals to the hydraulic components. For example, an air-piloted directional control valve may be used to control the (push or pull) direction of the grip actuators 260 , 262 . In this example, if the operator wants to extend the grip actuators, an air signal may be sent to one side of the directional valve. In the alternative, if the operator wants to retract the grip actuators, an air signal may be sent to the other side of the directional valve.
[0061] The foregoing description of implementations has been presented for purposes of illustration and description. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. The claims and their equivalents define the scope of the invention. | A self-adjusting spinner is provided that is capable of accommodating various pipe sizes without requiring the need for an operator to climb up the support mechanism and manually change the position of the drive assembly. The self-adjusting spinner includes a case having two pivotally connected members: a stationary case member and a moving case member. Upper and lower plates having gear racks are mounted on the stationary case member for moving a drive assembly horizontally across the case. The drive assembly includes a motor that drives gear sprocket through a drive shaft. The drive sprocket then drives a chain that rotates a drill pipe in an operative position relative to the case. The spinner also includes an adjusting assembly mounted on the case that moves the drive assembly along the gear rack upon the actuation of an adjustment sequence. When the adjustment sequence is initiated, the effective length of the chain is adjusted to accommodate drill pipes of varying diameters. | 4 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/571,926, filed May 18, 2004, which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to telecommunications services. More particularly, the present invention relates to systems and methods for providing services that are initiated or controlled using messaging, such as the short message service (SMS) available through mobile telephony.
[0004] 2. Background of the Invention
[0005] As mobile telephones become even more ubiquitous, there exists an opportunity to leverage the ever-increasing ability to “connect” directly with consumers who are in the position to purchase goods and services, but who may not be in a position to interface directly with a merchant or point-of-sale terminal.
[0006] There is therefore a constant need to provide improved and more efficient systems and methods for allowing consumers to gain access to goods and services.
BRIEF SUMMARY OF THE INVENTION
[0007] According to one exemplary aspect, the present invention relates to a method for providing message-based interactive services, comprising receiving a short code message from a mobile subscriber relating to service desired by the mobile subscriber from an interactive service device, routing the short code message for processing, and instructing the interactive service device to operate in accordance with the short code message.
[0008] According to another exemplary aspect of the invention, a method is disclosed for providing message-based interactive services. The method involves receiving a short code message from a mobile subscriber relating to service desired by the mobile subscriber from an interactive service device, routing the short code message to an inter-carrier vendor for processing, and instructing the interactive service device to operate in accordance with the short code message.
[0009] According to yet another exemplary aspect of the invention, a system is disclosed for providing message-based interactive services. The system includes a mobile wireless device, an interactive services device, an application provider network, and an inter-carrier vendor network. The system is operable to route a short code message from the mobile wireless device to the application provider network via the inter-carrier vendor network to effectuate a desired service from the interactive service device. These and other features of embodiments of the invention will be more full explained below in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a call flow diagram depicting the flow of calls, messages and information in accordance with an embodiment of the present invention.
[0011] FIG. 2 depicts call flow according to another exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The acronyms below are used throughout the following description.
Term Meaning AP Application Provider API Application Programming Interface BA Billing Augmentation BGW Billing Gateway BS Base Station CG Content Gateway CM Campaign Manager CSC Common Short Code CSCA Common Short Code Administrator DN Directory Number EMI External Machine Interface HLR Home Location Register ICV Inter-Carrier Vendor IP Internet Protocol IX InphoXchange LBS Location-Based Service MMS Multimedia Message Service MNP Mobile Number Portability MS Mobile Subscriber MSC Mobile Switching Center SMPP Short Message Peer-to-Peer SMS Short Message Service SMSC Short Message Service Center SMTP Simple Mail Transfer Protocol UCP Universal Computer Protocol USC Universal Short Code VLR Visitor Location Register
[0013] As a result of different implementations of the short message service (SMS) and inadequate connectivity among wireless service providers, especially in the Untied States, one mobile subscriber (MS) might be unable to communicate via SMS with another MS services by a different service provider. To address this problem, an inter-carrier vendor may be employed as a go-between among several service providers. For example, once a given service provider determines that an SMS message initiated in its own network cannot be delivered, that service provider will forward the SMS message to the inter-carrier vendor for appropriate routing. An illustrative example of aspects of an inter-carrier vendor (ICV) may be found in pending U.S. application Ser. Nos. 10/426,662, entitled “Systems and Methods for Interconnecting Heterogeneous Networks,” and 10/831,329 (a continuation-in-part of U.S. application Ser. No. 10/426,662) both of which are incorporated by reference herein.
[0014] One aspect of an Inter-Carrier Vendor (ICV) is to support the ongoing development and deployment of services that sit atop of, and thus leverage functions that may be provided by the ICV's capability to route, process, and deliver Short Message Service (SMS) messages. The ICV may also utilize such concepts as a comprehensive content gateway (CG) solution and a comprehensive campaign manager (CM), all of which are described more fully below.
[0015] An illustrative example of aspects of the aforementioned comprehensive Content Gateway (CG) solution can be found in pending U.S. application Ser. No. 10/852,101, entitled “Content Gateway,” which is incorporated by reference herein.
[0016] An illustrative example of aspects of a comprehensive Campaign Manager (CM) platform can be found in pending U.S. application Ser. No. 10/837,696, entitled “Campaign Manager Application-Based Services,” which is also incorporated by reference herein.
[0017] As described in the cited pending applications, operative elements of the presented solutions may, where appropriate, take advantage of the SMS message routing opportunities that exist through the use of a Universal Short Code (USC) and Billing Augmentation (BA) services.
[0018] SMS message routing opportunities exist through the use of a Universal Short Code (USC). An illustrative example of a USC environment may be found in pending U.S. application Ser. No. 10/742,764, entitled “Systems and Methods for a Universal Short Code Administration Facility,” and which is incorporated by reference herein. Such common short codes (CSCs) are administered in the US by an organization known as the Common Short Code Administration.
[0019] For immediacy of impact and unprecedented levels of consumer involvement, few innovations can rival common short codes (CSCs). Long popular in Europe, CSCs—short strings of numbers to which text messages can be addressed—allow wireless subscribers to access applications on all participating wireless carriers' networks, at any time and give content providers access to approximately 150 million SMS subscribers. The possibilities for this functionality are endless: voting and polling, contests, surveys, direct marketing, chat, games, and the like all can benefit from CSCs.
[0020] It is noted that a short code is usually a number to which an SMS or text message can be sent. A short code often has fewer digits than a 10-digit telephone number. For example, a short code could be 54321. A common short code, or CSC, is a short code that is common across all wireless service providers in the U.S. The Common Short Code Administrator (CSCA) assigns CSCs to applicants allowing them to be used for the same application across multiple wireless service providers.
[0021] Services, such as the instant Message-Based Interactive Services, fit precisely within the framework outlined by the several patent applications cited herein.
[0022] For purposes of illustration consider the following embodiment of a Message-Based Interactive Service, in accordance with the principles of the present invention. Under this illustrative example Jane, a Mobile Subscriber (MS), has visited a local do-it-yourself laundry establishment and has deposited her dirty laundry in one of the available clothes washing machines. The term mobile subscriber as used herein may refer to the person who subscribes to a mobile service, but it may also refer to the mobile wireless device itself that is associated with a particular mobile carrier's network. This definition of mobile subscriber is not intended to be limiting and merely adds on to any plain and ordinary meaning that may be ascribed to the term mobile subscriber.
[0023] The telephone number or Directory Number (DN) of Jane's mobile device (e.g., her cellular telephone) is 703-555-1212. A placard on the washing machine that Jane has selected indicates that for Jane to use the machine she should:
Please send a text (SMS) message containing the value 3198 (the unique identifying code of this washing machine) to the address “MyWash” (i.e., the CSC 699274).
[0025] FIG. 1 depicts, at a high-level, the interactions that, in accordance with the present invention, typically take place following Jane's dispatch of her SMS message:
[0026] (A) Following the instructions that Jane finds on the washing machine Jane dispatches an SMS message from her mobile device to CSC 699274 with the body of her message containing the code 3198 (i.e., the unique code of the specific washing machine that Jane is utilizing). In stylized fashion this message may be represented as:
--- Message Start --- From: 1-703-555-1212 To: 699274 Body: 3198 ---- Message End ----
[0027] (B) A Mobile Switching Center (MSC) within Jane's wireless carrier's network environment receives and processes Jane's SMS message and passes the message to a Short Message Service Center (SMSC). (Note that this depiction is intentionally simplified and as a result does not include network elements such as Base Stations [BSs], etc. and the messaging interaction with same.)
[0028] (C) The SMSC receives and processes Jane's SMS message. The SMSC examines the destination address of the message, discovers that the destination address is the CSC 699274, determines that that destination resides outside of its environment, and passes the message, along to its ICV for subsequent routing and delivery. It should be readily apparent to one of ordinary skill in the relevant art that numerous proprietary communication mechanisms and/or standards-based communication mechanisms (including, inter alia, Short Message Peer-to-Peer [SMPP], External Machine Interface/Universal Computer Protocol [EMI/UCP], Simple Mail Transfer Protocol [SMTP], etc.) may be utilized to support the SMSC-to-ICV linkage.
[0029] (D) The ICV receives and processes the message. The ICV examines the destination address of the message, discovers that the destination address is the CSC 699274, and uses its routing facilities to identify the Application Provider (AP) that is (at that moment in time) associated with CSC 699274. As mentioned above, an illustrative ICV comprehensive routing facility may be found in pending U.S. application Ser. Nos. 10/426,662 and 10/831,329 (a continuation-in-part of pending U.S. application Ser. No. 10/426,662).
[0030] While not explicitly illustrated in FIG. 1 , the ICV may dispatch an inquiry to the AP to, among other things, validate the body of the received message (3198 in the instant example), confirm that the device that is associated with the supplied code (the washing machine that Jane wishes to use) is available for use, secure the applicable billing parameters from the AP (e.g., if they are not already cached by the ICV), etc. The AP may return a response to the ICV (containing, based on the ICV's inquiry, a positive or negative validation, the applicable billing parameters, etc.). It should be readily apparent to one of ordinary skill in the relevant art that numerous communication mechanisms may be employed to support such an ICV-to-AP message exchange (see, for example, Step C above).
[0031] Using the applicable billing parameters the ICV dispatches a billing authorization request to the Billing Gateway (BGW) within the wireless carrier's environment. As described at length in pending U.S. application Ser. No. 10/837,695, which is incorporated by reference herein for any purpose, telecommunication billing systems are traditionally large, slow-changing, closed solutions. As a result, it is frequently a challenge for an external, third-party to (a) obtain access to a carrier's billing system and (b) for the carrier's billing system to offer the features, functions, flexibility, etc. that are required by the third-party.
[0032] To address the first impediment that was noted above (i.e., access), the ICV may access a wireless carrier's billing environment directly through a BGW resident within the carrier's environment. Alternatively, the ICV may access a wireless carrier's billing environment indirectly through a third-party facilitator (an example of such a third-party facilitator is Qpass, Inc., Seattle, Wash.). It should be readily apparent to one of ordinary skill in the relevant art that numerous communication mechanisms may be employed to support the associated linkage. In the instant example we assume a direct (ICV→BGW) mechanism.
[0033] (E) The BGW receives and processes the message. Among other things, the BGW may generate a line-item, capturing the particulars (date, time, source, destination, amount, etc.) of the instant transaction, said line item ultimately appearing on Jane's monthly statement from the carrier. The BGW dispatches a positive billing authorization response to the ICV. (In the instant example a BGW is employed; as described in Step D above, alternative arrangements are easily possible.)
[0034] (F) The ICV receives and processes the message. The ICV dispatches a message, such as a billing confirmation message, to the AP identifying the MS and confirming the successful completion of the billing event. As described in Step C above numerous communication mechanisms are available to support this linkage. As described previously, the message processing, routing, and delivery capabilities of the ICV support this message exchange and it should be readily apparent to one of ordinary skill in the relevant art that numerous mechanisms exist (see, for example, Step C above) to support this message exchange.
[0035] (G) The AP receives and processes the message. Among other activities, the AP validates the received message (e.g., confirming that the body of the received message (3198 in the instant example) is structurally correct, valid, etc.; confirming that the device that is associated with the supplied code (the washing machine that Jane wishes to use) is available for use; etc.) and appropriately updates its local repository (e.g., to temporarily associate code 3198 with 703-555-1212 (the DN of Jane's mobile device) in support of Step N below).
[0036] The AP then dispatches a ‘Start’ message to the identified washing machine, which may take the form of an authorization message. For example, the washing machine may reside at an Internet Protocol (IP) address that the AP may access in an open fashion (e.g., via the Internet) or in a closed fashion (e.g., via a private, secured network) and control via a defined set of messages/functions that are exposed through an Application Programming Interface (API). It should be readily apparent to one of ordinary skill in the relevant art that other access and/or control mechanisms are easily possible. In stylized fashion this message may be depicted as:
--- Message Start --- To: 3198 Action: Start ---- Message End ----
[0037] (H) The washing machine receives the message, initiates its wash cycle, and dispatches a positive acknowledgement or response to the AP, which may take the form of an acknowledgement message.
[0038] (I) The AP receives and processes the message. The AP formulates and dispatches a service confirmation SMS message (e.g., “Thank you very much for using TechnoWash!”) to the ICV for subsequent delivery to the MS (Jane). In stylized fashion this message may be represented as:
--- Message Start --- From: 699274 To: 1-703-555-1212 Body: Thank you very much for using TechnoWash! ---- Message End ----
[0039] It should be readily apparent to one of ordinary skill in the relevant art that numerous mechanisms exist (see, for example, Step C above) to support this message exchange.
[0040] (J) The ICV receives and processes the message. The ICV examines the destination address of the message, discovers that the destination address is the telephone number 703-555-1212, uses routing facilities to identify the wireless carrier that (at that moment in time, given the presence of Mobile Number Portability (MNP) regimes) owns or services the telephone number, and passes the message to an SMSC within the identified wireless carrier's environment. See, for example, Steps C and D above for a discussion of the numerous message processing, routing, and delivery particulars for this message exchange.
[0041] (K) The SMSC receives and processes the message. The SMSC passes the message along to the MSC that is currently servicing Jane's mobile device. (As described previously, the present depiction is intentionally simplified and as a result does not include network elements such as Home Location Register (HLR), etc. and the messaging interaction with same.)
[0042] (L) The MSC receives and processes the message. The MSC delivers the message to Jane's mobile device. (As described previously, the present depiction is intentionally simplified and as a result does not include network elements such as Visitor Location Register (VLR), etc. and the messaging interaction with same.)
[0043] (M) When the washing cycle is completed, the washing machine dispatches a ‘Done’ message to the AP. See, for example, Step G above. In stylized fashion this message may be depicted as:
--- Message Start --- From: 3198 Action: Done ---- Message End ----
[0044] (N) The AP receives and processes the message. The AP utilizes the information in its local repository (that, among other things, temporarily associates code 3198 with 703-555-1212 (the DN of Jane's mobile device)) to formulate and dispatch a notification SMS message (e.g., “Your laundry is done!”) to the ICV for subsequent delivery to the MS (Jane). This type of message may also be considered a service confirmation message that denotes completion, rather than initiation of the service. In stylized fashion this message may be represented as:
--- Message Start --- From: 699274 To: 1-703-555-1212 Body: Your laundry is done! ---- Message End ----
(O) The ICV receives and processes the message. See Step J above.
[0046] (P) The SMSC receives and processes the message. See Step K above.
[0047] (Q) The MSC receives and processes the message. See Step L above.
[0048] It should be readily apparent to one of ordinary skill in the relevant art that numerous other embodiments are easily possible. For example, other appliances (including, among others, clothes dryers, vending machines, etc.) within the do-it-yourself laundry establishment might be similarly equipped or outfitted. Outside of the Laundromat context, for example, Jane (our MS) may park her car in a parking garage or in front of a parking meter and follow the instructions found on a placard on the instant parking meter which announce that for parking Jane should:
Please send a text (SMS) message containing the value 2103456 (the unique identifying code of this parking meter) to the address “MyPark” (i.e., the CSC 697275).
[0049] The messaging interactions for this embodiment would occur under a structure like that shown in FIG. 2 , using a similar logic for the actual message routing as shown in FIG. 1 . In addition to the above-mentioned devices, it may also be possible to apply the interactive messaging capabilities to operate other devices, such as an ATM machine, an internet kiosk, a pay phone, gas pumps, etc. Practically any device currently operated by coin or credit card or other such automated payment facilities could be augmented to operate using such message-based interactive controls as described herein, although adaptation to the particular interactive device may require minor modifications fully within the scope of one of skill in the art based upon the description contained herein.
[0050] It is useful to note that under this embodiment additional messaging opportunities become available. For example, in the message that the AP dispatches to the MS to alert the MS to the impending expiration of the parking meter the AP may optionally allow the MS to re-charge the parking meter for some new interval. Such an action would be accomplished through an additional exchange of request and response messages involving, among others, the AP and the ICV (to request such a re-charge and to positively or negatively acknowledge the completion of same) and between the ICV and the BGW (to request such a re-charge and to positively or negatively acknowledge the completion of same).
[0051] It should be readily apparent to one of ordinary skill in the relevant art that other arrangements of the individual embodiments are also easily possible. For example, while there are a range of not-insignificant advantages or benefits that arise from the use of a centralized ICV, including among others:
[0052] Ubiquitous message transport across multiple wireless carriers.
[0053] Access to wireless carrier billing environments.
[0054] Ubiquitous access to APs.
[0055] Comprehensive message routing capabilities across and among wireless carriers and APs including native support for things like USCs/CSCs, MNP initiatives that may be active, etc.
[0056] it is possible, as one of many conceivable alternatives, for the AP to perform the carrier billing system interaction that was described above in Step D and Step E in the narrative for FIG. 1 . There are clearly a number of practical logistical, etc. measures that would arise from such an arrangement.
[0057] Additionally, it should be readily apparent to one of ordinary skill in the relevant art that the use of other supportive mobile services may be incorporated into various of the embodiments. For example, a Location-Based Service (LBS) capability might be leveraged during a portion of the previously described messaging exchanges to associate the physical location of the requesting MS with the physical location of the device which the MS is attempting to utilize as part of additional security, fraud protection, etc. controls.
[0058] While the narrative that was just presented concerned SMS, it should be obvious to one of ordinary skill in the relevant art that other messaging constructs (e.g., Multimedia Message Service [MMS]) are easily possible.
[0059] The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein should be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
[0060] Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. | A method and system for providing message-based interactive services includes receiving a short code message from a mobile subscriber relating to a service desired by the mobile subscriber from an interactive service device, routing the short code message for processing, and instructing the interactive service device to operate in accordance with the short code message. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to solar-radiation collection apparatus of the self-tracking high- concentration variety, high-concentration being understood to apply to concentrations exceeding 100 suns, and especially in the range of 500 or more suns.
Our U.S. Pat. No. 4,086,485 discloses such a system involving multiple use of self-tracking collecting optical systems, each with its associated utilization device, such as a photovoltaic cell. The concentration of solar radiation is high and, for efficient utilization, the full image of the sun covers the exposure surface substantially only when the axis of the optical system is aligned with the sun. The angle subtended by observed diametral limits of the sun thus represents substantially the limit of optical-system axial misalignment which can be tolerated by the self-tracking mechanism. As a practical matter, the system is inherently self-tracking as long as a portion of the sun's image remains on the cell, since clock-operated diurnal-drive mechanism enables approximately correct optical-axis orientation for intervals in which the sun is not available, i.e., when the sun cannot be sensed for tracking or any other purpose. But for more prolonged intervals, for example days without sunshine, the inherently small off-axis angle of self-tracking capability can present a problem.
Further, the collecting optical system of said patent is of the Cassegrain variety, involving a centrally apertured primary mirror and a mounting of the cell to receive secondary-mirror reflected light via the aperture and at a location offset behind the primary mirror. And since the axis of the optical system must at all times be inclined, consistent with the sun's seasonal and diurnal elevation ranges, there is a substantial exposure of the cell to vertical convection currents of air, with attendant loss of thermal efficiency.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to provide improved solar-radiation collection apparatus of the character indicated.
A specific object is to provide an inherently greater off-axis angle of self-tracking capability in apparatus of the character indicated.
Another specific object is to provide structure for substantially reducing thermal losses attributable to convection currents of air in such apparatus.
A general object is to achieve the foregoing objects with structure of elemental simplicity and low cost, lending itself to application in existing collecting-optical systems and compatible with existing self-tracking gear.
These and other objects and features are realized, in the context of the illustrative Cassegrain-type collecting-optical system here involved, by providing tubular shroud-like structure to locally surround a bundle of rays which converges to focus at the cell, following reflection by the secondary mirror. A mirror surface within the shroud enables capture (and redirection toward the cell) of thus-reflected convergent solar rays, for a substantially greater angle of misalignment with the sun than is otherwise achievable. If the shroud fully surrounds and supports the cell throughout its axial offset behind the primary mirror, a major rejection in convection-current loss is achieved. However, most complete convection-current loss is achieved if, as here to be described, the shroud extends through the primary-mirror aperture and projects therebeyond, to an axial extent short of interference with that radially innermost ray alignment between primary and secondary mirrors as will produce cell incidence for incoming light that is parallel to the axis of the optical system.
DETAILED DESCRIPTION
Preferred and other illustrative embodiments of the invention are described in conjunction with the accompanying drawings, in which:
FIG. 1 is a vertical sectional view through an optical system of the invention, for collecting and concentrating solar radiation, and with a fragmentary and schematic showing of associated suspension and self-tracking components;
FIG. 2 is a simplified fragmentary optical diagram, to illustrate an axially aligned condition of the axis of the optical system, with respect to the direction of the sun;
FIG. 3 is a view similar to FIG. 2, to illustrate an optical-axis misalignment α s with respect to the direction of the sun;
FIG. 3A is a simplified diagrammatic representation to illustrate the localized nature of certain ray-vignetting within the optical system of FIG. 1, for the axis alignment α s ;
FIG. 4 is a graph, comparatively depicting image incidence upon the cell, as a function of optical-axis misalignment α s , with and without use of the invention;
FIGS. 5(a) through 5(g) are simple diagrams to show image incidence at the cell, without use of the invention, for a succession of progressive misalignments of the optical axis;
FIGS. 6(a) through 6(g) are diagrams corresponding to FIGS. 5(a) through 5(g), but illustrating use of the invention;
FIG. 7 is a graph to illustrate properties of an element of FIG. 1; and
FIG. 8 is an enlarged view in perspective to illustrate modification of an element of FIG. 1.
Referring initially to FIG. 1, the invention is shown in application to Cassegrain-type optical system for collecting solar radiation and for highly concentrating the same at focus upon the exposure surface of suitable utilization means 10, such as a photovoltaic cell. The optical system comprises a concave primary mirror 11 and a convex secondary mirror 12, rigidly positioned by struts 13 in axially spaced relation to the primary mirror 11, and directing secondary-mirror reflections to focus at the cell 10, via a central aperture in the primary mirror. A two- axis gimbal suspension for the optical system comprises a first gimbal frame 14 having freedom to tilt about a first gimbal axis A with respect to a fixed mounting (not shown), and a second gimbal frame 15 having freedom to tilt about a second gimbal axis B, orthogonal to axis A, the second frame 15 being mounted to the first frame 14 via tilt axis B, and the optical system being secured to the second frame 15 by bolts 16.
For self-tracking purposes, a single microprocessor 20, programmed with a maximization algorithm, serves each of the two coordinates of corrective displacement (about axis A and about axis B) of each of a plurality of collecting optical systems, of which the system 10-11-12 is but one; in this connection, reliance is upon time-multiplexing of solar-cell outputs and of control signals to tilt-axis drives for all collecting sytems, at suitably sequenced intervals. Reference is made to our U.S. Pat. No. 4,086,485 for more detailed description of such self-tracking operation, and it suffices here only to identify a simplified showing of components, namely: a sensing multiplexer 21 for sequentially sensing the cell outputs pertaining to the respective optical systems (specifically including the output of cell 10), the sequencing being governed via a control-line connection 22 to the microprocessor 20; and separate drive-control devices 23-24 to provide tilt-corrective drive of frames 14-15 about the respective axes A-B, based on the respective component-correction outputs 25-26 of the microprocessor 20, and with multiplexing at 27-28 to provide time-interlace with corresponding drive- control functions for the other optical systems served by the microprocessor. The indicated correctional drive mechanism for frames 14-15 about their gimbal axes A-B will be understood to be symbolized by the arrows for connections shown from devices 23-24 to the axis designations A-B in FIG. 1.
In accordance with the invention, a tubular shroud 30 is provided at the central aperture of the primary mirror 11. Preferably, shroud 30 extends as a single element for the axial distance L, from a lower location surrounding cell 10, through the primary-mirror aperture, and to an upper position axially beyond mirror 11. A peripheral flange 31 provides a convenient means for positioning or securing shroud 30 with respect to the backside of mirror 11 and, if desired, for also mounting the cell 10 in its rearwardly offset location behind the aperture region of mirror 11. The nature and function of shroud 30 will become clear, following an identification of geometrical and dimensional relationships, initially in connection with FIG. 2.
In FIG. 2, the secondary mirror 12 is seen to be of diameter D which exceeds the operative exposure-surface dimension d of cell 10, it being also understood for purposes of present discussion that the sun's image diameter has the same dimension d. For the sun-aligned condition depicted in FIG. 2, the secondary mirror 12 casts a circular masking shadow upon primary mirror 11, so that solar radiation collected by mirror 11 must all be developed from incident parallel rays including and external to internal limiting rays a--a. The dimensions D and d, the primary and secondary-mirror radii, and the relative axial positions of components 10-11-12, will also be understood to determine a primary-to-secondary ray b of first reflection attributable to each ray a, and an inner secondary-to-cell ray b' of second reflection attributable to each ray b, whereby ray b' impinges upon the remote transverse limit of the exposure surface of cell 10. In similar fashion, an outer ray c (reflected by the primary to the secondary mirror) will be understood to determine an outer secondary-to-cell ray c' of second reflection attributable to each ray c, whereby ray c' impinges upon the near transverse limit of the exposure surface of cell 10, it being noted that such limiting rays c' also establish a minimum value of the diameter H of the central aperture in mirror 11, and that the locus of all such rays c' is a geometrical cone of divergence angle α 1 .
Stated in other words, the locus of all primary- to-secondary rays b is a geometrical cone of convergence angle α 2 , and any primary-to-secondary ray attributable to parallel light from the sun and striking mirror 11 at a point radially inside of the incidence of ray a on mirror 11 would fail to be second-reflected to cell 10 and would therefore be useless. Thus, for the on-axis or sun-aligned condition of FIG. 2, an optically inutile annular geometrical solid 32 is defined by and between the conical loci of rays b-c', on the primary-mirror side of the intersection of these loci, and it is within this geometrical solid 32 that shroud 30 may be placed without interfering in any way with optimum cell response to the sun, when the optical-system axis is aligned with the sun. Stated in other words, if shroud 30 is of circular section at its upper end, then the shroud length L should be such that its upper end extends to an axial extent short of interference with that radially innermost ray alignment between the primary and secondary mirrors as will achieve cell incidence for incoming light which is parallel to the axis of the optical system.
For a tubular shroud 30 of circular section, it is preferred that the internal wall surface thereof be frusto-conical and that the divergence angle thereof be the same α 1 , as previously noted for the convergent frusto-conical locus of second-reflection rays c', with these two frusto-conical surfaces being substantially coincident. It is also preferred that a mirror finish be provided on the inner wall surface of shroud 30, to permit capture and reflection to cell 10 for rays that might otherwise fail to be reflected to impingement upon the exposure surface of cell 10. However, for the sun-aligned condition of FIG. 2, it will be clear that there are no such other rays to be thus captured or reflected into cell impingement.
FIG. 3 illustrates the utility and function of shroud 30, namely within off-axis misalignments to a materially greater degree than if shroud 30 were not employed. In particular, in FIG. 3, an off-axis misalignment α s exists to the extent that, were it not for shroud 30 and for a locally interfering near- center region of the primary mirror 11, the focused image of the sun would appear as suggested by the dashed outline 10' of the cell (i.e., centered on the instantaneous axis S' of sun direction, and having the offset α s from the optical-system axis S); dashed outline 10' is eccentrically offset from the solid-line showing of cell 10, the outlines 10-10' being shown for the case of their mere tangency. The tangent relation will mean that, without shroud 30, no part of the sun's image (at offset misalignment α s , corresponding to the cell dimension d) will impinge upon cell 10. However, using shroud 30 and its reflecting inner wall, the instantaneous axis S' and its surrounding bundle of second-reflection rays from the sun will be reflected by the inner wall of shroud 30, so that a substantial cell response will be achieved; FIG. 3 also shows, for the case of an inner ray a, with first-reflection and second-reflection ray alignments b-b', respectively, there is further capture by shroud 30, with ultimate reflected guidance to cell impingement.
FIG. 3A illustrates that for the off-axis misalignment situation of FIG. 3, the shroud 30 becomes a mask for some first-reflection rays that might otherwise be the source of second reflection, to otherwise possible capture within shroud 30. The offset P in FIGS. 3 and 3A expresses the maximum extent of offset for which such masking applies, accounting for at least a crescent (see FIG. 3A) of sectional area which is thus precluded from cell response; however, it will be appreciated that the fractional loss attributable to the crescent of FIG. 3A is of no moment, since cell 30 only requires some (i.e., not optimum) ray incidence for self-tracking purposes, and a full-response to cell 10 automaticaly develops from self-tracking action, to correct from misalignment (FIG. 3) to full alignment (FIG. 2) with the sun.
FIG. 4 graphically illustrates the at least two-fold increase in tolerable off-axis misalignment α s achievable through use of shroud 30 in the described optical system, as compared to omission of the shroud. And in FIGS. 5 and 6, simplified diagrams progressively account for such difference. In particular, the diagrams of FIG. 5 depict the no-shroud situation, beginning at FIG. 5(a) for the sun-aligned condition, and ending at FIG. 5(g) with the tangent condition above-described at 10-10' in connection with FIG. 3. Progressive offsets Δ d are considered at six equal increments, from 0 (FIG. 5(a)) to d (FIG. 5(g)), i.e., to the point of loss of cell response to the sun, with shading to depict the extent to which the sun's rays impinge upon cell 10. Similarly, the diagrams of FIG. 6 depict the situation when shroud 30 is used, beginning at FIG. 6(a) with the sun-aligned condition, and ending at FIG. 6(g) with offset-axis condition Δ d=d. Progressive offsets Δ d are considered at the same six equal increments in FIG. 6 as in FIG. 5, but dahsed shading is adopted as an indication of the fact that shroud reflection adds to the light flux incident at the cell; it will be understood that the showings of FIG. 6 are purely schematic, in that light flux incident at the cell will not necessarily be uniformly distributed over the cell for the angular misalignments depicted, but rather that there will be important contributions to such incidence for all Δ d misalignments depicted. Thus, in the assumed condition of a reflecting shroud of length L (i.e., to the upper limit of the geometrical solid 32), at least a two- fold increase is achieved for the range of off-axis misalignment within which cell response can be relied upon to enable self-tracking functions.
FIG. 6(a) additionally schematically shows, at 41-42-43-44, four like quadrature cell elements carried at equal angular offset around the cell 10, being part of an alternative means for sensing and correcting misalignment of the optical-system axis with respect to the sun; such a tracking system operates from detected polarized differences in response between opposite pairs of cells 71-73 and 72-74, and is more fully described as an alternative, in U.S. Pat. No. 4,086,485. However, in the event of employing such an alternative in the case of an optical system which includes shroud 30, it will be appreciated that certain angles of second-reflection ray incidence upon the inner wall of shroud 30 can cause misleading incidence upon one or both of the cells of either of the pairs 71-73, 72-74, with at least an impaired ability to automatically correct the axis orientation. To offset this difficulty, FIG. 7 graphically indicates the provision of progressively varying reflectivity as a function of axial location along the inner wall of shroud 30. Thus, in the solid line of FIG. 7, a non-linear function characterizes varying reflectivity of this inner wall, from a maximum at and near cell 10 to a minimum at and near the upper end, at axial distance L from cell 10; alternatively, the dotted line of FIG. 7 indicates another varying-reflectivity characteristic, it being understood that a different such characteristic may be indicated, unique for the particular dimensions and proportions of any given collecting optical-system (with shroud 30) configuration.
FIG. 8 is a perspective view of a tubular shroud 30' representing an alternative of the circular-section shroud 30 thus far discussed, shroud 30' having a square or rectangular section, at any given point along its central axis. Thus, shroud 30' provides a first pair of opposed flat sides 45-46 and a second pair of opposed flat sides 47-48; and a cell 50 with a square or rectangular exposure face is supported at the lower end of shroud 30', while a mounting flange 51 surrounds the shroud for locating reference or mounting to the backside of primary mirror 11. The inner surface of shroud 30', i.e., each of the opposed facing surfaces of each pair 45-46 and 47-48, is of reflecting character, and each pair is opposed in the directional sense of one of the orthogonal gimbal axes A-B, as suggested by legend in the drawing. Thus, corrective input radiation for B-axis tilt correction is derived by cell 50 with the aid of reflecting surfaces of sides 45-46; and corrective input radiation for A-axis tilt correction is derived by cell 50 with the aid of reflecting surfaces of sides 47-48. Finally, it is observed that for maximum upward extent of each of the sides 45-46-47-48, the above-stated criterion to avoid interference with the radially innermost first- reflection ray alignment (i.e., between the primary and secondary mirrors 11-12) dictates elliptically arcuate upper edges, as shown, and this is true whether shroud 30' is of constant section or if, as in preferred, the opposed sides of each pair diverge in accordance with principles discussed above the for frusto-conical embodiment.
The described embodiments of the invention will be seen to have achieved all stated objects. By the simple modification of adding a shroud between the cell 10 and the primary-mirror aperture, there is an immediate protection of the exposure surface of the cell from the convection currents of all air which would otherwise be free to circulate across the highly concentrated heat region in which it is necessarily immersed. And the provision of a mirror surface between the primary mirror and the cell, and/or in the region thereabove to the point of avoiding interference with first-reflection on-target rays provides a substantial widening of the capability of the tracking mechanism to reacquire sun alignment, even following a prolonged absence of available sunlight.
While the invention has been described in detail for the forms shown, it will be understood that modifications may be made without departure from the claimed scope of the invention. For example, the decision whether to employ a shroud 30 of circular section, or of frusto-conical or cylindrical shape, or of square section (whether or not flared), or only within the space between cell 10 and primary mirror 11, or only upward beyond the primary mirror, or with a particularly characterized reflectivity characteristic as a function of axial location--will all depend upon the geometry of the optical system and associated cell 10, upon local geographical and meteorological consideration, and upon the nature of the self-tracking instrumentalities employed, it being desired that for use of a maximization algorithm at microprocessor 20, the overall response of the cell 10 to sun exposure should always be maximum when the sun is in on-target alignment, and that such response should drop (not necessarily uniformly) as a function of increasing off-axis misalignment α s . | The invention contemplates improved apparatus for use in a self-tracking optical system for directing highly concentrated solar radiation upon utilization means such as a photovoltaic cell, wherein the full image of the sun covers the exposure surface substantially only when the axis of the optical system is aligned with the sun. Certain structural features associated with the optical system in the vicinity of cell support effectively enlarge the margin of off-axis misalignment within which self-tracking is achievable. At the same time, certain aspects of these features inherently prevent thermal losses which would otherwise be attributable to convection currents of air in the region of heat concentration. | 5 |
This is a continuation, of application Ser. No. 68,720, filed Aug. 22, 1979, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to metal cords, such as those used for reinforcing tires and to a process for the manufacture of the metal cords.
2. Description of the Prior Art
Metal cords, including those used for reinforcing tires, are generally manufactured in two steps: the first step is the stranding and consists, starting from single wires, in twisting the said wires together in a given direction, and the second step is the strand-laying which consists in twisting the strands together, or twisting one strand together with single wires, in the same direction or in the opposite direction to the twisting used in stranding, but, in general, to a different extent.
This sequence of operations is long and results in relatively high manufacturing costs.
A process for the manufacture of a metal wire cord is also known from Addition No. 88,666 to French Pat. No. 1,340,702, which process consists in passing the wires of two or more groups of wires, which groups are each composed of two to six wires inclusive, wound on a single bobbin, from their respective bobbins through a twisting apparatus which forms a cord from the wires, and then onto a receiving device. This gives a single-strand cord in which all the wires are twisted in the same direction and to the same extent. A cord of this type can be used in tire reinforcements. In the process, the use of a rotating twister-collector is envisaged, which is located upstream of the twisting apparatus and the function of which is to draw off the appropriate lengths of wire so as to obtain the arrangement which the wires must have in the finished cord. An over-twisting device is also provided in order to give a temporary over-twist by means of false twist, which makes it possible to set the true twist and to obtain an inert cord.
This process makes it possible to dispense with the stranding operation. However, it exhibits certain disadvantages. Since the feed comes from groups of wires, each group being wound on a bobbin, it is first necessary to make up coils of grouped wires and this constitutes an additional operation involving grouping onto a bobbin. However, this grouping operation can be avoided by collecting a group of wires directly at the outlet of a multiple wire-drawing device; however, the field of application of the process is then restricted and dependent on the use of multiple wire-drawing devices, this use being far from widespread. Furthermore, the wires of each group are drawn off simultaneously and unwind at the same speed.
Now if the finished cord is to be compact, the wires must not have the same length in accordance with their distance from the axis, that is to say in accordance with the successive layers to which they belong. In the patent in question, the simultaneous unwinding means that the wires have the same length. This results in non-uniformities along the cord. In an attempt to limit these defects, positioning means (positioning guides and perforated plates), located between the feed bobbins and the twisting apparatus, are provided. However, apart from making the device more complex, these means do not succeed in eliminating the nonuniformity defects.
This process produces cords of which the properties, in particular the tensile strength, can vary along the cord because of the lack of uniformity in positioning the strands.
Now, metal cords for reinforcing tires must possess both a high tensile strength and a good fatigue resistance, coupled with the smallest possible diameter. In fact, in the making of calendered plies, the diameter of the cord determines the thickness of the ply. A thin ply has a dual advantage: from the economic point of view the amount of rubber used is smaller and the cost of the ply is reduced, and, from the technical point of view, a thinner ply provides a better resistance to heat.
An attempt has been made to reconcile these contradictory characteristics in specific manufactured products.
Thus, U.S. Pat. No. 3,358,435 described a cord of the 3+6 type, that is to say with 3 core wires and 6 outer wires, which exhibits improved compactness. The 6 wires of the outer layer are laid around the core in the same direction and with the same pitch as the latter; however, in order to make the cord compact, these 6 wires consist of two groups of three wires, the diameter of the wires being different in the two groups and different from the diameter of the core wires. In this manner, while retaining an identical external diameter to that of the conventional 3+6 cord, 3 wires of larger diameter are used for the outer layer and this results in a better packing and a higher tensile strength. However, the improvement in the tensile strength only results from the increase in the linear mass, which constitutes a handicap in the tire. Moreover, this method of construction is restricted to the 3+6 structure. Furthermore, it necessitates the use of cores of different diameters, which results in a deformed cord, it is expensive, it carries the risk of mixing the wires together, and, in particular, it requires a device for the very strict positioning of the strands, any transposition of two outer wires in the process leading to a poor result.
SUMMARY OF THE INVENTION
The present invention proposes to provide a metal cord which possesses a good compactness combined, inter alia, with good tensile strength and fatique resistance, while being able to be manufactured by a simple process on existing machines which have undergone a few minor modifications.
It relates to a single-strand metal cord for reinforcing rubber articles, such as tires, which cord consists of wires of the same diameter, twisted together in the same direction and to the same extent, characterised in that, in cross-section, it has the shape of a compact stack of polygonal contour, which is uniform in the lengthwise direction.
This cord comprises at least nine single wires, but there is no upper limit to the number of wires. In practice, the cords advantageously consist of 9 to 52 wires of the same diameter. The preferred products are cords having 9, 10, 12, 14, 19, 24, 27, 28, 30, 37, 44, 48 or 52 wires for reasons of geometry. In fact, for wires having identical diameters, the above numbers correspond to arrangements of maximum compactness, in which the wires arranged in concentric layers are all tangential to one another, including those in the outer layer, the whole being inscribed as completely as possible in a circle.
These cords are intended to replace the earlier products which comprised the same number of wires but were obtained in two steps, namely stranding and strand-laying. The assembling twist of the single wires may or may not be the same as the strand-laying twist of the earlier products obtained in two steps.
The cords are constructed around a central structure based on 1, 2, 3 or 4 wires.
The shape of the cross-section varies with the number of wires forming the cord, but it is essentially the shape of an irregular hexagon.
In the preferred constructions mentioned by way of example, the number of wires on two consecutive sides of the hexagon only varies by one unit.
For a given diameter of monofilament, the compactness of the cord manifests itself in a lower diameter of the cord. This is particularly advantages where calendered plies are manufactured, which are subsequently used for making up carcasses or belts of tires.
Since the calendering rubber with which the cords are coated is very expensive, its thickness is calculated with precision, to about 1/100th of a millimeter. Thus, any reduction in the diameter of the cord makes it possible to reduce the thickness of the calendered ply and has an immediate beneficial effect on the cost of the said calendered ply. Furthermore, since the ply is thinner, it resists a temperature rise in the tire better. In addition, the packing of the cords in the ply can be increased, thereby increasing the strength of the ply per unit of width.
The cords according to the invention furthermore have an increased breaking load for a given number of wires of the same type. This phenomenon is due to better cohesion between the individual wires which are all oriented in the same direction and which participate more uniformly in the tensile force, this cohesion being uniform along the cord.
The combination of these two properties, namely a higher breaking load and greater compactness, manifests itself in a greater possibility of reinforcement per unit of width of the calendered ply, where the cord is used in tires.
The cords furthermore have a very markedly improved fatigue resistance, which is a vital factor in the use of the cords in tires, and a greater flexibility than the conventional stranded cords.
The other properties, such as adhesion to rubber, remain unchanged compared to the conventional cords.
The present invention also relates to a process for obtaining the cord defined above.
This is a process of manufacture of a single-strand cord from non-twisted single metal wires, in a single stage, according to which the wires unwound from feed means are brought to a means of regrouping, and then to a strand-laying device comprising, at its inlet, an assembling twister which imparts to the assembly of wires a twist close to the nominal twist, the finished cord being collected on a receiving device, the process being characterised in that the wires are fed from coils each consisting of a single wire.
The unwinding tension of each single wire is so adjusted as to impart the twist efficiently at the twister, cause the strand-laying twist to travel back efficiently, and thus give maximum twist at all points of the path of the cord.
The means of regrouping can consist of grids (distributing grids) suitably located, the grids being used in accordance with the number of layers of wires in the cord, and the various strands passing through the holes in the grids.
The strand-laying device can be a simple-twist or double-twist device, or a device of the tubular type. Advantageously, a double-twist device is used, in which the strand-laying spindle is of the conventional type.
To obtain a compact product, with good location of the wires, and free from flaws such as loops and the like, it is necessary that all the wires should, at the point of assembly, be distributed in exactly the length which they are to have in the finished cord. It is this which is the function of the assembling twister, which forms successive layers of wires and imparts to the cord a twist identical to its final twist. Since the twister works by false twist, the twist imparted upstream would normally be destroyed downstream if it was not taken up by the strand-laying spindle. However, in order to ensure the quality of the product, it is necessary that the cord should, as from when it is assembled, retain its twist to the greatest possible extent along its entire path until it reaches the receiving device. Thus, if a double-twist strand-laying device is used, where the twist is imparted in two stages, means are provided which facilitate the travelling-back of the twist as far as the inlet of the strand-laying spindle, that is to say as far as the outlet of the draw-off twister. In this way, the untwisting of the assembly of wires downstream of the draw-off twister is immediately compensated by the travelling-back of the true twist imparted by the strand-laying spindle.
Still with the object of good location of the wires in the product, and good travel-back of the twist, provisions are made to lower and adjust the tension of the single wires at the unwind stage. For this purpose, motor-driven unwinding means, which may or may not be controllable, are used, which consist, for example, of positively driven rollers revolving at a higher speed than the forward travel of the wires. The said rollers make it possible to regulate the tensions at the assembly point and thus facilitate the location of the wires of the various layers. It is possible to use rollers which may or may not be independent of one another and are allotted to individual wires or groups of wires.
To set the twist of the cord and obtain an "inert" product it is possible, in a known manner to subject the cord to a termporary over-twist by false twist and/or to straighten the cord on suitable godets, preferably when it has received its final configuration. This operation can be carried out continuously on the machine or can be carried out discontinuously, thus constituting a separate subsequent operation.
By virtue of the characteristics of the above process, namely individual draw-off of each wire to the correct length and with the correct tension, imparting of the final twist at the assembly point, and maintenance of the twist over the entire path downstream from the twister, the wires locate themselves individually in the best way in the free spaces, resulting in compact and uniform cords. Since this compact structure is required as from leaving the draw-off twister, it is not disturbed over the subsequent path of the cord, by virtue of the effect of the travel-back of twist.
Finally, the strand-laying assembly may or may not include a lapping spindle integral with the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The examples and figures which follow are given to illustrate the invention and do not imply a limitation.
FIG. 1 illustrates a method of carrying out the process according to the invention.
FIGS. 2 to 12 schematically represent cross-sections of cords according to the invention.
FIGS. 13 and 14 represent actual cross-sections of two cords, viewed under a scanning electron microscope.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 represents a strand-laying device for carrying out the process according to the invention.
It comprises, on the one hand, a framework 1 carrying a double-twist strand-laying spindle 2, an assembling twister 3, two assembling dies 4 and distributing grids 5, and on the other hand, means of feeding single wires F, the means essentially consisting of a creel 6 carrying bobbins of single wires 7. The creel 6 carries a number of bobbins at least equal to the number of wires constituting the cord, only six of the bobbins being shown in the drawing. In order to adjust the tension of the wires at the point of assembly in the die 4, the wires are positively driven by unwind rollers 8. The wires F can slip on the rollers 8, so that the speed of draw-off of each wire is determined by a capstan 12 and the assembling twister 3 in accordance with the position of each wire in the cord.
The strand-laying spindle 2 is a double twist windup spindle, having a double loop 9-10. One of the loops serves to guide the cord and defines a path of the double twist type, while the other loop is provided for balancing purposes. Inside the space defined by the loops is provided a cradle 16 which is not movable and which carries a receiving bobbin 11, with reciprocating means of distribution of the cord, a capstan 12, an over-twister 13 and a straightener 14. The capstan 12 serves to draw the cord C. The over-twister serves to set the strand-laying twist by applying a temporary overtwist by false twist, making it possible to exceed the elastic limit. The straightener 14 also plays a part in fixing the twist. It is also possible to fit onto the path of the cord any device which is in itself known and which allows the twist to travel back towards the assembly zone.
The process is carried out as follows with the device of FIG. 1:
The single wires F and the cord C which is being formed and subsequently has been formed are drawn by the capstan 12, which determines the speed of advance of the cord. From the feed bobbins 7, the single wires F pass around rollers 8 which drive the wires positively, but allow the possibility of slip, the speed of each being adjusted so as to provide the necessary tension at the assembling dies 4. It is also possible to have identical speeds and adjust the tensions by varying the number of turns of the wires over the said rollers. The wires pass successively through the distributing grids 5 and the assembling dies 4 and then, in the form of a cord, into the assembling twister 3. For a given speed of advance of the cord determined by the capstan 12, the speed of rotation of the draw-off twister 3 is set so that this component imparts to the cord an assembling twist equal to its nominal twist. Thus, at the twister 3 the cord already has its final twist configuration and the said twister draws off each wire to the correct length, in accordance with the position which it is to occupy in the cord. At the outlet of the twister 3, the cord enters the spindle 2 and describes a path of the double twist type in one of the two loops 9-10, equipped with means which facilitate the travel-back of the twist. On leaving the said loop, the cord is subjected to an over-twist by means of false twist applied by the over-twister 13, in order to obtain an "inert" cord, free from twist reaction, and is then straightened in the straightener 14 and, after passing over the capstan 12, is collected on the bobbin 11.
As already indicated in the general description, the process makes it possible to obtain a cord having the required properties, namely improved compactness, uniformity, breaking load and flexibility. These properties are achieved by the combination of the following main points of the process:
individual draw-off of each wire, to the correct length, and imparting of final twist at the assembly stage, by means of the assembling twister 3,
positioning of the wires in the cord being formed, facilitated by the drive rollers 8 which make it possible to lower and adjust the assembling tension, and
maintenance of the twist imparted by the twister 3 over the entire path, by virtue of the travel-back of twist imparted by the spindle as far as the outlet of the said twister 3.
Thus, the wires are placed simultaneously and individually in the best way in the free spaces, which results in compact cords. Since this compact structure is acquired as from leaving the twister 3, it is not disturbed over the subsequent path of the cord, and this contributes to good uniformity. Furthermore, the individual drawing-off of the wires makes it possible to reduce the precautions regarding the positioning during assembly. It is simply necessary to provide a particular guide for the basic structure, and the other wires automatically place themselves around this basic structure.
FIGS. 2 to 12 show, in cross-section, cords according to the invention, consisting of wires of identical diameters, which cords can be obtained by the process described above. It will be noted that the cords are in the form of compact stacks, and the wires all touch. These stacks or arrangements are in the form of concentric layers deposited around a central basic structure (shown shaded) which structure may consist of 1, 2, 3 or 4 wires.
FIGS. 2 and 3 represent cords constructed around a central basic structure of one wire. The cord according to FIG. 2 comprises 19 wires; it is of the (1+6+12) type. The cord according to FIG. 3 comprises 37 wires; it is of the (1+6+12+18) type. The numbers 6, 12 and 18 denote the number of wires which the various layers around the central basic structure comprise.
FIGS. 4, 5 and 6 represent cords constructed around a central basic structure of two wires. The cord according to FIG. 4 comprises 10 wires; it is of the (2+8) type. The cord according to FIG. 5 comprises 24 wires; it is of the (2+8+14) type. The cord according to FIG. 6 comprises 44 wires and is of the (2+8+14+20) type.
FIGS. 7, 8 and 9 represent cords constructed around a basic central structure of three wires. The cord according to FIG. 7 comprises 12 wires; it is of the (3+9) type. The cord according to FIG. 8 comprises 27 wires; it is of the (3+9+15) type. The cord according to FIG. 9 comprises 48 wires and it is of the (3+9+15+21) type.
FIGS. 10, 11 and 12 represent cords constructed around a central basic structure of 4 wires. The cord according to FIG. 10 comprises 14 wires; it is of the (4+10) type. The cord according to FIG. 11 comprises 30 wires; it is of the (4+10+16) type. The cord according to FIG. 12 comprises 52 wires and it is of the (4+10+16+22) type. FIG. 13 is a cross-sectional view, under an electron microscope, of a cord of the (4+10) type, consisting of wires of 0.22 diameter, lapped with a wire of 0.17 diameter.
FIG. 14 is a cross-sectional view, under an electron microscope, of a cord of the (3+9+15) type, consisting of wires of 0.22 diameter, lapped with a wire of 0.15 diameter.
The examples which follow show the good quality of the cords according to the invention. The object is to compare the characteristics and properties of the cords according to the invention with the conventional cords comprising the same number of wires of the same nature.
Nomenclature
In the examples, the nomenclature of the cords conforms to the rules illustrated by the following examples:
(a) A 7×4×0.22+0.15 cord; SZS twists; 9.5/18/3.5 pitch
The cord thus designated is a cord of 7 strands, each strand consisting of 4 single wires, each of 0.22 mm diameter; the cord is lapped with a wire of 0.15 mm diameter. S, Z, S twist signifies: S stranding twist, Z strand-laying twist, S lapping twist. 9.5/18/3.5 pitch signifies: stranding pitch 9.5 mm, strand-laying pitch 18 mm, lapping pitch 3.5 mm.
(b) A (3+9)×0.175+0.15 cord; SSZ twists; 5/10/3.5 pitch
The cord thus designated consists of a central strand of 3 wires of 0.175 mm diameter, assembled by S twist with a pitch of 5 mm, the said strand being surrounded by 9 wires of 0.175 mm diameter wound with S twist around the strand, with a pitch of 10 mm; the cord is lapped with a wire of 0.15 mm diameter, with a Z twist, and a pitch of 3.5 mm.
The comparisons are made in respect of the following characteristics:
diameter (expressed in millimeters),
breaking load (expressed in daN-decaNewton), ##EQU1##
Taber rigidity (expressed in Taber units) measured on an apparatus in accordance with U.S. Pat. Nos. 2,465,180 and 2,063,275, and
fatigue (measured in kc-kilocycles, on a SODETAL machine, trade code SFA 10).
In all the examples, wires produced from the same type of steel containing 0.7% of carbon, and commonly used in tyres, are employed. These examples demonstrate the great improvement in the characteristics and properties of the cords according to the invention, namely compactness, breaking load, flexibility and fatigue resistance, compared to relatively tight cords of the (3+9) or (3+9+15) type, but above all compared to constructions of the 7×4 type (see Examples I, II, III and IV).
In all the cases, the other properties of the cords, such as adhesion to the rubber, remain unchanged compared to stranded cords.
When using the cords in a calendered ply, these improvements manifest themselves in the important advantages which have been mentioned in the general description. Coupled with the advantages concerned with the properties of the product is the simplification of the process of manufacture. The said process, which is a single-stage process, eliminates the stranding stage and also the prior grouping on bobbins stage of the earlier processes; it is thus less expensive.
Though the invention is particularly advantageous in the case of cords for the reinforcement of rubber articles such as tires, the invention is also applicable to metal cords intended for any other uses.
EXAMPLE I
Cords Nos. 1 to 4, of which Nos. 2 and 4 are according to the invention and Nos. 1 and 3 are conventional cords. The example concerns cords of 9 wires.
__________________________________________________________________________ (1) (2) Comparison (3) (4) Comparison (2 + 7) × 1 × 9 × 0.22 of (2) (2 + 7) × 0.22 1 × 9 × 0.22 of (4) Designation 0.22 + 0.15 +0.15 with (1) not lapped not lapped with (3) Twists SSZ SZ rounded-off SS S rounded-offCharacteristics Pitch 6.3/12.5/3.5 12.5/3.5 values in % 6.3/12.5 12.5 values in__________________________________________________________________________ %Final product 1.07 1.04 -3 0.82 0.80 -2diameterBreaking load 93 97 +4 95 99 +4Apparent strength 1,035 1,142 +10 1,802 1,969 +9Taber rigidity 39 37 -5 29 28 -3Fatigue 9.5 11.5 +21 10 12 +20__________________________________________________________________________
EXAMPLE II
Cords Nos. 5 to 8, of which Nos. 6 and 8 are according to the invention and Nos. 5 and 7 are conventional cords. The example concerns cords of 12 wires.
__________________________________________________________________________ (5) (6) Comparison (7) (8) Comparison (3 + 9) × 0.175 1 × 12 × of (6) (3 + 9) × 0.175 1 × 12 × of (8) Designation + 0.15 0.175 + 0.15 with (5) not lapped not lapped with (7) Twists SSZ SZ rounded-off SS S rounded-offCharacteristics Pitch 5/10/3.5 10/3.5 values in % 5/10 10 values in__________________________________________________________________________ %Final product 0.96 0.92 -4 0.74 0.71 -4diameterBreaking load 66 68 +3 67 70 +4Apparent strength 912 1,022 +12 1,561 1,768 +13Taber rigidity 21 20 -5 17 16 -6Fatigue 25 35 +40 30 40 +33__________________________________________________________________________
EXAMPLE III
Cords Nos. 9 to 12, of which Nos. 10 and 12 are according to the invention and Nos. 9 and 11 are conventinal cords. The example concerns cords of 27 wires.
__________________________________________________________________________ (9) (10) Comparison (11) (12) Comparison (3 + 9 + 15) × 1 × 27 × of (10) (3 + 9 + 15 × 1 × 27 of (12) Designation 0.175 + 0.15 0.175 + 0.15 with (9) 0.22 + 0.15 0.22 + 0.15 with (11) Twists SSZS ZS rounded-off SSZS ZS rounded-offCharacteristics Pitch 5/10/16/3.5 16/3.5 values in % 6.3/12.5/18/3.5 16/3.5 values in__________________________________________________________________________ %Final product 1.36 1.34 -1 1:65 1.63 -1diameterBreaking load 170 182 +7 266 282 +6Apparent strength 1,170 1,290 +10 1,244 1,335 +7Taber rigidity 55 54 -2 109 97 -11Fatigue 26 29 +11 11 12 +9__________________________________________________________________________
EXAMPLE IV
Cords Nos. 13 to 16, of which Nos. 14 and 16 are according to the invention and Nos. 13 and 15 are conventional cords. The example concerns cords of 28 wires.
__________________________________________________________________________ (13) (14) Comparison (15) (16) Comparison 7 × 4 × 1 × 28 × of (14) 7 × 4 × 1 × 28 × of (16) Designation 0.175 + 0.15 0.175 + 0.15 with (13) 0.22 + 0.15 0.22 + 0.15 with (15) Twists SZS ZS rounded-off SZS ZS rounded-offCharacteristics Pitch 10/18/3.5 16/3.5 values in % 9.5/18/3.5 16/3.5 values in__________________________________________________________________________ %Final product 1.47 1.37 -7 1.80 1.66 -8diameterBreaking load 176 187 +6 273 290 +6Apparent strength 1,037 1,268 +22 1,073 1,340 +25Taber rigidity 73 61 -16 140 107 -23Fatigue 15.3 28.5 +86 7.7 12.3 +60__________________________________________________________________________ | A compact single-strand cord consisting of at least nine single wires of the same diameter twisted together in the same direction and with the same pitch, characterized in that, in cross-section, the cord has the shape of a compact stack of polygonal, preferably hexagonal, contour. The cord can be used for reinforcing rubber articles or elastomeric articles, in particular for reinforcing tires.
The method of manufacture of the cord includes unwinding the wires from coils each consisting of a single wire. The wires are delivered by positive slip-drive rollers to a means for regrouping and a strand-laying means. The wires are assembled in a grid and die and twisted by an assembling twister. The wires are then guided through a double twist path loop, overtwisted, straightened and collected on a capstan.
The machine for performing the process includes an unwinding means in the form of a plurality of feed bobbins, a positive slip-drive roller system, means for regrouping the advanced wires including a grid and a die, a revolving assembling twister and a spindle means including a loop and stationary cradle carrying an overtwisted, straightener and capstan for collecting the cord. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
DESCRIPTION OF ATTACHED APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to the field of tongue cleaning devices and more specifically to portable tongue vacuum cleaner.
[0005] It is a known fact that the human tongue can be a breeding ground for bacteria that may prove to be harmful to an individual if not removed periodically. Methods for removing bacteria from the tongue include brushing, scraping and mouthwash. However, all these techniques can still leave bacterial debris on the tongue because the tongue's surface is like a miniature deep pile carpet, and some debris remain in the deeper crevices of the tongue's surface. In dental offices, some dentists take advantage of the availability of a vacuum system normally used for removing liquid from a person's mouth, and add a vacuum scraping tool to the vacuum tube to scrape clean the patient's tongue.
[0006] Sajid Khan in his patent application 2005/0050676 describes a hand held tongue vacuum cleaner. Although Kahn describes the basic concept of using a vacuum to clean the tongue, the specific details of the device's construction and use have not been delineated in either drawing form or written form and therefore make it very difficult to imagine a device that can be reduced to practice. For example Kahn talks about dirty matter passing through into a detachable waste chamber, but does not say how or where this occurs. Additionally, there is talk of a filter to allow clean air to pass into an exhaust port but also does not show how or where this acutely occurs. Finally, there is no discussion of the shape, angle or surface characteristics of the cleaning head. Therefore, although the idea of a portable vacuum cleaner for a tongue has been shown in the prior application sited, the specific and novel mechanism for the ideal execution of this idea has not been previously described or illustrated.
BRIEF SUMMARY OF THE INVENTION
[0007] The primary object of the invention is to provide a portable hand held device for cleaning a person's tongue.
[0008] Another object of the invention is to provide a tongue cleaning device that uses a vacuum and bristles to help remove debris from the tongue.
[0009] Another object of the invention is to provide a tongue cleaning device that uses an angled removable cleaning head that includes bristles, a central vacuum aperture and a filter trap for trapping debris as it is sucked from the surface of the tongue.
[0010] A further object of the invention is to provide a tongue cleaning device that securely holds and locks the cleaning head in the correct orientation for use until the user removes the head.
[0011] Yet another object of the invention is to provide a tongue cleaning device that is water resistant and can be recharged by an induction type charger.
[0012] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
[0013] In accordance with a preferred embodiment of the invention, there is disclosed tongue vacuum cleaner comprising: a hollow housing, a diaphragm type vacuum pump, a pump connection tube, a pair of O rings, a motor, an on-off switch, a cleaning head, a cleaning head extension tube, a filter trap, an extension tube retaining assembly, a battery power supply, a recharging station, said vacuum pump, motor, switch and battery contained within said hollow housing, said on-off switch mounted on the front surface of said housing just below said cleaning head extension tube, said battery powering said motor, said motor powering said vacuum pump, said pump connection tube fixedly attached to said vacuum pump and extending outwardly in a perpendicular fashion from the upper portion of said housing, said O rings surrounding said pump connection tube, said cleaning head including a flat rigid plate having a plurality of bristles extending there-from and having a central tubular aperture extending to just below the height of said bristles, said cleaning head fixedly attached to said cleaning head extension tube, said cleaning head extension tube capable of being slidably inserted or removed over said pump connection tube and said O rings, said filter trap removably retained within said cleaning head extension tube between said cleaning head and the end of said pump connection tube, said extension tube retaining assembly attached to the outside of said housing and engaging in a spring biased manner at least one detent located on the outside wall of said cleaning head extension tube, and the base of said housing capable of being inserted into a recharging station for recharging said battery power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
[0015] FIG. 1 is a perspective view of the portable tongue cleaner and recharging station of the present invention.
[0016] FIG. 2 is a side section view that bisects the invention.
[0017] FIG. 3 is a side view of the invention.
[0018] FIG. 4 is a perspective view of the filter trap.
[0019] FIG. 5 is a front section view of the extension tube and tube retaining assembly.
[0020] FIG. 6 is an exploded view of the invention.
[0021] FIG. 7 is a partial side section view of an alternate embodiment of the invention.
[0022] FIG. 8 is a partial side section view of a second alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0024] Referring now to FIG. 1 we see a perspective view of the tongue cleaner 100 of the present invention and a recharging stand 50 . A hollow housing 2 contains a pump 24 and motor 30 as will be explained in FIG. 2 . An on off button 14 is placed at the front of the housing 2 so that it can be easily turned on by a user's thumb while holding the main body 2 in his or her hand. A cleaning head 10 is attached to a cleaning head extension tube 4 which has been slid onto a pump extension tube 46 as shown in FIGS. 2 and 6 . A retaining assembly 16 helps lock the extension tube 4 to the rest of the main body during use.
[0025] The cleaning head 10 includes a rigid flat plate 6 that has a plurality of bristles 16 emanating from it. The bristles are all approximately one quarter of an inch tall. A central vacuum tube tip 8 is centrally fixed onto plate 6 and extends out to almost the same length as the bristles. The entire cleaning head 10 is angled at approximately a forty-five degree angle with respect to the cleaning head extension tube 4 . This is an ideal ergonomic angle for the intended function of holding housing 2 in ones hand and brushing ones tongue with bristles 16 . In operation, the bristles 16 tend to dislodge debris from the carpet-like surface of the tongue while the vacuum tip 8 sucks the loosened debris into the extension tube 4 . Housing 2 base 3 can be inserted into a receptacle 5 in recharging station 50 to so that the batteries 32 inside the housing 2 can be recharged. The side section view FIG. 2 shows one of two batteries that are placed side by side in the housing 10 .
[0026] FIG. 2 shows a section view that bisects the invention 100 . Inside housing 2 is a battery power supply 32 , a DC motor 30 and a diaphragm type vacuum pump 24 . An offset shaft 28 causes the diaphragm 26 to pulse in and out creating a vacuum that causes suction into pump extension tube 46 . Cleaning head extension tube 4 is slide over pump extension tube 46 and associated O rings 22 that fit in grooves in the tube 46 creating an air tight seal. A filter trap 20 is located between the tip of extension tube 46 and the rear of plate 6 and can catch debris that are sucked into the trap 20 during use. The filter trap is shaped to match the inside wall of extension tube 4 as shown in FIG. 4 . The filter trap 20 is made of expanded polyethylene and has a trade name of Porex. The air holes in the walls of the trap 20 are large enough to let air through, but small enough to not let liquids or debris through. The filter 20 includes a pull tab 21 to make it easy for the user to remove the filter trap 20 after use. The unique location and construction of the filter trap 20 is important because it eliminates the requirement for a separate debris holding chamber and helps retain the air tight requirements of the entire assembly 100 because the filter 20 is trapped within the extension tube 4 so that O rings 22 are the only air tight seal needed in the assembly 100 other than the standard seals located in the vacuum pump 24 .
[0027] After each use, the user can remove the cleaning head assembly 10 , 4 and pull out the filter trap 20 by pull tab 21 , and then clean the filter trap 20 under running water before returning it to the extension tube 4 making it ready for the next use. Optionally, the entire cleaning head 10 , 5 and filter 20 can be discarded after each use.
[0028] Coils 36 inside the bottom area of housing 2 interact with induction coils 38 and associated electronics 44 in the recharging station 50 to recharge batteries 32 . This type of recharging system allows the housing 2 to remain water resistant because no apertures are needed within the housing to gain access to metal connectors. The recharging stand is powered by standard 110VAC electricity from plug 42 and cord 40 .
[0029] FIG. 3 shows a side view of the invention 100 . The diameter of housing 2 is approximately one and one half inches which is the ideal diameter for grasping in one's hand. One of the retaining members of retaining assembly 16 can be clearly seen. FIG. 5 shows a section view as defined by section line 180 in FIG. 3 . FIG. 5 shows the tips 52 , 53 of spring biased tabs 168 , 166 engaged with detents 170 , 171 in the side walls of pump extension tube 46 . The tabs 168 , 166 are hinge pinned 166 , 158 to an extension arm 174 off the main body 2 . A compression spring 164 spans the distance between the two tabs 160 , 162 to provide inward force to tips 52 , 53 . To remove the extension tube 4 and attached cleaning head 10 , the user presses the two tabs 160 , 162 between his or her thumb and fore finger thereby releasing tips 52 , 53 from detents 170 , 171 .
[0030] FIG. 6 shows an exploded view of the invention. Detent 52 can be clearly seen, as well as filter trap 20 as it is ready to be installed into extension tube 4 . O rings 22 are clearly seen surrounding the pump extension tube 46 .
[0031] FIG. 7 is a partial side section view of the invention 200 where in place of the air filter 20 , a saliva reservoir 261 can catch excess saliva that is drawn in through opening 218 and directed downward by L shaped tube 204 . The vacuum pump 208 terminates in an upwardly directed L shaped suction port tube 220 . O ring 206 creates a vacuum retaining seal between removable head 250 and main body 214 . The upward orientation of tube 220 and the downward orientation of tube 204 helps insure that the saliva that is drawn into the reservoir 216 does not accidentally enter vacuum suction port tube 220 . Pump motor 210 and diaphragm pump member 208 operate in the same manner as described in the first embodiment. Tongue bristles 202 also operate in the same manner as described in the first embodiment.
[0032] FIG. 8 is a partial side section view of a second embodiment of the invention 300 which is similar in concept to the version shown in FIG. 7 except that The vacuum tube 314 coming from pump and motor area 302 is in a vertical position, as is the saliva exit tube 312 coming from brush head 316 as it enters the brush head at central aperture 318 . The head body 310 is removable from the main body 320 and is made air tight by gasket 308 . When the user applies the tool 300 , any excess saliva and or debris is sucked into area 306 . The saliva is precluded from entering upwardly disposed vacuum tube 314 because tube 314 terminates at a much higher position than downwardly disposed saliva vacuum tube 312 . Push button 322 operates in the same fashion as the main embodiment.
[0033] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. | A portable hand held tongue vacuum cleaner that includes a small vacuum pump and power supply contained within a hollow housing. A removable cleaning head is attached to a vacuum port which extends out from the housing. The cleaning head includes bristles and a centrally located vacuum tube whose end terminates just below the height of the bristles. The cleaning head is oriented at a forty-five degree angle with respect to the cleaning head extension tube. A removable filter trap is located inside the extension tube to catch debris removed from the surface of the tongue. | 0 |
FIELD OF THE INVENTION
An axially actuated drain valve for draining pools and spas which enables connection with a hose.
BACKGROUND OF THE INVENTION
Pools and spas of every kind require drainage of their water so the pool itself can be cleaned and supplied with fresh water. Every pool and spa incorporates some plumbing for this function.
Free standing pools and spas have special requirements that are not necessary for subgrade installations. Free standing installations are elevated where their sides are in plain sight. Conventional hardware in plain sight is neither attractive nor convenient, and can be run into. Also, especially in home installations, low cost, low maintenance, and high reliability are of great importance.
Especially in colder regions where freezing is a risk, although the entire tank of water may not freeze, local regions such as drain valves may indeed freeze and be damaged.
It is an object of this invention to provide a conveniently installed and conveniently used drain valve that can be molded from suitable resins which is unobtrusive in contour, comparatively inexpensive to manufacture, and which when closed provides no regions where water could be confined which could create a risk when frozen.
It is another object of this invention to provide a drain valve adapted conveniently to be engaged by a hose coupling for conveying away the drained water and which valve when closed and disconnected from the hose is recessed and mostly out of sight.
BRIEF DESCRIPTIONS OF THE INVENTION
A valve according to this invention has a central axis of actuation. It includes a body attachable to an opening in a vessel wall. It has a central passage with an inlet end which extends into the vessel, an outlet end facing outwardly from the vessel, and an internal bore extending from end to end.
The body includes a peripheral wall, an inlet port, an axially extending first peripheral sealing surface in communication with said inlet port, an axially extending second peripheral sealing surface in said passage spaced from said first peripheral sealing surface, and an axially extending relief located between said peripheral sealing surfaces.
A plunger has a central axis and is mounted coaxially in said passage for axial reciprocable movement therein. The plunger has an inner end and an outer end. Adjacent to its inner end the plunger has a first peripheral sliding seal. A second peripheral sliding seal also surrounds said plunger. Said sliding seals are adapted to make respective sliding sealing contacts with said first and second peripheral sealing surfaces in said passage, a central flow bore extending from said outer end into said plunger, and a side port extending laterally from the flow bore through said plunger, opening from said flow bore between said first and second sliding seals, and a hose coupler adjacent to said outer end.
According to a preferred but optional feature of the invention, the diameter of the inlet port is smaller than the diameter of the first peripheral sealing surface, and an end seal is formed on the said inner end to close the inlet port when the plunger is fully inserted in the passage.
The above and other features of this invention will be fully understood from the following detailed description and the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a valve according to the invention installed in the wall of a vessel;
FIG. 2 is an axial cross-section of the valve of FIG. 2 in its open condition, taken at line 2 — 2 in FIG. 1 ;
FIG. 3 is an axial cross-section of a portion of the valve of FIG. 1 ;
FIG. 4 is a side view of the plunger shown in FIG. 2 ; and
FIGS. 5 , 6 and 7 are lateral cross-sections taken at lines 5 — 5 , 6 — 6 , and 7 — 7 , respectively in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
A drain valve 20 according to this invention is shown installed in the wall 21 of a vessel 22 . The term “vessel” as used herein is intended to include all such pools, spas, tanks, and ponds of the sort that are used for recreation purposes, and also to such structures as may be used for aquariums. The common feature of these applications is the need to remove and replace the water in them, and to clean its structure while empty. The most pertinent installations will be above grade, where any related plumbing will be visible.
Valve 20 includes a body 25 with an outer wall 26 that carries a thread 27 which receives a pair of collars 28 , 29 . These collars, when threaded onto the body will hold the body to the vessel wall. It is a desirable feature of the invention that the valve, when closed, need not project beyond the vessel wall. This product when installed is unobtrusive.
Valve body 25 has a central passage 30 which extends from its inner end 31 to its outer end 32 . The passage has an internal peripheral wall. At its inner end it closes down to an inlet port 34 . Inlet port 34 is bounded by a seat 35 .
Passage 30 has a central axis 36 . Adjacent to its inner end, the passage includes a first peripheral sealing surface 37 . A second peripheral sealing surface 38 is spaced from the first peripheral sealing surface 37 by axially-extending peripheral recesses 39 . These sealing surfaces are cylindrical and coaxial.
The reduced-dimension inlet port 34 is optional. If desired it can be eliminated, and the first peripheral sealing surface will define, at its inner end, the entry port to the valve.
First peripheral sealing surface 37 has a dimension of axial length, which will be discussed in further detail below. Similarly second peripheral sealing surface will have an axial length.
For molding convenience, the inlet port 34 and first peripheral sealing surface 37 are formed on a separate insert 44 that is pressed into the body.
It will be observed that the inside diameter of the first sealing surface 37 is the same as the diameter of the second peripheral sealing surface 38 . There is a minor gap 45 of no significance between them.
Again for molding convenience, body 25 provides recesses 39 between axially-extending vanes 46 . These recesses terminate between the two sealing surfaces.
A plunger 50 has a central axis 57 . It is mounted coaxially in the body passage for axial reciprocation. When fully inserted to the right in FIG. 2 , it will close the valve. In FIG. 2 the valve is shown in its fully open configuration. When sufficiently extended, the plunger will open the valve to drain the vessel. When closed, there will remain no region in the valve in which water would be confined so as to be locally frozen.
The plunger has an inner end 52 and an outer end 53 . Its wall 54 carries a thread 55 which forms part of a hose coupling (not shown). It can also receive an internally threaded closure cap 56 if desired.
The plunger includes a flow bore 60 which extends into the plunger from its outer end toward its inner end, at which it is closed. A flow port 61 extends from the flow bore through the wall of the plunger to its outside surface.
When the reduced-dimension inlet port 34 is provided, the plunger will carry an inlet port closure 64 . Preferably the closure will carry a sealing ring (not shown), but may instead be a simple tapered or rounded plug to close the inlet port when the plunger is fully inserted.
A first peripheral seal 65 is formed around the plunger near its inner end. Preferably it includes a pair of ring seals 66 , 67 (see FIG. 2 ) which make a sliding fluid sealing fit in the first peripheral sealing surface 37 . Here it will be observed that, so long as seal 65 remains in sealing surface 37 , the valve will be closed. When the reduced area inlet port is used, it will provide a secondary seal against leakage. If it is not provided, then surface 37 and seal 65 act as an inlet port closure.
Notice particularly that the plunger can move from fully closed to fully open by axially moving past sealing surface 37 to permit flow through recesses 39 . This is an important function, because it enables the plunger to be pulled out by a useful distance without opening the valve. This exposes thread 55 so that after removing cap 56 , a hose coupling can be threaded onto the plunger while the valve still remains closed.
A second peripheral sliding seal 70 is formed on the plunger, spaced from the first by an axial spacing 71 . Sealing rings 72 slide along and seal with the second peripheral sealing surface. Flow port 61 opens through the wall of the plunger between sliding seals 65 and 70 . Flow port 61 will always face into recess 39 .
It is necessary that the plunger be axially reciprocable so the valve can be opened and closed. It is desirable, although not necessary, for the plunger to be restrained against excessive rotation so a hose coupling can more readily be threaded onto it. If not so provided, the valve will still function and can be coupled, but then the user would have to hold the plunger against rotation, which he could do.
To facilitate this function, two sets of splines 75 , 76 are formed, with the sets angularly disposed relative to one another. Their function is to react with a notched stop 77 with an equal number of equally spaced notches 78 . This stop extends into the passage, and will stop the plunger from moving excessively toward the outer end of the passage unless the splines pass through a notch. Also it will always block sliding seal 70 to prevent the expulsion of the plunger from the outside end. Accordingly, the valve must be assembled from its inner end.
When the plunger is in its outer position, splines 75 will be engaged in the notches, and splines 76 are angularly placed so they will engage the stop. The plunger will be restrained against rotation. Instead of the illustrated cap (which will close the valve in all plunger positions, a hose coupling (not shown) may be threaded on to the plunger instead.
It will be observed that the body forms a receptacle cavity 80 which will receive the cap when the valve is closed, so that it will not protrude beyond the vessel wall.
The operation of this drain valve will be evident from the foregoing. With the plunger fully inserted, the valve is closed, and the threads remain inside body cavity 80 . In order to attach a hose, the plunger is pulled partway out, so that the first sliding seal remains engaged to the first peripheral sealing surface 37 .
Then the valve will be opened by pulling the plunger farther out. At this time the first sliding seal clears the first sealing surface, so that the inlet port is open and water can flow into recesses 39 , and from the recesses into the flow port and out the flow bore.
At this time the second sliding seal will have engaged the second sealing surface to prevent leakage pass the plunger. The outward movement of the plunger will be stopped when the stop surface 41 is engaged by the plunger.
Closure of the valve will be accomplished by moving the plunger into the body. When the first sliding seal again engages the first sealing surface, the hose can be disconnected, and the plunger then shoved all the way in. The hydraulic pressure involved is so small that the friction forces in the valve will suffice to hold the valve closed, especially when the smaller inlet port is used. However, with a cap on the plunger, the valve will not leak even if the plunger is fully out.
It will be observed that the regions on the outside of the plunger vented to atmospheric are fully drained. Similarly, with the valve closed and before the cap is applied, the inside of the plunger will be fully drained. There is no “loose” water to be frozen.
This valve is readily produced by injection molding processes, and requires only the application of ring seals for completion. It is inexpensive, unobtrusive, and reliable.
This invention is not to be limited by the embodiment shown in the drawings and described in the description, which is given by way of example and not of limitation, but only in accordance with the scope of the appended claims. | An axially actuated drain valve for pools and spas mountable in a wall thereof. It includes a tubular body and a coaxial plunger. The body opens into the spa or pool at an inner end. The plunger has a passage opening near the outer end of its passage. A cylindrical seal engages with a seal on the plunger for a substantial range of movement to keep the valve closed. Beyond that, the plunger passage is opened for flow from the body passage opening. The plunger may have threads on its outer end to be coupled to a hose fitting. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of U.S. patent application Ser. No. 09/974,154, filed Oct. 11, 2001 and entitled “Intervertebral Spacer Device Utilizing a Belleville Washer Having Radially Spaced Concentric Grooves”, which is fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to a spinal implant assembly for implantation into the intervertebral space between adjacent vertebral bones to simultaneously provide stabilization and continued flexibility and proper anatomical motion, and more specifically to such a device which utilizes a belleville washer, having radially spaced concentric grooves, as a restoring force generating element.
BACKGROUND OF THE INVENTION
[0003] The bones and connective tissue of an adult human spinal column consists of more than 20 discrete bones coupled sequentially to one another by a tri-joint complex which consists of an anterior disc and the two posterior facet joints, the anterior discs of adjacent bones being cushioned by cartilage spacers referred to as intervertebral discs. These more than 20 bones are anatomically categorized as being members of one of four classifications: cervical, thoracic, lumbar, or sacral. The cervical portion of the spine, which comprises the top of the spine, up to the base of the skull, includes the first 7 vertebrae. The intermediate 12 bones are the thoracic vertebrae, and connect to the lower spine comprising the 5 lumbar vertebrae. The base of the spine is the sacral bones (including the coccyx). The component bones of the cervical spine are generally smaller than those of the thoracic spine, which are in turn smaller than those of the lumbar region. The sacral region connects laterally to the pelvis. While the sacral region is an integral part of the spine, for the purposes of fusion surgeries and for this disclosure, the word spine shall refer only to the cervical, thoracic, and lumbar regions.
[0004] The spinal column of bones is highly complex in that it includes over twenty bones coupled to one another, housing and protecting critical elements of the nervous system having innumerable peripheral nerves and circulatory bodies in close proximity. In spite of these complications, the spine is a highly flexible structure, capable of a high degree of curvature and twist in nearly every direction.
[0005] Genetic or developmental irregularities, trauma, chronic stress, tumors, and degenerative wear are a few of the causes that can result in spinal pathologies for which surgical intervention may be necessary. A variety of systems have been disclosed in the art which achieve immobilization and/or fusion of adjacent bones by implanting artificial assemblies in or on the spinal column. The region of the back which needs to be immobilized, as well as the individual variations in anatomy, determine the appropriate surgical protocol and implantation assembly. With respect to the failure of the intervertebral disc, the interbody fusion cage has generated substantial interest because it can be implanted laparoscopically into the anterior of the spine, thus reducing operating room time, patient recovery time, and scarification.
[0006] Referring now to FIGS. 1 and 2, in which a side perspective view of an intervertebral body cage and an anterior perspective view of a post implantation spinal column are shown, respectively, a more complete description of these devices of the prior art is herein provided. These cages 10 generally comprise tubular metal body 12 having an external surface threading 14 . They are inserted transverse to the axis of the spine 16 , into preformed cylindrical holes at the junction of adjacent vertebral bodies (in FIG. 2 the pair of cages 10 are inserted between the fifth lumbar vertebra (L 5 ) and the top of the sacrum (S 1 ). Two cages 10 are generally inserted side by side with the external threading 14 tapping into the lower surface of the vertebral bone above (L 5 ), and the upper surface of the vertebral bone (S 1 ) below. The cages 10 include holes 18 through which the adjacent bones are to grow. Additional material, for example autogenous bone graft materials, may be inserted into the hollow interior 20 of the cage 10 to incite or accelerate the growth of the bone into the cage. End caps (not shown) are often utilized to hold the bone graft material within the cage 10 .
[0007] These cages of the prior art have enjoyed medical success in promoting fusion and grossly approximating proper disc height. It is, however, important to note that the fusion of the adjacent bones is an incomplete solution to the underlying pathology as it does not cure the ailment, but rather simply masks the pathology under a stabilizing bridge of bone. This bone fusion limits the overall flexibility of the spinal column and artificially constrains the normal motion of the patient. This constraint can cause collateral injury to the patient's spine as additional stresses of motion, normally borne by the now-fused joint, are transferred onto the nearby facet joints and intervertebral discs. It would therefore, be a considerable advance in the art to provide an implant assembly which does not promote fusion, but, rather, which nearly completely mimics the biomechanical action of the natural disc cartilage, thereby permitting continued normal motion and stress distribution.
[0008] It is, therefore, an object of the present invention to provide a new and novel intervertebral spacer which stabilizes the spine without promoting a bone fusion across the intervertebral space.
[0009] It is further an object of the present invention to provide an implant device which stabilizes the spine while still permitting normal motion.
[0010] It is further an object of the present invention to provide a device for implantation into the intervertebral space which does not promote the abnormal distribution of biomechanical stresses on the patient's spine.
[0011] Other objects of the present invention not explicitly stated will be set forth and will be more clearly understood in conjunction with the descriptions of the preferred embodiments disclosed hereafter.
SUMMARY OF THE INVENTION
[0012] The preceding objects of the invention are achieved by the present invention which is a flexible intervertebral spacer device comprising a pair of spaced apart base plates, arranged in a substantially parallel planar alignment (or slightly offset relative to one another in accordance with proper lordotic angulation) and coupled to one another by means of a spring mechanism. In particular, this spring mechanism provides a strong restoring force when a compressive load is applied to the plates, and may also permit rotation of the two plates relative to one another. While there are a wide variety of embodiments contemplated, a preferred embodiment includes a belleville washer utilized as the restoring force providing element, the belleville washer having radially spaced concentric grooves.
[0013] More particularly, as the assembly is to be positioned between the facing surfaces of adjacent vertebral bodies, the base plates should have substantially flat external surfaces which seat against the opposing bone surfaces. Inasmuch as these bone surfaces are often concave, it is anticipated that the opposing plates may be convex in accordance with the, average topology of the spinal anatomy. In addition, the plates are to mate with the bone surfaces in such a way as to not rotate relative thereto. (The plates rotate relative to one another, but not with respect to the bone surfaces to which they are each in contact with.) In order to prevent rotation of a plate relative to the bone, the upper and lower plates can include a porous coating into which the bone of the vertebral body can grow. (Note that this limited fusion of the bone to the base plate does not extend across the intervertebral space.)
[0014] In some embodiments (not in the preferred embodiment), between the base plates, on the exterior of the device, there is included a circumferential wall which is resilient and which simply prevents vessels and tissues from entering within the interior of the device. This resilient wall may comprise a porous fabric or a semi-impermeable elastomeric material. Suitable tissue compatible materials meeting the simple mechanical requirements of flexibility and durability are prevalent in a number of medical fields including cardiovascular medicine, wherein such materials are utilized for venous and arterial wall repair, or for use with artificial valve replacements. Alternatively, suitable plastic materials are utilized in the surgical repair of gross damage to muscles and organs. Still further materials that could be utilized herein may be found in the field of orthopedic in conjunction with ligament and tendon repair. It is anticipated that future developments in this area will produce materials that are compatible for use with this invention, the breadth of which shall not be limited by the choice of such a material.
[0015] As introduced above, the internal structure of the present invention comprises a spring member, which provides a restoring force when compressed. More particularly, it is desirable that the restoring forces be directed outward against the opposing plates, when a compressive load is applied to the plates. In addition, in certain embodiments, it is necessary that the restoring force providing subassembly not substantially interfere with the rotation of the opposing plates relative to one another. In the preferred embodiment, the spring subassembly is configured to allow rotation of the plates relative to one another. In other embodiments, the spring subassembly can be configured to either allow rotation of the plates, or prevent rotation of the plates (through the tightening of a set screw as discussed below). As further mentioned above, the force restoring member comprises at least one belleville washer.
[0016] Belleville washers are washers which are generally bowed in the radial direction. Specifically, they have a radial convexity (i.e., the height of the washer is not linearly related to the radial distance, but may, for example, be parabolic in shape). The restoring force of a belleville washer is proportional to the elastic properties of the material. In addition, the magnitude of the compressive load support and the restoring force provided by the belleville washer may be modified by providing grooves in the washer. In the preferred embodiment of the present invention, the belleville washer utilized as the force restoring member has radially uniformly spaced concentric grooves of uniform width and depth.
[0017] As a compressive load is applied to a belleville washer, the forces are directed into a hoop stress which tends to radially expand the washer. This hoop stress is counterbalanced by the material strength of the washer, and the strain of the material causes a deflection in the height of the washer. Stated equivalently, a belleville washer responds to a compressive load by deflecting compressively, but provides a restoring force which is proportional to the elastic modulus of the material in a hoop stressed condition. With radially spaced concentric grooves formed in the washer, it expands and restores itself far more elastically than a solid washer.
[0018] In general, the belleville washer is one of the strongest configurations for a spring, and is highly suitable for use as a restoring force providing subassembly for use in an intervertebral spacer element which must endure considerable cyclical loading in an active human adult.
[0019] In the preferred embodiment of the present invention, a single modified belleville washer, which has radially spaced concentric grooves as described above, is utilized in conjunction with a ball-shaped post on which it is free to rotate through a range of angles (thus permitting the plates to rotate relative to one another through a corresponding range of angles). More particularly, this embodiment comprises a pair of spaced apart base plates, one of which is simply a disc shaped member (preferably shaped to match the end of an intervertebral disc) having an external face (having the porous coating discussed above) and an internal face having an annular retaining wall (the purpose of which will be discussed below). The other of the plates is similarly shaped, having an exterior face with a porous coating, but further includes on its internal face a central post portion which rises out of the internal face at a nearly perpendicular angle. The top of this post portion includes a ball-shaped knob. The knob includes a central threaded axial bore which receives a small set screw. Prior to the insertion of the set screw, the ball-shaped head of the post can deflect radially inward (so that the ball-shaped knob contracts). The insertion of the set screw eliminates the capacity for this deflection.
[0020] As introduced above, a modified belleville washer having radially spaced concentric grooves is mounted to this ball-shaped knob in such a way that it may rotate freely through a range of angles equivalent to the fraction of normal human spine rotation (to mimic normal disc rotation). The belleville washer of this design is modified by including an enlarged inner circumferential portion (at the center of the washer) which accommodates the ball-shaped portion of the post. More particularly, the enlarged portion of the modified belleville washer includes a curvate volume having a substantially constant radius of curvature which is also substantially equivalent to the radius of the ball-shaped head of the post. The deflectability of the ball-shaped head of the post, prior to the insertion of the set screw, permits the head to be inserted into the interior volume at the center of the belleville washer. Subsequent introduction of the set screw into the axial bore of the post prevents the ball-shaped head from deflecting. Thereby, the washer can be secured to the ball-shaped head so that it can rotate thereon through a range of proper lordotic angles (in some embodiments, a tightening of the set screw locks the washer on the ball-shaped head at one of the lordotic angles).
[0021] This assembly provides ample spring-like performance with respect to axial compressive loads, as well as long cycle life to mimic the axial biomechanical performance of the normal human intervertebral disc. The radially spaced concentric grooves of the belleville washer allow the washer to expand radially as the grooves widen under the load, only to spring back into its undeflected shape upon the unloading of the spring. As the washer compresses and decompresses, the annular retaining wall maintains the wide end of the washer within a prescribed boundary on the internal face of the base plate which it contacts, and an annular retaining ring maintains the wide end of the washer against the internal face.
[0022] Finally, inasmuch as the human body has a tendency to produce fibrous tissues in perceived voids, such as may be found within the interior of the present invention, and such fibrous tissues may interfere with the stable and/or predicted functioning of the device, some embodiments of the present invention (although not the preferred embodiment) will be filled with a highly resilient elastomeric material. The material itself should be highly biologically inert, and should not substantially interfere with the restoring forces provided by the spring-like mechanisms therein. Suitable materials may include hydrophilic monomers such as are used in contact lenses. Alternative materials include silicone jellies and collagens such as have been used in cosmetic applications. As with the exterior circumferential wall, which was described above as having a variety of suitable alternative materials, it is anticipated that future research will produce alternatives to the materials described herein, and that the future existence of such materials which may be used in conjunction with the present invention shall not limit the breadth thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a side perspective view of an interbody fusion device of the prior art.
[0024] [0024]FIG. 2 is a front view of the anterior portion of the lumbo-sacral region of a human spine, into which a pair of interbody fusion devices of the type shown in FIG. 1 have been implanted.
[0025] [0025]FIGS. 3 a and 3 b are side cross-section views of the upper and lower opposing plates of the preferred embodiment of the present invention.
[0026] [0026]FIGS. 4 a and 4 b are top and side cross-section views of a belleville washer having radially uniformly spaced concentric grooves of uniform width and depth, for use in a preferred embodiment of the present invention.
[0027] [0027]FIGS. 5 a - 5 c are top and side cross-section views of a belleville washer having radially non-uniformly spaced concentric grooves of varying width and depth, for use in an alternate embodiment of the present invention.
[0028] [0028]FIG. 6 a is a top view of the upper plate of FIG. 3 a , with the belleville washer of FIGS. 4 a and 4 b fitted within a retaining wall and a retaining ring of the upper plate.
[0029] [0029]FIG. 6 b is a top view of the lower plate of FIG. 3 b.
[0030] [0030]FIG. 7 is a side cross-section view of the preferred embodiment of the present invention, which utilizes a belleville washer of the type shown in FIGS. 4 a and 4 b , showing the plates of FIGS. 6 a and 6 b assembled together.
[0031] [0031]FIG. 8 a is a top view of the upper plate of FIG. 3 a , with the belleville washer of FIGS. 5 a - 5 c fitted within a retaining wall and a retaining ring of the upper plate.
[0032] [0032]FIG. 8 b is a top view of the lower plate of FIG. 3 b.
[0033] [0033]FIG. 9 is a cross-section view of an alternate embodiment of the present invention, which utilizes a belleville washer of the type shown in FIGS. 5 a - 5 c , showing the plates of FIGS. 8 a and 8 b assembled together.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] While the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which particular embodiments and methods of implantation are shown, it is to be understood at the outset that persons skilled in the art may modify the invention herein described while achieving the functions and results of this invention. Accordingly, the descriptions which follow are to be understood as illustrative and exemplary of specific structures, aspects and features within the broad scope of the present invention and not as limiting of such broad scope. Like numbers refer to similar features of like elements throughout.
[0035] Referring now to FIGS. 3 a and 3 b , side cross-section views of upper and lower plate members 100 , 200 of the preferred embodiment of the present invention are shown. As the device is designed to be positioned between the facing surfaces of adjacent vertebral bodies, the plates include substantially flat external face portions 102 , 202 which seat against the opposing bone surfaces. In addition, the plates are to mate with the bone surfaces in such a way as to not rotate relative thereto. It is, therefore, preferred that the external faces of the plates include a porous coating 104 , 204 into which the bone of the vertebral body can grow. (Note that this limited fusion of the bone to the base plate does not extend across the intervertebral space.) A hole (not shown) can be provided in the upper plate such that the interior of the device may be readily accessed if a need should arise.
[0036] The upper plate 100 includes an internal face 103 that includes an annular retaining wall 108 and an annular retaining ring 109 . The lower plate 200 includes an internal face 203 that includes a central post member 201 which rises out of the internal face 203 at a nearly perpendicular angle. The top of this post member 201 includes a ball-shaped head 207 . The head 207 includes a series of slots which render it compressible and expandable in correspondence with a radial pressure (or a radial component of a pressure applied thereto). The head 207 includes a central threaded axial bore 209 which extends down the post 201 . This threaded bore 209 is designed to receive a set screw 205 . Prior to the insertion of the set screw 205 , the ball-shaped head 207 of the post 201 can deflect radially inward because of the slots (so that the ball-shaped head contracts). The insertion of the set screw 205 eliminates the capacity for this deflection.
[0037] Referring now to FIGS. 4 a and 4 b , a belleville washer 130 having radially spaced concentric grooves is provided in top and side cross-section views. The belleville washer 130 is a restoring force providing device which comprises a circular shape, having a central opening 132 , and which is radially arched in shape. The belleville washer 130 has a radial convexity 134 (i.e., the height of the washer 130 is not linearly related to the radial distance, but may, for example, be parabolic in shape). The restoring force of the belleville washer 130 is proportional to the elastic properties of the material.
[0038] The belleville washer 130 comprises a series of grooves 133 formed therein. The grooves 133 are concentric and radially spaced from the outer edge of the belleville washer toward the center of the element. In the preferred embodiment shown in FIGS. 4 a and 4 b , the width 135 of each groove 133 is uniform along the length of the groove 133 . Further in the preferred embodiment, the depth 137 of each groove 133 is uniform along the length of the groove 133 . Further in the preferred embodiment, each groove 133 has a different width configuration and a different depth configuration than each other groove 133 . More specifically, in the preferred embodiment, the width dimension and the depth dimension both vary from groove to groove, each increasing incrementally from groove to adjacent groove with increasing distance from the center of the washer 130 . Stated alternatively, grooves that are relatively more narrow and more shallow than the other grooves are closer to the center of the washer, whereas grooves that are relatively wider and deeper than the other grooves are closer to the outer edge of the washer. This is illustrated by example in FIGS. 4 a and 4 b , which show three concentric grooves 133 a - c , with the outermost groove 133 c being deeper and wider than groove 133 b , which is in turn deeper and wider than groove 133 a . Further in the preferred embodiment, the radial spacing of the grooves is uniform.
[0039] It should be understood that in other embodiments, one or both of the depth and the width of each groove can be (1) increasing along the length of the groove, (2) decreasing along the length of the groove, or (3) varied along the length of each groove, either randomly or according to a pattern. Moreover, in other embodiments, it can be the case that each groove is not formed similarly to one or more other grooves, with or without respect to width and depth dimensions, but rather one or more grooves are formed in any of the above-mentioned fashions, while one or more other grooves are formed in another of the above-mentioned fashions or other fashions. Also, in other embodiments, it can be the case that the radial distance between the grooves is not the same, but rather the spacing increases the closer the space is to the outer edge of the washer, decreases the closer the space is to the outer edge of the washer, or varies either randomly or according to a pattern. Also, while the grooves of the preferred embodiment and the illustrated alternate embodiment have lengths that form closed loops, it should be noted that in other embodiments, the concentric grooves can have lengths that form open loops or arcs; for example, a two concentric grooves forming open loops or arcs can be used in place of a single concentric groove forming a closed loop. It should be clear that any concentric groove pattern can be implemented without departing from the scope of the present invention. To illustrate an alternate embodiment showing an alternate radially spaced concentric groove pattern, FIGS. 5 a - 5 c show a belleville washer 130 having radially spaced concentric grooves 133 in top and side cross-section views, with each groove 133 having a width and a depth each varying along the length of the groove 133 , with each groove 133 being formed differently than at least one other groove 133 , with the radial spacing of the grooves 133 being varied, and with both closed loops and open loops or arcs being used. In this alternate embodiment, the difference between the grooves 133 , is characterized in that the wider and deeper portion of any particular groove 133 is on a different side of the washer 130 than the wider and deeper portion of at least one other groove 133 .
[0040] As a compressive load is applied to the belleville washer 130 of the present invention, the forces are directed into a hoop stress which tends to radially expand the washer. This hoop stress is counterbalanced by the material strength of the washer, and the force necessary to widen the radially spaced concentric grooves 133 along with the strain of the material causes a deflection in the height of the washer. Stated equivalently, the belleville washer 130 responds to a compressive load by deflecting compressively; the radially spaced concentric grooves cause the washer to further respond to the load by spreading as the grooves in the washer expand under the load. The spring, therefore, provides a restoring force which is proportional to the elastic modulus of the material in a hoop stressed condition.
[0041] More particularly, the central opening 132 of the belleville washer is enlarged. This central opening 132 includes a curvate volume 233 for receiving therein the ball-shaped head 207 of the post 201 of the lower plate 200 described above. More particularly, the curvate volume 233 has a substantially constant radius of curvature which is also substantially equivalent to the radius of the ball-shaped head 207 of the post 201 . Preferably, the center of the washer 130 is flat; therefore, the central opening 132 can be formed from flat edges. It should be understood that this is not required, but rather is preferred.
[0042] Referring now to FIG. 6 a , a top view of the upper plate 100 of FIG. 3 a , with the concentrically grooved belleville washer 130 of FIGS. 4 a and 4 b fitted within a retaining wall 108 and a retaining ring 109 of the upper plate 100 , is shown. The diameter of the retaining wall 108 is preferably slightly wider than the diameter of the undeflected belleville washer 130 such that the loading thereof can result in an unrestrained radial deflection of the washer 130 . FIG. 6 b shows a top view of the lower plate 200 of FIG. 3 b.
[0043] [0043]FIG. 7 shows the fully assembled preferred embodiment of the present invention. The radially grooved belleville washer 130 of FIGS. 4 a and 4 b is placed with its wide end against the top plate 100 within the annular retaining wall 108 as shown in FIG. 6 b . The annular retaining ring 109 is provided to hold the belleville washer 130 against the internal face 103 of the upper plate 100 within the retaining wall 108 . The post 201 of the lower plate 200 is fitted into the central opening 132 of the belleville washer 130 (the delectability of the ball-shaped head 207 of the post 201 , prior to the insertion of the set screw 205 , permits the head 207 to be inserted into the interior volume 233 at the center of the belleville washer 130 . Subsequent introduction of the set screw 205 into the axial bore 209 of the post 201 eliminates the deflectability of the head 207 so that the washer 130 cannot be readily removed therefrom, but can still rotate thereon. In some embodiments (not in this preferred embodiment), the post head 207 can be locked tightly within the central volume 233 of the belleville washer 130 by the tightening of the set screw 205 , to prevent any rotation of the plates 100 , 200 . Compressive loading of the assembly causes the washer 130 to deflect (with the radially spaced concentric grooves enhancing the deflection) so that the wide end radially expands while being maintained centrally against the upper plate 100 by the retaining wall 108 and the retaining ring 109 . When the load is removed, the washer 130 springs back to its original shape.
[0044] Referring now to FIG. 8 a , a top view of the upper plate 100 of FIG. 3 a , with the concentrically grooved belleville washer 130 of FIGS. 5 a - 5 c fitted within a retaining wall 108 and a retaining ring 109 of the upper plate 100 , is shown. The diameter of the retaining wall 108 is preferably slightly wider than the diameter of the undeflected belleville washer 130 such that the loading thereof can result in an unrestrained radial deflection of the washer 130 . FIG. 8 b shows a top view of the lower plate 200 of FIG. 3 b.
[0045] [0045]FIG. 9 shows a fully assembled alternate embodiment of the present invention. The concentrically grooved belleville washer 130 of FIGS. 5 a - 5 c is placed with its wide end against the top plate 100 within the annular retaining wall 108 as shown in FIG. 6 b . The annular retaining ring 109 is provided to hold the belleville washer 130 against the internal face 103 of the upper plate 100 within the retaining wall 108 . The post 201 of the lower plate 200 is fitted into the central opening 132 of the belleville washer 130 (the deflectability of the ball-shaped head 207 of the post 201 , prior to the insertion of the set screw 205 , permits the head 207 to be inserted into the interior volume 233 at the center of the belleville washer 130 , and the washer 130 to be rotated into the desired angulation; subsequent introduction of the set screw 205 into the axial bore 209 of the post 201 eliminates the deflectability of the head 207 so that the washer 130 cannot be readily removed therefrom, but can still rotate thereon.). The post head 207 can be locked tightly within the central volume 233 of the belleville washer 130 by the tightening of the set screw 205 , to prevent any rotation of the plates 100 , 200 . Compressive loading of the assembly causes the washer 130 to deflect (with the radially spaced concentric grooves enhancing the deflection) so that the wide end radially expands while being maintained centrally against the upper plate 100 by the retaining wall 108 and the retaining ring 109 . When the load is removed, the washer 130 springs back to its original shape.
[0046] Inasmuch as the human body has a tendency to produce fibrous tissues in perceived voids, such as may be found within the interior of the present invention, and such fibrous tissues may interfere with the stable and/or predicted functioning of the device, some embodiments of the present invention (although not the preferred embodiment) will be filled with a highly resilient and biologically inert elastomeric material. Suitable materials may include hydrophilic monomers such as are used in contact lenses. Alternative materials include silicone jellies and collagens such as have been used in cosmetic applications.
[0047] While there has been described and illustrated embodiments of an intervertebral spacer device, it will be apparent to those skilled in the art that variations and modifications are possible without deviating from the broad spirit and principle of the present invention. The invention, therefore, shall not be limited to the specific embodiments discussed herein. | An intervertebral spacer device having a pair of opposing plates for seating against opposing vertebral bone surfaces, separated by at least one spring mechanism. The preferred spring mechanism is at least one belleville washer having radially spaced concentric grooves. In a preferred embodiment there is a single such belleville washer which is modified to mount onto a ball-shaped head. The lower plate of this embodiment includes a post extending upwardly from the inner surface of the plate, the post including a ball-shaped head. The modified belleville washer can be rotatably mounted to the head such that the wider portion of the washer seats against the upper plate. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of, and claims priority to U.S. Nonprovisional application Ser. No. 14/011,565, entitled “Method and System for utilizing a device's user location to monitor and control the device power usage” and filed on Aug. 28, 2013, which claims priority to U.S. Provisional Application Ser. No. 61/694,113, entitled “Method and System for utilizing a device's user location to monitor and control the device power usage,” filed Aug. 28, 2012.
BACKGROUND OF THE INVENTION
[0002] Accurate monitoring and control at the individual electrical device level provides a significant opportunity to limit electrical power utilization to the minimum necessary for the needs of the device user. In addition, most electrical devices require the close proximity of the end user to provide useful output (lights, monitors, space heaters). There are a number of devices currently available that offer limited monitoring and control of electrical devices based on schedules, sensing, or manual user configurations. Brambley et al. stated in their support for advanced sensors and controls that “controls appear to have the potential to significantly reduce commercial building energy consumption in the United States, but, at present, building controls have probably realized only a fraction of their national energy-savings potential. Overall, Energy Management Control Systems (EMCSs) manage only about one-third of commercial building floor space (˜10% of all buildings), while more advanced control approaches have an even smaller market share”.
[0003] The ability to provide significant monitoring and control at the individual plug node, sensed node or switched node level faces a number of challenges for both commercial and residential users. In order to solve these issues, the present invention provides a simple system for monitoring and controlling power to individual plug, sensed or switched loads based on the proximity of the user to the device thereby minimizing overall power utilization. Additional characteristics of the present invention include ease of installation and automation of controls to limit end user requirements, providing for cost-effective use.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is to provide a system for monitoring and control of electrical devices' power utilization based on the device user or user's proximity to the device. An object of the invention is to control power to the electrical device in order to minimize the power consumption of the device and limit device utilization to its zone of effectiveness. Another object of the present invention is to provide a system to improve entire building monitoring and control by providing a mechanism to remotely monitor and control individual devices at the plug, sensed, or switch node level and to continuously report power consumption for devices for utilization monitoring, maintenance monitoring and system health monitoring.
[0005] To achieve these objectives, the present invention comprises an electrical interface unit for power consumption sensing, control and wireless communications [SPS] with a central receiving unit for data acquisition, data storage, data display, and control [CR] and an electronic user device or system to allow determination of the users location relative to the electrical device being used [UD].
DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 depicts the overall system block diagram showing the three primary components of the proposed invention to include; the Power sensing and control device ( 200 ) [SPS], the central control receiving unit ( 100 ) [CR], and the user locating device ( 300 ) [UD]. FIG. 1 also depicts the interface to the electrical device being monitored and controlled ( 400 ). Depending on configuration being used, FIG. 1 depicts the user locating device ( 300 ) as communicating either to the central control unit ( 100 ) or the power sensing and control device ( 200 ).
[0007] FIG. 2 depicts the various functional, physical and/or logical sub components that comprise the central control unit ( 100 ). FIG. 2 also depicts how these items logically interact with each other. This unit is hereafter referred to as the CR unit.
[0008] FIG. 3 depicts the various functional, physical and/or logical sub components that comprise the power sensing and control device. FIG. 3 also depicts how these items logically interact with each other. This unit is hereafter referred to as the SPS unit.
[0009] FIG. 4 depicts the various functional, physical and/or logical sub components that comprise the User location device ( 300 ). FIG. 4 also depicts how these items logically interact with each other. This unit is hereafter referred to as the UD unit.
[0010] FIG. 5 depicts the logical flow diagram for the configuration where the SPS directly senses the proximity of the UD and controls the power availability to the electrical device based directly on that proximity. In this configuration, after initial set up from the CR to the SPS, the CR is not required for any power control decisions and functions only in a passive monitoring capacity. The SPS is the active power control decision device based on information from the UD.
[0011] FIG. 6 depicts the logical flow diagram for the configuration where the SPS directly senses the proximity of the UD and reports the UD information to the CR where the CR determines the appropriate actions and commands the individual SPS controls. In this configuration, the CR is the active power control decision device based on the pass through UD data from the SPS.
[0012] FIG. 7 depicts the logical flow diagram for the configuration where a separate real time location system (not part of this present invention) determines the UD location and transmits that location to the CR which then determines the appropriate action and commands individual SPS controls. In this configuration, the CR is the active power control decision device based on UD data received separately from the SPS.
DETAILED DESCRIPTION
[0013] In the following description of the present invention there are multiple details established to provide a thorough understanding of the invention and the preferred implementations of the invention. It should be clear that the description is not intended to limit the invention to these specific embodiments and that variations, changes, substitutions, or equivalent components will be apparent to those skilled in the art and should not be considered significant differences from the intended scope of the invention.
[0014] The invention intends to monitor and control the use of electricity to electrical devices. The invention is intended to apply to the monitoring and control of any and all pluggable electrical devices, permanently installed buss bar connected electrical devices, permanently installed switch controlled electrical devices or permanently installed sensor controlled electrical devices. FIG. 1 depicts the interface between the power sensing device [SPS] ( 200 ) and the power utilization device ( 400 ) as well as the interfaces between the three primary units of the present invention. The arrows in FIG. 1 depict the flow of information from one subsystem to another. The dashed arrows in FIG. 1 depict that the information from the UD ( 300 ) can be transmitted either to the CR ( 100 ) or to the SPS ( 200 ) depending upon the desired configuration. The figure is also intended to convey that there can be multiple electrical devices connected to either a single or multiple SPSs and each SPS can work with either a single or multiple UDs.
[0015] The CR unit ( 100 ) is depicted in detail in FIG. 2 . The CR consists of a central processor ( 150 ), an RF Transceiver ( 110 ), a database of the SPSs ( 120 ), a database of UDs ( 130 ), a database of power utilization for each node of the SPS ( 140 ), an interface for a local user to monitor and control the system ( 160 ), an internet connection ( 170 ), a remote user interface ( 180 ), and one or more decision algorithms ( 190 ).
[0016] The central processor ( 150 ), local user interface ( 160 ), various databases ( 120 , 130 , 140 ), internet connection ( 170 ) and decision algorithms ( 190 ) are intended to be comprised of a single personal computer, notebook, tablet or smart phone capable of hosting various software and providing display and human machine interfaces. The current embodiment utilizes a PC based system running widows 7 and utilizing various customized software for data acquisition, database storage, display, decision management, control and reporting. The SPS database ( 120 ) consists of tables of information on various SPS configurations, locations, communications protocols, sensor types, sensor calibration numbers, connected power utilization devices attached to the SPS, sensing limits and UD assignments. The End user database ( 130 ) consists of various tables of UD configuration, names of individuals assigned to the UD, communication protocols for each UD and time and sensor location of the sensed UD. The Power Usage database ( 140 ) consists of tables of information on power usage from each sensor on each SPS. This information includes unconverted transmitted data as well as converted data based on individual sensor calibration information. Sensor data is not limited to power sensing and may include environmental or motion sensing information. The decision algorithms ( 190 ) can consist of a variety of items but effectively use logical rules and the information from the individual databases to determine both the current state and the desired state of an individual control node. If the current state is different from the desired state, the central processor institutes a change communication to bring the node from the current state to the desired state.
[0017] The RF transceiver ( 110 ) is intended to be any one of a number of possible devices including proprietary RF communication, Wi-Fi, Bluetooth, UWB, ZigBee or other IEEE supported protocols. The device is in communication with the central processor through any one of a number of wired or wireless standard or proprietary protocols including USB, Wi-Fi, Bluetooth, UWB, ZigBee or other IEEE supported protocols.
[0018] If desired, the central processor can communicate through various wired or wireless standard or proprietary protocols ( 170 ) to a remote interface unit ( 180 ) allowing a physically remote user to monitor and control each of the SPS nodes independently through the internet or cell communications. The remote unit ( 180 ) can be another computer, tablet, smartphone or other device.
[0019] FIG. 3 depicts the individual logical and functional components of the SPS ( 200 ) to include and RF transceiver ( 210 ), various sensors ( 220 ), an interface to a power utilization device ( 230 ), logical memory ( 240 ), a microcontroller ( 250 ), relays to control power flow ( 260 ), decision algorithms ( 270 ), and a local override device ( 280 ). The microcontroller ( 250 ) provides the ability to communicate through the RF transceiver ( 210 ) to the UDs and the CR as well as the ability to interrogate the various sensors ( 220 ) and to use the decision algorithms ( 270 ) and memory ( 240 ) to properly interpret the sensed data and control the flow of electricity through the interface ( 230 ) by controlling the power relays ( 260 ). The current embodiment utilizes a System on a Chip (SOC) to encompass the functions of the RF transceiver ( 210 ), memory ( 240 ), and microcontroller ( 250 ). Furthermore the SOC provides the analog and digital interfaces to the sensors ( 220 ) and allows decision algorithms ( 270 ) to be stored in local memory ( 240 ). If required, the SPS can be battery powered or connected to a power source.
[0020] The sensors ( 220 ) can be current sensors, power sensors, temperature sensors, motion sensors, radiation sensors, or other sensors. They can have either a digital or analog interface to the microcontroller ( 250 ). The sensors work through the interface to the power utilization device to accurately monitor the amount of power being used by each device being sensed.
[0021] The power control relays ( 260 ) are used to interrupt or allow power to flow through the interface ( 230 ) to the power utilization device. The power relays can be controlled either by commands from the microcontroller ( 250 ) or from a local override device ( 280 ). The local override device ( 280 ) is a switch that turns power on or off to the interface ( 230 ) by overriding the command from the microcontroller ( 250 ).
[0022] The decision algorithms ( 270 ) can be either control algorithms for the relays ( 260 ) or can be algorithms for properly interpreting the sensor ( 220 ) data such as a peak detection algorithm or integration algorithm.
[0023] FIG. 4 depicts the various components associated with the UD ( 300 ). The UD is comprised of a microcontroller ( 340 ), and an RF transmitter ( 310 ). If required, the UD can include sensors ( 320 ) and/or local memory ( 330 ). The UD is intended to be battery powered and physically located with the user similar to an active RFID device.
[0024] The microcontroller ( 340 ) provides the ability to communicate through the RF transceiver ( 310 ) to the SPS and/or the CR as well as the ability to interrogate the various sensors ( 320 ) and to use a command set and memory ( 330 ) to properly interpret the sensed data. The current embodiment utilizes a System on a Chip (SOC) to encompass the functions of the RF transceiver ( 310 ), memory ( 330 ), and microcontroller ( 340 ). Furthermore the SOC provides the analog and digital interfaces to the sensors ( 320 ) and allows the command set to be stored in local memory ( 330 ). The current embodiment of the UD goes from a sleep mode to a wake mode approximately every 4 seconds. In wake mode the UD transmits the UD ID number and current battery level and returns to sleep mode. No acknowledgement of receipt of information is made to the UD. It is a ‘dumb’ asynchronous transmitter.
[0025] The devices described in FIGS. 1-4 can be utilized in a number of logical configurations to provide monitoring and control of electrical loads based on user proximity to the electrical device. FIG. 5 depicts the logical flow diagram for the first of 3 independent configurations for the present invention. In this configuration, the SPS ( 200 ) is connected to an electrical load desired to be sensed and controlled. The SPS information, load information and intended load user is uploaded to the CR. Based on its decision algorithm, the CR transmits control logic information to the SPS. The SPS begins to sense and transmit the power utilization information of each node to the CR for database storage, display and reporting. Through the SPS transceiver, the SPS listens for communication from the UD or UDs associated with the connected load. The UDs transmit their identification continuously. If the UDs are in and remain in range of the SPS, the SPS makes no change to the flow of electricity to the load. If the UDs go out of range of the SPS receiver for greater than a predetermined time period, the SPS utilizes its control algorithms to turn off the connected load until the UD(s) come back into range of the SPS. All power control decisions are accomplished by the SPS microcontroller without further communication to or from the CR. In this mode, the CR monitors changes but does not control the local SPS.
[0026] In the current embodiment whenever the UD signal is received by the SPS, an internal SPS timer is reset to indicate user presence. With the UD transmitting approximately every 4 seconds, this SPS internal timer is set to approximately 1 minute and must be reset by the receipt of the UD RF signal to continue to allow power to the controlled devices. If the SPS timer is not reset before it expires, power to the devices being controlled is removed and the SPS waits until it receives the UD signal before turning on power to the devices being controlled and resetting the timer.
[0027] In the current embodiment, the SPS cycle of listening for the UD's, monitoring the power load from its controlled devices, and transmitting its information to the CR, is approximately every 10 seconds. The SPS transmits the ID of any UD's heard in that 10 seconds, the power being used by the various SPS sensed loads, and the SPS ID information to the CR. The SPS information is transmitted to the CR asynchronously and without an acknowledgement from the CR.
[0028] If the user determines that the state of a given node is not what is desired they can utilize the manual override on the SPS to change the state of the node. In the current embodiment, the manual override changes the relay state but does not change the microcontroller sequence relative to it's decisions based on UD movement in and out of range. That is, after the manual override is used, the system automatically reverts to UD control upon the next full UD proximity detection change cycle (out/in/out or in/out/in). Various UD and SPS transmission times and ranges can be used to control sensitivity of the device to a state change. These are controlled through the various algorithms on the CR, UD and SPS.
[0029] FIG. 6 depicts a second logical flow diagram for a configuration where the control decisions are made not at the SPS but by the CR. In this configuration, the SPS transmits to the CR both the SPS sensors information and the UD ID numbers that it is receiving as before. No decision information is held by the SPS. No SPS internal timer is used to change relay positions. The CR utilizes the information received from all SPSs to determine the correct state for each SPS node and transmits that information to the various SPSs to change specific relays and either interrupt or allow power flow to end devices. Because there may be UD information from multiple SPSs, this configuration may allow for a higher level of control including better relative position determination between the UD and SPS.
[0030] FIG. 7 depicts a third configuration where the UD does not communicate in any way to the SPS but instead communicates its real time absolute location to the CR. The CR then determines the relative location of the UD to the SPS and commands any required state changes to the SPS nodes. This is intended to provide the highest possible level of control as well as allow for third party RTLS or location service systems to provide the necessary information, removing the need for a redundant UD.
[0031] All three configurations include the ability of the CR to command SPS nodes based on; commands from the CR user interface (permission controlled), scheduled commands, power usage rules such as maximum SPS power usage, or other logical requirements.
[0032] In the current embodiment if the CR transmits information to an SPS, the SPS sends the received command ID number back to the CR for the next 3 standard transmissions to the CR. In this way, the CR ensures the SPS state and control logic is as desired. In addition, in the current embodiment, the CR can command the SPS to transmit its memory load information to allow monitoring of UD and SPS control information directly by the CR. All three configurations allow the local user to utilize the override system.
[0033] The preferred embodiment of the SPS includes either a smart power strip or smart outlet for plugged loads, a smart switch for switched loads or a smart thermostat for sensed nodes. The smart outlet and smart switch can take the form of a standard AC box unit such that no difference to the end user is perceived. The intended embodiment of the UD includes a key fob or security card device for any of the three depicted configurations. In addition, the UD can take the form of a cell phone, smartphone, or other personal electronic device transmitting RF signals. | An autonomous system for managing power distribution to an electrically-powered device that includes a power controller module that includes power input and power output abilities and operably connected power switching abilities, wherein the power switching is configured for actuation by an integral power management module operably connected thereto, the integral power management module including integral actuation signal detection and actuation abilities configured for, in accordance with commands and operational parameters, upon detection of an actuation signal, actuation the integral power switching to alter power output through the power output from a first output level to a second output level. The system further includes memory for storing the commands an operational parameters, and wherein the actual signal include an identification component for identifying an actuating signal, and wherein the integral actuation signal detection and actuation is configured for, upon detecting signals other than actual signals, reacting other than in response to the actuation signal. | 6 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/883,415, filed Jun. 30, 2004 and issued as U.S. Pat. No. 6,882,587 on Apr. 19, 2005; which is a continuation of U.S. application Ser. No. 10/608,060, filed Jun. 27, 2003 and issued as U.S. Pat. No. 6,778,452 on Aug. 17, 2004; which is a continuation of U.S. application Ser. No. 10/253,844, filed Sep. 23, 2002 and issued as U.S. Pat. No. 6,600,687 on Jul. 29, 2003; which is a continuation of U.S. application Ser. No. 09/735,119, filed Dec. 11, 2000 and issued as U.S. Pat. No. 6,469,944 on Oct. 22, 2002; which is a continuation of U.S. application Ser. No. 09/483,549, filed Jan. 14, 2000 and issued as U.S. Pat. No. 6,181,617 on Jan. 30, 2001; which is a continuation of U.S. application Ser. No. 09/260,232, filed on Mar. 1, 1999 and issued as U.S. Pat. No. 6,028,799 on Feb. 22, 2000; which is a divisional of U.S. application Ser. No. 08/855,555, filed May 13, 1997 and issued as U.S. Pat. No. 5,877,993 on Mar. 2, 1999.
TECHNICAL FIELD
The present invention relates generally to semiconductor circuit devices and, more specifically, to a circuit for changing the voltage applied to selective portions of a memory array. Such portions include digit line pairs as well as the gate of a transistor used to regulate sense amplifiers.
BACKGROUND OF THE INVENTION
In the operation of certain semiconductor circuit devices, pullup and pulldown sense amplifiers (sense amps) detect and amplify a small charge stored within a memory cell. In general, two complementary digit lines are attached to a pullup sense amp and a pull down sense amp. At the beginning of a reading operation, both lines are at an equilibrate voltage Veq, which is generally between the potential of a voltage source used to operate the semiconductor device (V CC ) and ground potential (0 volts). While Veq is changeable either intentionally or inadvertently through a defect, Veq is ideally equal to V CC /2 during non-test operations. This midpoint voltage is defined as DVC 2 .
One of the digit lines is coupled to a memory cell. The reading process involves a discharge from the memory cell to the corresponding digit line, which creates a slight difference in voltage between the two digit lines. This difference is then amplified by the sense amps: the digit line with the slightly lower voltage has its voltage further decreased by the pulldown sense amp, and the voltage of the other digit line is increased by the pullup sense amp. Once the voltage difference has been amplified, the digit lines can then be used to operate less sensitive circuitry.
Between reading cycles, it is necessary to return the complementary digit lines to Veq. This occurs during what is known as a precharge cycle, wherein equilibration transistors short the complementary digit lines together. Further, a signal having a potential of DVC 2 is communicated from a DVC 2 voltage generator to the shorted digit lines through a bleeder device.
Concerning the operation of the sense amps, it should be noted that pulling down the voltage of a digit line involves coupling the line to ground through a pulldown transistor. Because an entire row of digit line pairs often connects to the same pulldown transistor through a common node, the pulldown transistor will most likely have to draw current from one line of each of several pairs. In doing so, there is a risk that the transistor will become saturated with current and therefore become slower in pulling down the voltage of additional digit lines. This may lead to errors in reading, especially if an entire row of memory cells is storing logic 1's except for one cell storing a logic 0; for once the logic 0 is discharged, a slow pulldown may result in an improper reading of that logic 0 value.
One known way to solve this problem is to include an optional active area in the gate of the pulldown transistor. The increased size of the gate raises the threshold at which the pulldown transistor becomes saturated. However, one of ordinary skill in the art will appreciate that this solution requires a costly metal mask change. Further, any attempt to speed up the slowed pulldown raises other problems in reading, as disclosed in U.S. Pat. No. 5,042,011, by Casper, et al. The Casper '011 reference discloses that pulling down the common node too quickly may result in capacitive coupling between the sources and drains of the sense amp's transistors. During capacitive coupling, both digit lines in one sense amp are pulled down before the common node is pulled down low enough to turn on one of the sense amp transistors. When the sense amp finally turns on, it shorts out the capacitive coupling, bouncing the digit lines and, in the process, creates line noise that will interfere with the ability to read the data properly.
Early saturation and capacitive coupling could be avoided if one knew the margin—the difference in voltage between a logic 0 signal and a logic 1 signal—that the pulldown transistor was capable of accommodating. The only way to do so, as taught by the prior art, is to separate the pulldown transistor with a laser and probe the gate.
As an alternative to determining the sense amp's margin, one could simply test the sense amp's ability to operate at the given source voltage used in non-test operations. Prior art suggests entering a series of test data patterns into memory. Logic 1's are written to the cells of each memory array, with the exception of one column of logic 0's. As a result, each row contains only one cell storing a logic 0, thereby creating the most likely circumstance for an error in reading the data. The data in the array is then read and checked for errors. Once the first group of test data has been processed, a second sample of test data is entered with the logic 0's written to the next column. This process repeats until a logic 0 has been written to and read from every cell in any given row in the memory array. The results will indicate the pulldown transistor's ability to read data accurately. The problem with this process, however, is that it is time consuming to enter multiple samples of test data.
Thus, there is a need in the art for a quicker circuit and method for testing the capabilities of a sense amp. Further benefit would be derived if this test could indicate the margin of the sense amp's pulldown transistor.
In addition to inadequate pulldown transistors, other problems, such as defects arising during the processing of semiconductor devices, may contribute to reading errors. Various techniques involving equilibration of the complementary digit lines can be used during testing to detect these problems. For example, occasionally a digit line will inadvertently have a short to ground. As a result, the potential of that digit line will leak towards 0 volts. To detect this problem, prior art teaches extending the time for the precharge cycle during a test mode. If the short has a low enough resistance, the short will overcome the charging ability of the DVC 2 voltage generator, which remains coupled to the digit lines, and Veq of the digit lines will decrease. Thus, a longer precharge cycle allows Veq to lower even further. As a result, line noise is more likely to register as a logic 0 discharge on the digit line when in fact the storage cell contains a logic 1 and has not yet discharged. Alternatively, assuming that a logic 1 is properly discharged and sensed, a reading error is still likely: Veq may be so low due to the short that the pullup sense amp may not be able to pull up the digit line's voltage in time to register as a logic 1 for purposes of driving external circuitry. Increasing the likelihood of error is desirable in the test mode, as it helps to identify errors that would affect non-test operations. Further, a reading error occurring after this extended precharge cycle will indicate the nature of the defect—in this case a short in at least one of the digit lines. However, this testing process can be time consuming. As an example, a 64 meg DRAM having a 16 meg×4 configuration requires approximately 170 seconds to carry out this test. It would be a benefit to the art to have a faster way to test for this problem.
A second problem that could be detected by altering the equilibration rate of the digit lines involves a short between the cell plate and the digit line. The typical technique for discovering this problem is to initiate a long RAS (Row Address Strobe) low signal. During the low RAS, the digit lines are not equilibrated. Rather, they are charged to their complementary voltage levels. Ideally, once the low RAS ends and the lines are shorted, both digit lines should approach a Veq level of DVC 2 . However, a short between one of the digit lines and the cell plate will allow the DVC 2 generator 68 to change that digit line's voltage during the RAS low period. Thus, once the lines are shorted, their respective voltages will meet at a different Veq level. This will affect the margin between Veq and the voltage corresponding to one of the logic values and thereby increase the likelihood of a reading error. Eventually, the signal from the DVC 2 voltage generator will restore the proper equilibrate voltage once the RAS low signal ends. Nevertheless, for purposes of detecting this problem before non-test operations begin, it would be desirable to slow the restoration of the proper Veq level.
A third example concerns a defect that could exist within the memory cell's storage capacitor, such as a defect in a nitride layer acting as a dielectric between the memory cell's conductive plates. Such a defect could cause a short within the storage capacitor. Because the storage capacitors are coupled to the DVC 2 voltage generator, a defective capacitor “storing” a 0 volt charge, representing a logic 0, will slowly charge to the DVC 2 level. The closer the storage capacitor approaches a DVC 2 charge, the more likely that a logic 1 value may be misread during the next reading. One way to detect this problem in the prior art is to initiate a static refresh pause, wherein the memory cell's access transistor remains deactivated for a longer time than usual—generally 100 milliseconds. As a result, the capacitor, which should be storing a logic 0, has a longer time to charge to a higher voltage, thereby making an error in the next reading cycle more likely.
Once again, a speedier test is desired. The defect might be detected earlier if the problem were exacerbated to the point where the leaked charge for the stored logic 0 exceeded the equilibrate charge of the digit lines. As a result, a logic 1 would be read from the cell even though it was known that a logic 0 had been written. One could speed up the leakage into the storage capacitor by forcing DVC 2 to a higher voltage. However, the equilibrate voltage of the digit lines would also increase accordingly and remain higher than the voltage of the charge in the storage capacitor. Thus, forcing DVC 2 would not appreciably increase the ability to detect an error unless the equilibration of the digit lines could be slowed. The only way to do this in the prior art is through the use of a costly metal option to change the gate voltage of the bleeder device.
SUMMARY OF THE INVENTION
Given the need for regulating the drive of a sense amp, as well as the need for regulating the equilibration signal from a DVC 2 voltage generator, a test circuit is provided for varying the voltage of a signal used to drive a connection device that allows electrical communication within a semiconductor circuit. One preferred circuit embodiment includes a contact pad for carrying a range of test voltage signals to the connection device. In another preferred circuit embodiment, a regulator circuit enables a series of discrete voltages to drive the connection device.
In one set of applications involving the regulation of a sense amp, the connection device comprises a sense amp's voltage pulling transistor. Any circuit embodiment covered by the present invention can be used to test drive the transistor. In a preferred method of use, a test data pattern is entered and the data is read several times, with a different voltage driving the sense amp's pulldown transistor each time. One advantage of this preferred method is that it reduces the need for entering several elaborate test data patterns and, therefore, allows for quicker testing of memory arrays. A second advantage is that the embodied method and devices allow a determination of the lowest supply voltage that can be used during normal operation without errors in reading data. Yet another advantage is the ability to determine the highest supply voltage, and therefore the fastest reading speed, that can be used during normal operations without causing capacitive coupling. In doing so, the preferred circuit embodiments and method increase the sense amp's ability to distinguish between a logic 0 voltage and a logic 1 voltage without physically altering the sense amp. Further, in the process of determining the lowest and highest voltages at which the sense amp is capable of functioning, the preferred embodiments and method also provide a way to ascertain the margin without dissecting components of the sense amp.
Concerning the specific errors that may be detected in relation to equilibrating the digit lines, the connection device comprises an isolation bleeder device coupled between the DVC 2 voltage generator and a digit line pair. The circuit embodiments provide a test mode apparatus for driving the bleeder device in order to slow or quicken the equilibration of the digit line pair. Applying these embodiments provides the advantage of a quicker detection of defects such as a short from a digit line to ground, a short from a digit line to a cell plate, and a short within the storage capacitor of a memory cell. The embodiments also provide an alternative advantage of overcoming the influence of these defects during non-test modes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a row of n-channel pulldown sense amps with associated D, D*, and WL lines; a pullup sense amp; and a series of memory cells, as found in the prior art. FIG. 1 also shows a digit line equilibration circuit as found in the prior art.
FIG. 2 is a graph indicating the voltage of the conductive paths D and D* over time in the event that a memory cell storing a logic 0 discharges to D. FIG. 2 also demonstrates the resulting amplification of the difference in voltage.
FIG. 3 is a graph demonstrating the relationship between drive current (I DV ) and the gate-source voltage of a pulldown transistor (V GS ) at various levels of voltage applied to the gate (V GATE ).
FIG. 4 details one exemplary circuit embodiment in accordance with the present invention as used with a sense amp.
FIG. 5 illustrates a second exemplary circuit embodiment in accordance with the present invention as used with a sense amp.
FIG. 6 shows a third exemplary circuit embodiment in accordance with the present invention as used with a sense amp.
FIG. 7 a is a schematic of a portion of a memory array depicting an embodiment of the current invention as used in the digit line/cell plate region of a memory array. FIG. 7 a further depicts a first type of possible defect within the memory array.
FIG. 7 b is a graph illustrating the effect of the first defect and a first embodied method of the current invention.
FIG. 7 c is another graph illustrating the effect of the first defect and the first embodied method of the current invention.
FIG. 8 a depicts a cross-section of a portion of a memory array including a second type of defect.
FIG. 8 b demonstrates the effect on a memory array of the second type of defect as well as the effect of a second embodied method of the current invention.
FIG. 8 c further demonstrates the effect on a memory array of the second type of defect as well as the effect of a third embodied method of the current invention.
FIG. 8 d depicts the effect of a fourth embodied method of the current invention as it relates to the second type of defect.
FIG. 9 a is a schematic of a portion of a memory array depicting a third type of defect in the memory array.
FIG. 9 b is a graph indicating the effect of the third type of defect.
FIG. 9 c is a graph illustrating a method in the prior art for detecting the third type of defect.
FIG. 9 d is a graph illustrating the effect of a fifth embodied method of the current invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the general configuration of sense amps in a memory array. A pulldown sense amp 20 includes cross coupled n-channel transistors Q 1 and Q 2 , as well as a pulldown transistor Q 3 , which is an n-channel transistor driven by a signal designated as LENSA, These elements play a part in sensing and amplifying a voltage difference between D and D* caused by shorting a memory cell 22 to D by way of access transistor Q 4 . The sources of Q 1 and Q 2 are connected to a common pulldown node 24 , and the gate of each is connected to the other's drain. The gate of Q 1 also connects to the line D*, whereas the gate of Q 2 connects to the line D.
As discussed above, each line D and its corresponding line D* are initially at the same voltage DVC 2 . For purposes of explanation, DVC 2 is assumed to be 1.65 volts, or one half of the source voltage V CC , which is 3.3 volts. Lines D and D* connect to opposite sides of each sense amp 20 . Common pulldown nodes 24 found in the sense amp arrays will also be at DVC 2 . A signal sent through the path WL will cause a storage capacitor 150 of particular memory cell 22 to discharge to a line D, thereby slightly changing D's voltage while the voltage of D* remains at DVC 2 . Again, for purposes of explanation, a memory cell discharge will be assumed to cause a 0.2 volt difference in D. The pulldown sense amp 20 will then turn on when the common pulldown node 24 is one transistor threshold voltage below D or D*, whichever is highest. For instance, if a memory cell 22 is storing a logic 1, a discharge to D will increase D's voltage to 1.85 volts. As a result, the pulldown sense amp transistor gated by D (Q 2 ) turns on faster than the one gated by D* (Q 1 ). With transistor Q 2 on, D*'s voltage is pulled down from 1.65 volts towards ground as the common pulldown node 24 is pulled down as well. Further, the lowering voltage of D* serves to turn on the pullup sense amp transistor gated by D* (Q 14 ) before the other pullup sense amp transistor turns on. The voltage supply V CC then charges line D.
On the other hand, if the memory cell 22 had been storing a logic 0, then a discharge to D would slightly lower D's voltage to 1.45 volts. The pulldown sense amp transistor gated by D* (Q 1 ) would turn on first and D's voltage would be further decreased toward ground by the pulldown sense amp, thereby allowing the pullup sense amp to increase D*'s voltage toward V CC . In this way, a small voltage difference between D and D* is sensed and amplified. Once the voltage difference has been amplified, D and D* can drive less sensitive circuitry not shown in FIG. 1 . It should be noted that, if a logic 0 is transmitted to D, then the pulldown sense amp need only pull down D from 1.45 volts. If a logic is transmitted to D, then the pulldown sense amp must pull D* from the higher DVC 2 level—1.65 volts.
Therefore, if many logic 1's in a memory array row are read, the extra voltage that must be pulled contributes to saturating the pulldown transistor Q 3 with drive current, thereby slowing any further pulldown. The problem created by slow pulldown is illustrated in FIG. 2 , where slope X denotes the initial discharge to D from a memory cell 22 storing a logic 0. FIG. 2 further illustrates the amplification of the difference in voltage between D and D*. Slope Y denotes the time required for D to drop in voltage given a situation where a row of cells contains a roughly equal number of logic 1's and logic 0's. Should there be many logic 1's read amongst a single logic 0, then the outcome changes: as the logic 0 is read, the pulldown transistor Q 3 , having approached saturation, takes much longer to pull down D's voltage. This result is illustrated by slope Z. Other circuitry elements (not shown) that are driven by D may read D before its transition to a lower voltage has been completed. As a result, a logic 0 value may be misread as a logic 1.
As illustrated in FIG. 3 , increasing the voltage to the gate of the pulldown transistor allows the transistor to pulldown more current before saturation. One preferred embodiment of the current invention that uses this principal is detailed in FIG. 4 , where the pulldown transistor Q 3 is driven by a test circuit 26 through an inverter 27 . In this embodiment, the inverter 27 comprises a p-channel transistor Q 6 and an n-channel transistor Q 8 . The coupled gates of inverter transistors Q 6 and Q 8 form an input node 28 for receiving a signal ENSA*, which may be V CC , ground, or a signal from another driver. The coupled drains of the inverter transistors Q 6 and Q 8 output the LENSA signal that drives the pulldown transistor Q 3 . The source of Q 8 is coupled to ground. The source of Q 6 is coupled to a source node 30 that branches into a first conducting path 32 and a second conducting path 34 . The first conducting path 32 is coupled to an n-channel transistor Q 10 , which has a channel width-to-length ratio of around 500/2. The drain of transistor Q 10 is coupled to a contact pad 36 . It should be understood that the term “contact pad” includes any conductive surface configured to permit electrical communication with a circuit or a node. The gate of transistor Q 10 is coupled to an inverter 60 through another n-channel transistor Q 36 . Together, inverter 60 and transistor Q 36 comprise a latch device, and both are coupled to V CCP . Further, inverter 60 receives a TEST* signal as an input. In addition, the gate of transistor Q 10 is also coupled to a feedback capacitor 62 . This feedback capacitor 62 comprises an n-channel transistor having a size of approximately 100/100, wherein the drain and source are shorted and coupled to the first conductive path 32 . The second conducting path 34 is coupled to a p-channel transistor Q 12 , driven by a signal TEST, which is understood to be the complement of TEST*. The transistor Q 12 is also coupled to V CC , although no voltage source is considered to be a part of the invention.
During testing, TEST* transmits a low voltage signal which is received by the inverter 60 . In response, the inverter 60 initiates a V CCP signal, sending it through transistor Q 36 which outputs the V CCP signal to the gate of transistor Q 10 , thereby switching on Q 10 . The feedback capacitor 62 serves to maintain and replenish this V CCP signal in the event of leakage. Capacitive coupling between the gate and drain of transistor Q 10 allows Q 10 to carry signals having a range of voltages for modifying the drive of the pulldown transistor Q 3 . Simultaneously, the TEST signal, applying a high voltage to transistor Q 12 , isolates V CC . A test data pattern is entered into the memory cells 22 and read with varying voltages driving the pulldown transistor Q 3 . The data read at various alternate voltages sent through bond pad 36 can be compared with the data as originally written. This series of readings indicates the range of voltages through which the pulldown transistor Q 3 is capable of allowing accurate data readings. Once testing has ended, TEST* sends a high voltage signal and TEST becomes low, thereby isolating the bond pad and allowing the V CC signal to transmit to the pulldown transistor Q 3 .
The embodiment illustrated in FIG. 5 is a package part of the semiconductor circuit device and receives a plurality of voltage sources with different magnitudes. The test circuit 26 allows selection among these sources for driving the gate of the pulldown transistor Q 3 . The inverter 27 is the same as in FIG. 4 . In this exemplary embodiment, however, source node 30 is coupled to three discrete voltage sources. First, source node 30 is coupled to V CCP through a p-channel transistor Q 20 that is driven by a low signal A*. Source node 30 is also coupled to DVC 2 through another p-channel transistor Q 22 that is driven by a low signal B*. Finally, source node 30 is coupled to V CC by way of a p-channel transistor Q 24 . This p-channel transistor Q 24 is gated by the output of a logic unit, such as a NAND gate 46 , which will drive transistor Q 24 in response to receiving a high signal A as a first input and a high signal B as a second input. Given the input vector scheme of this embodiment, one of the transistors Q 20 , Q 22 , or Q 24 will be operable to the exclusion of the other two.
Thus, a low signal A* will drive the p-channel transistor Q 20 , thereby allowing V CCP to drive the pulldown transistor Q 3 . Simultaneously, signal B will be high, turning off p-channel transistor Q 22 . Further, the NAND gate output will also be high and turn off p-channel transistor Q 24 . If, on the other hand, signal B is low and signal A is high, then only p-channel transistor Q 22 will be on, allowing DVC 2 to transmit to the pulldown transistor Q 3 . Only when both signals A and B are high does the NAND gate 46 output a low signal and allow V CC drive the pulldown transistor Q 3 . The data read at these three voltage levels can then be compared with the data as originally written. It should be noted that this configuration does not require the die space needed for the contact pad 36 .
Another embodiment concerns varying the voltage applied to a pullup sense amp 40 . As seen in FIG. 1 , the pullup sense amp 40 includes cross coupled p-channel transistors Q 14 and Q 16 as well as a pullup transistor Q 18 . As one of ordinary skill in the art understands, there is generally a pullup sense amp 40 corresponding to every pulldown sense amp. Nevertheless, for purposes of clarity, only one pullup sense amp 40 is shown. The sources of Q 14 and Q 16 are connected to a common pullup node 42 , and the gate of each is connected to the other's drain. Further, the gate of Q 14 connects to line D*, and the gate of Q 16 connects to line D. Common pullup node 42 is coupled with pullup transistor Q 18 , which is another p-channel transistor. Pullup transistor Q 18 is also coupled to the voltage source V CC . The pullup transistor Q 18 is driven by a signal LEPSA*. FIG. 6 illustrates that the voltage driving pullup transistor Q 18 may also be varied through the use of a test circuit 26 analogous to that used with the pulldown transistor Q 3 in FIG. 5 . FIG. 6 depicts an inverter 27 comprising a p-channel transistor Q 26 and an n-channel transistor Q 28 . The coupled gates of inverter transistors Q 26 and Q 28 form an input pathway 48 for a control signal designated EPSA. The coupled drains transmit the inverted output signal EPSA* which, in turn, is received by a prior art device 50 that outputs the LEPSA* signal used to drive the pullup transistor Q 18 . The source of Q 26 is coupled to V CC , whereas the source of Q 28 is coupled to the test circuit 26 which, in this embodiment, includes three conductive paths. The first path 52 leads to DVC 2 by way of an n-channel transistor Q 30 , which is driven by a signal C. The second path 54 is coupled to a voltage source V BB through an n-channel transistor Q 32 , as driven by a signal D. The third path 56 leads to ground by way of n-channel transistor Q 34 . The gate of n-channel transistor Q 34 is coupled to the output of a NOR gate 58 . The NOR gate 58 accepts signal C as a first input and signal D as a second input and will activate transistor Q 34 only when both signals are low. Further, this embodiment is configured in a manner analogous to the embodiment in FIG. 5 , in that signals C and D will never simultaneously activate their respective transistors Q 30 and Q 32 .
The three n-channel transistors Q 30 , Q 32 , and Q 34 will turn on if a high, or logic 1, signal is transmitted to their respective gates. As with the embodiment shown in FIG. 5 for the pulldown sense amp, the signals and transistors are configured to allow only selective communication between one voltage source and the pullup transistor Q 18 . As a result, if signal C is high, it will latch the n-channel transistor Q 30 and provide electrical communication between DVC 2 and the pullup transistor Q 18 . At the same time, the low signal from D turns off n-channel transistor Q 32 . Under these circumstances, the signals C and D also result in a low signal output from the NOR gate 58 , thereby turning off n-channel transistor Q 34 . Thus, all of the other voltage sources are isolated. Similarly, if signal D is high, then only n-channel transistor Q 32 is turned on and V BB electrically communicates with pullup transistor Q 18 . When both signals are low, the NOR gate 58 outputs a high signal, thereby grounding the source of the n-channel inverter transistor Q 28 . This embodiment has benefits similar to the embodiment in FIG. 5 .
Returning to FIG. 1 , a prior art equilibration circuit can be seen as part of the memory device. For purposes of explaining the following embodiments of this invention, V CC is now presumed to be 5 volts. A transistor Q 101 is coupled between digit line D and its complementary digit line D*. The transistor is driven by an equilibration signal EQ. It should be noted that the signal EQ results from a logic function and is distinguishable from the equilibrate voltage Veq, which represents the common mid-range voltage level of the complementary digit lines before a reading operation.
The signal EQ also drives two additional transistors Q 102 and Q 103 , which are connected together in series at a node 120 . These connected transistors Q 102 and Q 103 are also coupled between lines D and D*. Moreover, node 120 is coupled to a cell plate 64 and a DVC 2 voltage generator 68 through a bleeder device 122 . The DVC 2 voltage generator 68 transmits a cell plate signal CP of voltage DVC 2 to the node 120 . For purposes of explaining the following embodiments of this invention, DVC 2 is now 2.5 volts. The bleeder device 122 is driven by a signal of voltage V CCP , wherein V CCP results from having pumped V CC to an even higher potential.
At the beginning of a precharge cycle, digit line D and its complementary digit line D* are at different voltages as a result of a discharge of the memory cell 22 during the reading cycle. One line will have a charge equal to the V CC value of 5 volts, while the other line will have a 0 volt charge. The equilibrate signal EQ is then sent, activating transistor Q 101 , which shorts D and D* together. Moreover, the signal EQ activates transistors Q 102 and Q 103 , which not only provide another short between D and D* but also allow the CP signal to be communicated to those lines, As a result, the lines D and D* equilibrate, both gaining a charge of potential DVC 2 (2.5 volts), which is the desired equilibrate voltage Veq in this example. Once the lines are equilibrated, they are ready for further testing.
For various reasons, a particular portion of the memory array may be defective. Hopefully, testing processes will identify those defects. As discussed above and illustrated in FIG. 7 a, a first defect 124 that may exist is a short to ground of the digit line D. FIG. 7 b illustrates the effect of the first defect 124 . During the precharge cycle, the CP signal is trying to charge the digit lines D and D* to the 2.5 volt DVC 2 level and maintain that level. However, if the resistance of the short is not too great, the first defect 124 may cause the digit lines to discharge toward ground faster than CP can charge them to 2.5 volts. As a result, once the precharge process has ended at time t 1 , the digit lines may be equilibrated at a potential lower than 2.5 volts, such as 1.7 volts. Having a Veq at a level other than DVC 2 makes the memory array susceptible to reading errors. For example, in the present situation illustrated in FIG. 7 b, where Veq is too low, line noise on D occurring at time t 2 is more likely to register as a logic 0 discharge when in fact the storage cell 150 contains a logic 1 and has not yet discharged. Alternatively, assuming that a logic 1 is properly discharged and sensed at time t 2 ′, a reading error is still likely: as seen in FIG. 7 c, Veq may be so low due to the short that the pullup sense amp may not be able to sufficiently pull up the digit line's voltage by the time t 3 , when external circuitry accesses line D. In order to find such a reading error, prior art requires an extended precharge time, up to time t 1 , in order to allow the discharge from the first defect 124 to overtake the charge from CP.
The current invention, however, provides an alternative to requiring a long precharge time. FIG. 7 a illustrates that the V CCP signal driving the bleeder device has been replaced with the test circuit 26 that applies a different voltage V REG to regulate the bleeder device. In the case of the first defect 124 , the test circuit 26 transmits a signal having a voltage lower than V CCP to drive the bleeder device 122 . This causes a slower charge rate and allows the discharge from the first defect 124 to quickly overtake the charging from CP, as seen by the dashed lines in FIGS. 7 b and 7 c. With the resulting increased disparity between the charge rate and the discharge rate, the precharge period need only endure until time t 1 ′ in order to increase the likelihood of detecting an error.
The design of test circuit 26 can be the same as those used in FIGS. 4 and 5 , wherein a source node 30 has access to at least one test voltage, either through a bond pad 36 or from a discrete voltage source. In this application, however, the source node 30 is coupled to the bleeder device 122 . Furthermore, V CCP is the voltage used in non-test operations to drive the bleeder device, and V CC and DVC 2 are used to slow the charge rate. It should be further understood that the number of voltage options could be increased. Alternatively, the number of voltage options could be decreased to offer only one test voltage and one non-test voltage.
These circuit embodiments, as well as others falling under the scope of the invention, have uses in detecting other defects. FIG. 8 a illustrates another defect 136 that might occur within a memory array. The cross-sectional view in FIG. 8 a shows the cell plate 138 coupled to a first n-region 140 of access transistor Q 4 . Ideally, the only way for the DVC 2 voltage generator 68 to charge the digit line D through the cell plate 138 is to drive the gate 142 of transistor Q 4 so that the charge may pass from the first n-region 140 to a second n-region 144 . From there, the charge travels through a tungsten plug 146 , which serves as a contact between the second n-region 144 and the digit line D. Occasionally, however, a second defect 136 in the memory array may occur in the form of a short between the cell plate 138 and the tungsten plug 146 . As discussed above, a long RAS low signal is used to detect this second defect 136 . Assuming line D is charged to 0 volts, FIG. 8 b shows that the long RAS signal allows line D to be charged to a higher voltage. Thus, when the low RAS signal ends at time t 1 and the digit lines are shorted to begin equilibration, the digit lines will no longer have an initial tendency to reach an average potential between 5 and 0 volts (2.5 volts). Rather, because line D is now higher than 0 volts, the shorted lines will settle at a higher midpoint, such as 3.5 volts. At this point, the margin between the new equilibrate voltage and the voltage representing a logic 1 has decreased. Thus, an erroneous reading is more likely, as discussed above.
Conversely, if line D is initially charged to V CC ( FIG. 8 c ), the short to the cell plate will cause D's voltage to lower during a long RAS low period. The resulting equilibrate voltage of lines D and D* could be lower than the preferred 2.5 volts. The lower equilibrate would again make an error in reading more likely. In either case, the CP signal will restore the equilibrate voltage to 2.5 volts by time t 2 . However, by decreasing the drive to the bleeder device 122 , any of the embodiments of the current invention will serve to slow down the restoration of Veq to DVC 2 . With restoration time extended to time t 2 ′, any circuit embodiment of the current invention increases the likelihood of detecting errors that would suggest the existence of the second defect 136 . Alternatively, FIG. 8 d shows that a circuit embodiment of the current invention could be used during a non-test mode to compensate for the second defect 136 by driving the isolation device 122 at a higher-than-normal level. As discussed above, the bleeder device 122 is normally driven at V CCP , a voltage level representing one or two V t 's above V CC . The potential V t , in turn is the threshold voltage of the bleeder device 122 . A further increase in the potential of V CCP would allow the bleeder device 122 to quickly restore Veq to 2.5 volts by time t 2 ″. The shorter restoration period reduces the chances of an erroneous reading.
FIG. 9 a demonstrates yet another instance wherein the current invention could shorten test time. This instance concerns a third defect 148 comprising a short that may be caused by a nitride defect within the storage capacitor 150 of a memory cell 22 . It should also be noted that one of the plates of the storage capacitor 150 is in fact the cell plate 138 or 64 and is therefore connected to the DVC 2 generator. Given this third defect 148 , FIG. 9 b indicates that the CP signal, having a potential of DVC 2 , will charge the storage capacitor 150 toward that potential even though a logic 0 has been written to that cell for test purposes. During a static refresh pause, the word line WL leading to the memory cell 22 will continuously transmit a low signal, which turns off access transistor Q 4 of the memory cell 22 and allows the storage capacitor 150 to take on a greater charge. With the stored charge having a higher voltage, such as 2 volts, it is more likely that the logic 0 will be misread at line D as a logic 1. In order to speed up the leakage into the storage capacitor 150 , DVC 2 is forced to a voltage higher than the normal 2.5 volts. Unfortunately, this would not result in much benefit under the prior art, as demonstrated by FIG. 9 c: because the CP signal has a voltage of DVC 2 and is in communication with D and D* during the static refresh pause, the CP signal would also charge lines D and D* to a higher voltage. With the circuit embodiments of the present invention, however, a lower voltage could be used to drive the bleeder device 122 and thereby slow the charging of the digit lines, as illustrated in FIG. 9 d. Thus, while D and D* are regulated to substantially remain at 2.5 volts despite the forced DVC 2 voltage, the storage capacitor may be quickly charged to a higher potential, such as 2.7 volts, which exceeds the equilibrate voltage and makes it very likely that a logic 1 will be mistakenly recognized.
One of ordinary skill can appreciate that, although specific embodiments of this invention have been described for purposes of illustration, various modifications can be made without departing from the spirit and scope of the invention. Concerning the invention as used with a sense amp, for example, a test circuit for the pullup sense amp could be configured to transmit an entire range of voltages through a contact pad, as done with the pulldown sense amp depicted in FIG. 4 . In addition, the test circuit 26 in FIG. 6 could be used with a pulldown sense amp. Conversely, the test circuit 26 in FIG. 5 could be used with a pullup sense amp. Moreover, both of these test circuits could be coupled to the same inverter and used to test drive either type of sense amp.
Further, regarding the embodiments use with a cell plate, it should be noted that the embodiments may be applied for other testing. Any circuit embodiment, for instance, may be used during the precharge cycle discussed above in order to detect a short between a row line and a column line. Moreover, a circuit embodiment of the current invention could also be used during a non-test mode to overcome other defects in addition to the short between a digit line and cell plate, as described above.
It should also be noted that, given a particular voltage source used in an embodiment, that source can be independent of V CC rather than a mere alteration of V CC , such as V CCP or DVC 2 . Accordingly, the invention is not limited except as stated in the claims. | As part of a memory array, a circuit is provided for altering the drive applied to an access transistor that regulates electrical communication within the memory array. In one embodiment, the circuit is used to alter the drive applied to a sense amp's voltage-pulling transistor, thereby allowing modification of the voltage-pulling rate for components of the sense amp. A sample of test data is written to the memory array and read several times at varying drive rates in order to determine the sense amp's ability to accommodate external circuitry. In another embodiment, the circuit is used to alter the drive applied to a bleeder device that regulates communication between the digit lines of the memory array and its cell plate. Slowing communication allows defects within the memory array to have a more pronounced effect and hence increases the chances of finding such defects during testing. The circuit is configured to accept and apply a plurality of voltages, either through a contact pad or from a series of discrete voltage sources coupled to the circuit. | 6 |
[0001] This application is a divisional of prior application Ser. No. 11/626,710, filed Jan. 24, 2007, currently pending;
[0000] Which was a divisional of prior application Ser. No. 10/962,950, filed Oct. 12, 2004, now U.S. Pat. No. 7,185,250, issued Feb. 27, 2007;
which was a divisional of prior application Ser. No. 10/172,568, filed Jun. 14, 2002, now U.S. Pat. No. 6,975,980, issued Dec. 13, 2005;
which was a divisional of prior application Ser. No. 09/252,573, filed Feb. 18, 1999, now U.S. Pat. No. 6,408,413, issued Jun. 18, 2002;
which claims priority from Provisional Application No. 60/075,035, filed Feb. 18, 1998.
FIELD OF THE INVENTION
[0002] The invention relates generally to evaluation of the functionality of electronic integrated circuits and, more particularly, to improvements in the control and design of test access ports (TAPs) within integrated circuits.
BACKGROUND OF THE INVENTION
[0003] The IEEE Standard Test Access Port and Boundary Scan Architecture (IEEE STD 1149.1) is a well known IEEE test standard that provides scan access to scan registers within integrated circuits (ICs), and is hereby incorporated herein by reference. FIG. 12 shows a schematic of the 1149.1 test logic. The test logic comprises a TAP controller 120 , an instruction register, and plural test data registers. The TAP controller is connected to test mode select (TMS), test clock (TCK), and test reset (TRST*) pins. The TAP controller responds to control input on TCK and TMS to scan data through either the instruction or data registers, via the test data input (TDI) and test data output (TDO) pins. TRST* is an optional pin used to reset or initialize the test logic, i.e. TAP controller, instruction register, and data registers. The inputs to the instruction and data registers are both directly connected to the TDI input pin. The output of the instruction and data registers are multiplexed to the TDO pin. During instruction register scans, the TAP controller causes the multiplexer 121 to output the instruction register on TDO. During data register scans, the TAP controller causes the multiplexer 121 to output the data register on TDO. The instruction scanned into the instruction register selects which one of the plural data registers will be scanned during a subsequent data register scan operation. When the TAP controller is scanning data through the instruction or data registers, it outputs control to enable the output stage to output data from the TDO pin, otherwise the TAP controller disables the output stage.
[0004] FIG. 13 shows how four ICs, each IC including the TAP controller, instruction register, and data registers of FIG. 12 , would be connected at the board level for serial data transfer (TDI, TDO) and parallel control (TMS, TCK).
[0005] FIG. 14 shows the state diagram operation of the FIG. 12 TAP controller. The TAP controller is clocked by TCK and responds to TMS input to transition between its states. The logic state of TMS is shown beside the paths connecting the states of FIG. 14 . The Test Logic Reset state is where the TAP controller goes to in response to a power up reset signal, a low on TRST*, or an appropriate TMS input sequence. From Test Logic Reset the TAP controller can transition to the Run Test/Idle state. From the Run Test/Idle state the TAP controller can transition to the Select DR Scan state. From the Select DR Scan state, the TAP controller can transition into a data register scan operation or to the Select IR scan state. If the transition is to the data register scan operation, the TAP controller transitions through a Capture DR state to load parallel data into a selected data register, then shifts the selected data register from TDI to TDO during the Shift DR state. The data register shift operation can be paused by transitioning to the Pause DR state via the Exit 1 DR state, and resumed by returning to the Shift DR state via the Exit 2 DR state. At the end of the data register shift operation, the TAP controller transitions through the Update DR state to update (output) new parallel data from the data register and thereby complete the data register scan operation. From the Update DR state, the TAP controller can transition to the Run Test/Idle state or to the Select DR Scan state.
[0006] If the Select IR Scan state is entered from the Select DR Scan state, the TAP controller can transition to the Test Logic Reset state or transition into an instruction register scan operation. If the transition is to an instruction register scan operation, Capture IR, Shift IR, optional Pause IR, and Update IR states are provided analogously to the states of the data register scan operation. Next state transitions from the Update IR state can be either the Run Test/Idle state or Select DR Scan state. If the TAP controller transitions from the Select IR Scan state into the Test Logic Reset state, the TAP controller will output a reset signal to reset or initialize the instruction and data registers.
[0007] FIG. 15 shows that state transitions of the FIG. 12 TAP controller occur on the rising edge of the TCK and that actions can occur on either the rising or falling edge of TCK while the TAP controller is in a given state.
[0008] The term TAP referred to hereafter will be understood to comprise a TAP controller, an instruction register, test data registers, and TDO multiplexing of the general type shown in FIG. 12 , but differing from FIG. 12 according to novel features of the present invention described with particularity herein. The 1149.1 standard was developed with the understanding that there would be only one TAP per IC. Today, ICs may contain multiple TAPs. The reason for this is that ICs are being designed using embedded megamodule cores which contain their Own TAPs. A megamodule is a complete circuit function, such as a DSP, that has its own TAP and can be used as a subcircuit within an IC or as a standalone IC. An IC that contains multiple megamodules therefore has multiple TAPs.
SUMMARY OF THE INVENTION
[0009] In example FIG. 1 , an IC 10 containing four TAPs is shown. TAP 1 is shown connected to the boundary scan register (BSR) to provide the 1149.1 standard's conventional board level interconnect test capability. TAP 1 can also be connected to other circuitry within the IC that exists outside the megamodules. TAP 2 is an integral part of megamodule MM 1 . Likewise TAP 3 and TAP 4 are integral parts of megamodules MM 2 and MM 3 . Each TAP of FIG. 1 includes a conventional 1149.1 TAP interface 11 for transfer of control (TMS, TCK and TRST) and data (TDI and TDO) signals. However, the 1149.1 standard is designed for only one TAP to be included inside an IC, and for the 1149.1 TAP interface of this one TAP to be accessible externally of the IC at terminals (or pins) of the IC for connection via 1149.1 test bus 13 to an external test controller.
[0010] It is therefore desirable to provide an architecture wherein all TAPs of an IC can be controlled and accessed from an external 1149.1 test bus via a single externally accessible 1149.1 TAP interface.
[0011] The present invention provides an architecture which permits plural TAPs to be selectively accessed and controlled from a single 1149.1 TAP interface. The invention further provides access to a single register via any selected one of a plurality of TAPs. The invention further provides a TAP controller whose state machine control can be selectively overridden by an externally generated override signal which drives the state machine synchronously to a desired state. The invention further provides a TAP instruction which is decodable to select an external data path. Also according to the invention, sequential access of TAPs from a single 1149.1 TAP interface permits test operations associated with different TAPs to timewise overlap each other. The invention further provides first and second TAPs, wherein the TAP controller of the second TAP assumes a predetermined state responsive to the TAP controller of the first TAP progressing through a predetermined sequence of states.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a test controller connected to an integrated circuit having multiple TAPs therein;
[0013] FIG. 2 illustrates an integrated circuit having multiple TAPs therein according to the present invention;
[0014] FIG. 3 illustrates the TAP Linking Module of FIG. 2 in greater detail;
[0015] FIG. 4 illustrates the TLM TAP Controller of FIG. 3 in greater detail;
[0016] FIG. 5 illustrates another exemplary integrated circuit having multiple TAPs therein according to the present invention;
[0017] FIG. 6 illustrates in greater detail the TAP Linking Module of FIG. 5 ;
[0018] FIG. 7 illustrates TAP 4 of FIGS. 2 and 5 in greater detail;
[0019] FIG. 8 illustrates multiplexing circuitry associated with the scan input of TAP 4 of FIG. 5 ;
[0020] FIG. 9 shows a state diagram associated with the TAP controller of FIG. 7 ;
[0021] FIG. 9A illustrates in more detail a portion of the TAP controller of FIG. 7 ;
[0022] FIGS. 10-11 are timing diagrams which illustrate examples of how the TAPs of FIGS. 2 and 5 can be synchronously linked to and unlinked from the test bus of FIGS. 2 and 5 ;
[0023] FIG. 12 illustrates the architecture of a conventional 1149.1 TAP;
[0024] FIG. 13 illustrates a plurality of integrated circuits connected in a conventional manner for 1149.1 testing;
[0025] FIG. 14 is a state diagram associated with the conventional TAP controller of FIG. 12 ;
[0026] FIG. 15 is a timing diagram which illustrates when state changes and other actions can occur in the conventional TAP architecture of FIG. 12 ;
[0027] FIG. 16 illustrates in greater detail a portion of prior art FIG. 12 ;
[0028] FIG. 16A illustrates conventional instructions associated with the architecture of FIG. 16 ;
[0029] FIG. 17 illustrates in greater detail a portion of TAP 4 from FIG. 7 ; and
[0030] FIG. 17A illustrates a set of instruction pairs associated with the architecture of FIG. 17 .
[0031] FIG. 18 is an electrical diagram, in block form, illustrating the use of embedded core circuitry in successive generation designs.
[0032] FIG. 19 is an electrical diagram, in block form, illustrating an integrated circuit arrangement with multiple test access ports (TAPs) controlled by a TAP linking module (TLM).
[0033] FIG. 20 is an electrical diagram, in block form, illustrating an integrated circuit arrangement in which hierarchical TAP access is enabled.
[0034] FIGS. 21 through 23 are electrical diagrams, in block form, illustrating the hierarchical arrangement of embedded cores with multiple TAPS, according to the preferred embodiment of the invention.
[0035] FIG. 24 is an electrical diagram, in block form, illustrating the placement and arrangement of scan cell circuitry for providing the hierarchical TAP access according to the preferred embodiment of the invention.
[0036] FIG. 25 is an electrical diagram, in schematic form, of a demultiplexer used in the circuitry of FIG. 24 according to the preferred embodiment of the invention.
[0037] FIG. 26 contains Table 1
DETAILED DESCRIPTION OF THE INVENTION
[0038] FIG. 2 shows an exemplary IC according to the invention, including a TAP Linking Module (TLM) 21 which is coupled to each TAP via select (SEL 1 - 4 ) and enable (EN 1 - 4 ) signals, and to an externally accessible 1149.1 interface 20 including TDI, TCK, TMS, TRST*, and TDO pins. The TAPs are connected to the TCK and TMS pins and to the Reset output from the TLM. The SEL 1 - 4 signals are outputs from the TAPs to the TLM, and the EN 1 - 4 signals are output from the TLM to the TAPs. Each TAP's select signal is output in response to a special instruction scanned into its instruction register. The instruction sets the select output from the TAP high, which causes the TLM to be selected as the data register scan path between the IC's TDI and TDO pins 26 and 27 . A conventional data register scan operation is used to capture data into and then shift data through the TLM from TDI to TDO. During such a TLM scan operation, the TLM Select output signal from TLM makes a connection from the TLM's TDO output 25 to the ICs TDO output 27 , via the multiplexer 3 SMUX. Also during a TLM scan operation, an Enable output from the currently enabled TAP (one of Enable 1 , 2 , 3 , 4 ) enables a TDO output buffer (in 3 SMUX via OR gate 29 . This is analogous to enabling the output stage in FIG. 12 . Following the TLM scan operation, TLM outputs EN 1 - 4 signals to the TAPs and TAPSEL 0 - 1 signals to the multiplexer 23 to establish a TAP link configuration. The data scanned into the TLM selects one of the four outputs EN 1 - 4 to be active to enable the corresponding one of the TAPs. Also the TAPSEL 0 - 1 and TLM-Select signals will cause the TDO of the enabled TAP (one of TDO 1 -TDO 4 ) to be connected to the IC's TDO pin 27 .
[0039] From this description it is seen that the TLM 21 operates to selectively enable one of the TAPs to be accessed via the IC's 1149.1 test pins. The circuit coupled to the enabled TAP (BSR, MM 1 , MM 2 , MM 3 ) can therefore be accessed directly from the 1149.1 test pins. A presently enabled TAP can select and scan the TLM 21 which in turn will select and enable another TAP. When another TAP is enabled, the previously enabled TAP is disabled and remains so until it is enabled again by the TLM. The EN 1 - 4 inputs to the TAPs can enable or disable the TAPs in many ways. For example, the EN 1 - 4 inputs could simply be used to gate TCK on and off. Alternatively and preferably, the EN 1 - 4 inputs could be included in the designs of the TAP controller state machines to keep the TAP in its Run-Test/Idle state when disabled. This preferred method of using the EN 1 - 4 signals is described below in connection with FIGS. 9 and 9A .
[0040] FIG. 3 shows one circuit example implementation of TLM 21 . The circuit comprises a TLM TAP controller 31 , a 2-bit shift register, decode logic, and a link update register. The TLM TAP controller 31 is always enabled to follow the test bus protocol on the TCK and TMS pins, i.e. the TLM TAP controller is always synchronized to the state of the 1149.1 test bus 13 connected to the TCK and TMS pins. However, the outputs of the TLM TAP controller (i.e. TLM-ShiftDR, TLM-ClockDR, TLM-UpdateDR, and TLM-Select) are only enabled during a data register scan operation and only if the select input (SEL 1 - 4 ) from the currently enabled TAP is high.
[0041] If the currently enabled TAP inputs a high select input at one of SEL 1 - 4 , the TLM TAP controller 31 will respond to TCK and TMS to output control on TLM-ShiftDR, TLM-ClockDR, and TLM-Select to capture and shift data through the 2-bit shift register, and then output TLM-UpdateDR control to update the decoded output from the shift register to the link update register. This capture, shift, and update operation is a well known TAP controller scan operation taught in IEEE STD 1149.1 and shown in FIGS. 5-1 and 5 - 7 thereof. During this scan operation, the TLM TAP controller outputs TLM-Select control to couple the TDO output of TLM 21 to the IC's TDO pin 27 , via the 3 SMUX of FIG. 2 . Also during the scan operation, the output of the 3 SMUX is activated by the enabled TAP (one of Enable 1 - 4 ) to output data on the IC's TDO pin 27 . The data from the link update register is output as EN 1 - 4 and TAPSEL 0 - 1 to enable the desired TAP and its TDO connection (one of TDO 1 - 4 ) to the IC's TDO pin 27 . The active one of enable signals EN 1 - 4 qualifies a corresponding one of select signals SEL 1 - 4 at one of AND gates 33 - 36 , whereby the corresponding one of SEL 1 - 4 can be input to the TLM TAP controller via the OR gate 37 . Select signals from disabled TAPs are gated off by the AND gates associated with the inactive ones of enable signals EN 1 - 4 . The decode from the 2-bit shift register allows each of TAP 1 , TAP 2 , TAP 3 , or TAP 4 to be individually selected, accessed, controlled and scanned from the 1149.1 pins at 20 .
[0042] Exemplary FIG. 4 shows a detail view of the TLM TAP controller 31 . The TLM TAP controller comprises the conventional 1149.1 TAP controller 120 of FIG. 12 and gating to enable or disable the TLM-Select, TLM-ClockDR, TLM-ShiftDR, and TLM-UpdateDR outputs of the TLM TAP controller. After power up reset, the 1149.1 TAP controller 120 is always synchronized to the state of the 1149.1 test bus. Note that the output signal 39 of the FIG. 3 AND gate 38 is connected to 1149.1 TAP controller 120 at input node 123 thereof where the TRST* signal would conventionally be connected (contrast FIG. 12 ). The 1149.1 TAP controller's conventional outputs are gated off by the OR gates 41 and 43 , and AND gates 45 and 47 so that the state of the TLM's shift register and link update register are not disturbed during data register scans occurring while the SEL input from OR gate 37 ( FIG. 3 ) is low. TLM-Select and TLM-ClockDR are high while SEL is low, and TLM-UpdateDR and TLM-ShiftDR are low while SEL is low. These output conditions match what the conventional 1149.1 TAP controller 120 would output on the analogous signal types (i.e. Select, ClockDR, ShiftDR, UpdateDR) when data register scans are not being performed. When the SEL input is high, the gated outputs from the TLM TAP controller follow the conventional 1149.1 TAP controller outputs. The Reset output from the TLM TAP controller is always enabled to output the conventional 1149.1 Reset signal to the TAPs within the IC. The TLM TAP controller can be viewed as the master TAP controller in the IC since it has reset authority over all other TAPs.
[0043] When the TLM TAP controller is reset (i.e. forced to the Test Logic Reset state of FIG. 14 ) by the power up reset circuit, or by activation of the TRST* pin, or by an appropriate TMS sequence, it outputs a Reset signal. Either the power-up reset circuit or the TRST* signal can drive the output 39 of AND gate 38 (see FIG. 3 ) low and thereby force the Test Logic Reset state. An appropriate sequence of logic 1's on TMS can also put the TLM TAP controller in the Test Logic Reset state (see FIG. 14 ). Internal to the TLM 21 , the Reset signal loads the link update register with EN 1 and appropriate TAPSEL 0 - 1 control (see FIG. 3 ) to enable and link TAP 1 between the TDI pin 26 and 3 SMUX (see FIG. 2 ). TLM Select is driven high when controller 31 is in the Test Logic Reset state because the Select output from the conventional 1149.1 TAP controller 120 goes high in the Test Logic Reset state. When TLM Select is high, the output of MUX 23 is connected to TDO pin 27 via 3 SMUX. By initially selecting TAP 1 to be active, the IC appears to test bus 13 to be operating as would a one-TAP IC described in the 1149.1 standard. Following the initial selection of TAP 1 , the TLM can be selected by TAP 1 and then scanned to select any other TAP in the IC to become the active TAP. External to the TLM 21 , the Reset signal initializes all the TAPs to the Test Logic Reset state of FIG. 14 .
[0044] FIG. 5 shows another example IC according to the invention, including a TAP Linking Module (TLM 51 ) which is coupled to TAPs, 1149.1 test pins, and multiplexers similarly to FIG. 2 . Additionally, the TLM 51 is coupled to the TAPs 2 - 4 via Link Control (LC 2 - 4 ) signals. The operation of TLM 51 is similar to TLM 21 of FIG. 2 , except: (1) the TLM 51 can be loaded with data to enable more than one TAP at a time in the IC; and (2) the TLM 51 outputs link control to the TAPs to allow linking the TAPs together in different arrangements within a single scan path between the TDI 26 and TDO 27 pins. The linking and enabling of multiple selected TAPs permits the circuits associated with the TAPs (BSR, MM 1 , MM 2 , MM 3 ) to be accessed at the same time.
[0045] In FIG. 5 it is seen that TAPs 2 - 4 have multiple scan inputs. In particular, the TAPs 2 - 4 have scan inputs as follows: TAP 2 has TDI pin 26 and TDO 1 ; TAP 3 has TDI pin 26 , TDO 1 and TDO 2 ; and TAP 4 has TDI pin 26 , TDO 1 , TDO 2 and TDO 3 . This is to allow for serially concatenating enabled TAPs together in different ways. For example TAP 1 and TAP 4 can be enabled at the same time and linked together into the serial path between TDI 26 and TDO 27 . In this arrangement, TAP 1 and TAP 4 can participate together during test while TAP 2 and TAP 3 are disabled. The Link Control signals LC 2 - 4 to TAPs 2 - 4 select the appropriate scan input to the TAPs to make a particular serial link between TAPs. TLM 51 can provide the following TAP linking arrangements between TDI 26 and TDO 27 :
[0046] TAP 1 Links. TAP 1 , TAP 1 & 2 , TAP 1 & 3 , TAP 1 & 4 , TAP 1 , 2 & 3 , TAP 1 , 2 ,& 4 , TAP 1 , 2 , 3 & 4 , TAP 1 , 3 & 4
[0047] TAP 2 Links: TAP 2 , TAP 2 & 3 , TAP 2 & 4 , TAP 2 , 3 & 4
[0048] TAP 3 Links: TAP 3 , TAP 3 & 4
[0049] TAP 4 Links: TAP 4
[0050] The more scan inputs per TAP, the more possible linking arrangements. For example, TAP 3 could also have TDO 4 as a scan input in addition to those shown in FIG. 5 . The multiplexing circuitry associated with the multiple scan inputs of the FIG. 5 TAPs is not shown in FIG. 5 for clarity, but an example is described below relative to FIG. 8 .
[0051] FIG. 6 shows one circuit example implementation of the TLM 51 . The TLM 51 is similar to the TLM 21 of FIG. 3 except: (1) the shift register is longer due to the additional decode required for linking multiple TAPs; (2) the decode circuit and link update register provide additional output for link controls LC 2 - 4 ; and (3) select inputs from all enabled and linked TAPs will be qualified by the corresponding active enable signals for input to the TLM TAP controller 31 via the AND and OR gates 33 - 37 .
[0052] Example FIG. 7 shows a portion of the design of TAP 4 of FIG. 2 . The other TAPs of FIG. 2 can be analogously designed. The TAP controller 71 includes an input for the EN 4 signal from the TLM 21 , which is used to enable or disable the TAP controller 71 . Also, TAP controller 71 has an input 73 connected to the Reset output from the TLM 21 to provide global reset of all TAPs. The TAP 4 instruction register decode includes the SEL 4 output to the TLM 21 . Also, an instruction is provided to allow setting the SEL 4 output high to enable scan access of the TLM 21 .
[0053] Example FIG. 8 shows TDI pin 26 , TDO 1 , TDO 2 and TDO 3 multiplexed onto the scan input of TAP 4 to support the design of FIG. 5 . The scan inputs of the other TAPs of FIG. 5 are multiplexed analogously. In this example, a 4:1 multiplexer 81 is connected to the TLM 51 via two link control signals LC 4 A and LC 4 B to control which scan input (TDI pin 26 , TDO 1 , TDO 2 , or TDO 3 ) is connected to the TAP's TDI input.
[0054] FIG. 9 shows an example TAP controller design to support enabling and disabling TAPs 1 - 4 of FIGS. 2 and 5 using the EN 1 - 4 outputs from either TLM 21 or TLM 51 . The TAP controller state diagram of FIG. 9 corresponds to the TAP controller 71 of FIG. 7 , and includes a Run Test/Idle state wherein the enable signal (in this case EN 4 ) is evaluated along with the TMS signal to determine the next state transition. In the Run Test/Idle state of FIG. 9 , the next state will always be the Run Test/Idle state if EN 4 is low, regardless of the logic level on TMS. If EN 4 is high, the next state from Run Test/Idle is determined by the logic level on TMS. In the UpdateDR state the EN 4 signal is evaluated along with the TMS signal to determine the next state transition. In the UpdateDR state of FIG. 9 , the next state will always be Run Test/Idle if EN 4 is low, regardless of the logic level on TMS. If EN 4 is high, the next state from UpdateDR is determined by the logic level on TMS. Although FIG. 9 illustrates an example state diagram for the TAP controller of TAP 4 , TAPs 1 - 3 can be analogously designed.
[0055] The Run Test/Idle state of FIG. 9 provides, in addition to its conventional run test or idle functions, a stable state for the TAP controller to assume and remain in when it is not enabled to be linked to the 1149.1 test bus pins. Using the Run Test/Idle state as the stable state for unlink is advantageous because one well known method of initialing test operations associated with a given instruction is to transition the TAP into Run Test/Idle with the given instruction in the instruction register. An example of this advantage of using Run Test/Idle as the stable state for unlink is described hereinbelow with respect to the RunBist instruction.
[0056] The UpdateDR state of FIG. 9 provides, in addition to its conventional data update function, a link change state where a presently enabled TAP controller gets disabled and goes to the Run Test/Idle state while a new TAP controller becomes enabled to follow the ICs test bus pins.
[0057] For example, in FIG. 2 and after a Reset, the TLM TAP controller 31 and all the TAP controllers of TAPs 1 - 4 will be in the Test Logic Reset state of FIG. 9 . The IC's 1149.1 test bus pins will also be in Test Logic Reset state as driven by the external test controller. When the test bus moves from Test Logic Reset to Run Test/Idle, all the TAP controllers of TAPs 1 - 4 will follow the test bus. However when the test bus moves from Run Test/Idle to Select DR Scan, only the TAP controller of TAP 1 (TAP 1 is enabled at reset to be the linked TAP as previously described) will follow. The other TAP controllers of TAPs 2 - 4 will remain in Run Test/Idle because their enable inputs EN 2 - 4 are low. TAP 1 will continue following the test bus until another TAP is enabled by scanning the TLM 21 . When the TLM 21 is scanned, the new enable and TAPSEL 0 , 1 control will be updated from the TLM 21 . For example if TAP 2 is the new TAP to be selected, the EN 1 for TAP 1 will go low and the EN 2 for TAP 2 will go high in the UpdateDR state. Also, the TAPSEL 0 , 1 outputs will change to output TDO 2 from multiplexer 23 . When the enable outputs from the TLM 21 change, the TAP controller of TAP 1 will see a low on EN 1 and it will be forced to transition from the UpdateDR state to the Run Test/Idle regardless of the logic level on TMS. When the TAP controller of TAP 2 sees a high on EN 2 , it will be enabled to either (1) transition from the Run Test/Idle state to the Select DR Scan state if TMS is high, or (2) remain in the Run Test/Idle state it TMS is low. So while a TAP being unlinked is forced to transition from the UpdateDR state to the Run Test/Idle state regardless of the logic level on TMS, a TAP being linked can either stay in the Run Test/Idle state if the next state of the test bus is the Run Test/Idle state (TMS=0), or transition to the Select DR Scan state if the next state of the rest bus is the Select DR Scan state (TMS=1).
[0058] FIG. 9A shows an example of how TAP controller 71 of FIG. 7 can use the EN 4 signal to realize the state diagram of FIG. 9 . The TAP state machine circuit 97 of FIG. 9A can be the conventional 1149.1 TAP state machine that implements the state diagram of FIG. 14 . However, the input 95 where TMS is conventionally applied to the state machine is connected in FIG. 9A to the output of a multiplexer 90 whose data inputs are TMS and the output 91 of an AND gate 93 whose inputs are TMS and EN 4 . The multiplexer 90 is controlled to select AND gate output 91 when the decoded state of the TAP state machine is Update DR or Run Test/Idle, and to otherwise select TMS.
[0059] Apart from the improvements associated with FIGS. 7-9A (and FIG. 17 below), TAPs 1 - 4 of FIGS. 2 and 5 can otherwise conform to the conventional 1149.1 TAP design of FIG. 12 . In fact, the TAP controller 71 of FIGS. 7-9A will operate as conventional 1149.1 TAP controller 120 of FIG. 12 if EN 4 is tied high. Note that input 73 of TAP controller 71 corresponds to the TRST* input of conventional TAP controller 120 (see FIG. 12 ).
[0060] The examples in FIGS. 10 and 11 illustrate two ways a TAP can be synchronously linked to the test bus 13 . The FIG. 10 example shows how a TAP is synchronously linked to the test bus 13 when the test bus transitions from UpdateDR to Run Test/Idle state. The FIG. 11 example shows how a TAP is synchronously linked to the test bus 13 when the test bus transitions from UpdateDR to Select DR Scan.
[0061] FIG. 10 shows a timing example wherein unlinked TAP 2 becomes linked and linked TAP 1 becomes unlinked while the test bus transitions from the UpdateDR state to the Run Test/Idle state to the Select DR Scan state. The link change occurs on the falling edge of the TCK in the UpdateDR state with EN 1 of TAP 1 going low and EN 2 of TAP 2 going high. On the next rising TCK edge, the test bus transitions into the Run Test/Idle state, TAP 1 (now unlinked) is forced to transition to Run Test/Idle (see FIG. 9 ), and TAP 2 (now linked) remains in Run Test/Idle (see FIG. 9 ). On the next rising TCK edge, the test bus transitions to the Select DR Scan state, TAP 2 transitions with the test bus to the Select DR Scan state, and TAP 1 remains in the Run Test/Idle state.
[0062] FIG. 11 shows a timing example wherein unlinked TAP 2 becomes linked and linked TAP 1 becomes unlinked while the test bus transitions from the UpdateDR state directly to the Select DR Scan state. The link change occurs on the falling edge of the TCK in the UpdateDR state with EN 1 of TAP 1 going low and EN 2 of TAP 2 going high. On the next rising TCK edge, the test bus transitions into the Select DR Scan state, TAP 1 is forced to transition to Run Test/Idle (see FIG. 9 ), and TAP 2 transitions with the test bus from Run Test/Idle to the Select DR Scan state (see FIG. 9 ). On the next rising TCK edge, the test bus transitions to the Select IR Scan state, TAP 2 transitions with the test bus to the Select IR Scan state, and TAP 1 remains in the Run Test/Idle state.
[0063] After completing all TAP accesses, the test bus can transition to the Test Logic Reset state. TAP(s) currently linked to the test bus will follow it into the Test Logic Reset state. TAP(s) not linked to the test bus (i.e. TAPs unlinked and left in Run Test/Idle state) will be forced to the Test Logic Reset state by the Reset output from the TLM TAP Controller 31 ( FIGS. 3 and 4 ) which always follows the test bus transitions and will output the Reset signal to all TAPs (see FIGS. 2-5 ) when the test bus enters the Test Logic Reset state.
[0064] To provide flexibility in using TLM 21 or TLM 51 to enable and disable TAPs within an IC, the TLMs should preferably be selectable during some or all of the instructions defined for each TAP. For example, the 1149.1 standard defines the following list of required and optional TAP instructions: Bypass, Extest, Sample/Preload, Intest, RunBist, Clamp, Highz, Idcode, and Usercode. During Bypass, Sample/Preload, Idcode, and Usercode instructions, the functional circuit associated with the TAP remains in its normal operation mode. During Extest, Intest, RunBist, Clamp, and Highz instructions, the functional circuit associated with the TAP is disabled from its normal operation mode. Users of the 1149.1 standard may define and add instructions to achieve customized test operations, such as internal scan, emulation, or on-line BIST.
[0065] The flexibility of using the TLMs is enhanced if each of the aforementioned conventional instructions is replaced by a pair of instructions according to the present invention, which pair of instructions determine whether or not the TLM is selected. For example, the conventional Extest instruction selects the boundary scan register to scan data between the IC's TDI and TDO pins, but does not at all comprehend the select output SEL 4 shown in FIG. 7 . Accordingly, one instruction of the Extest replacement pair would (1) select the boundary scan register like the conventional Extest instruction, (2) inactivate the SEL 4 output to deselect the TLM, and (3) otherwise affect the IC the same as the conventional Extest instruction. Another instruction of the Extest replacement pair would (1) deselect the boundary scan register, (2) activate SEL 4 to select TLM for scanning, and (3) otherwise affect the IC the same as the conventional Extest instruction.
[0066] One advantage is that TLM can be operated to disable one TAP and enable another while maintaining the effect of the current instruction on the functional circuit associated with the TAP being disabled. For example, in FIGS. 2 and 5 it may be desirable to disable the IC's I/O while performing a test or emulation operation on MM 1 . To do this, TAP 1 would be enabled and scanned with a Highz instruction version that selects the TLM and deselects the bypass register but otherwise affects the IC the same as the conventional Highz instruction, which will disable the IC's I/O. Next, a data register scan to the TLM disables scan access to TAP 1 and enables scan access to TAP 2 to enable the desired test or emulation operation on MM 1 . While test or emulation occurs on MM 1 , the Highz instruction version, left in effect in TAP 1 , keeps the IC's I/O disabled. Other 1149.1 instructions or user defined instructions can be similarly replaced by a first instruction that deselects TLM and selects a data register within the TAP and a second instruction that deselects the TAP data register and selects the external TLM, both replacement instructions otherwise affecting the IC the same as the corresponding conventional instruction.
[0067] Example FIGS. 16-17A illustrate the above-described replacement of a given conventional instruction with a pair of replacement instructions which select or deselect TLM. FIG. 16 illustrates various functions which are controlled by the instruction register in the conventional IEEE STD 1149.1 architecture of FIG. 12 . In FIG. 16 , an instruction is shifted into the shift register 162 , and shift register bits SRB 3 , SRB 2 , and SRB 1 (i.e. the instruction) are then decoded by decode logic 165 . The output of the decode logic is loaded into an update register 167 whose outputs control various functions in the test architecture. In the FIG. 16 example, six signals are output from the update register to control the various functions. Signal BR enables the bypass register to scan data therethrough, signal BSR enables the boundary scan register (BSR) to scan data therethrough, the MODE signal applied to BSR determines whether BSR is in a test mode for handling test data or a transparent mode for passing normal functional signals therethrough, the HIGHZ signal can disable the output buffers 163 of the integrated circuit or core megamodule, the BENA signal is a Bist enable signal for enabling Bist operations, and the REGSEL signal controls multiplexer 161 to determine which data register (in this example the bypass register or BSR) will be connected to the input of multiplexer 121 , which in turn determines whether a data register or the instruction register will be scanned.
[0068] FIG. 16A shows conventional instructions for use with the conventional architecture of FIG. 16 . Each of the instructions is decoded to produce the indicated logic levels on the six control signals of FIG. 16 . For example, the HighZ instruction enables the bypass register for scanning (BR=1) disables BSR for scanning (signal BSR=0), places BSR in the transparent mode (MODE=0), disables the output buffers 163 (HIGHZ=1), disables Bist (BENA=0), and selects the bypass register at multiplexer 161 (REGSEL=0). As another example, the conventional Extest instruction disables the bypass register for scanning (BR=0), enables BSR for scanning (signal BSR=1), places BSR in the test mode (MODE=1), enables the output buffers 163 (HIGHZ=0), disables Bist (BENA=0), and selects BSR at multiplexer 161 (REGSEL=1).
[0069] Exemplary FIG. 17 illustrates in more detail the instruction register control within TAP 4 of FIG. 7 according to the present invention. The remaining TAPs 1 - 3 can be designed analogously. The update register 175 of FIG. 17 outputs the six control signals of FIG. 16 plus the signal SEL 4 to select TLM. The shift register 171 of FIG. 17 has an additional shift register bit SRB 4 because the six example instructions from FIG. 16A require twelve replacement instructions according to the present invention as shown in FIG. 17A . The additional bit SRB 4 is thus needed to uniquely encode the twelve instructions of FIG. 17A .
[0070] Referring to FIG. 17A the replacement pair for the conventional HighZ instruction is seen at the third and ninth entries of the table of FIG. 17A . More specifically, the HighZ instruction with TLM not selected is decoded at 173 (see FIG. 17 ) to output the same logic levels as the conventional HighZ instruction and additionally to output a logic 0 on the SEL 4 output in order to ensure that TLM is not selected. The decoded output of the HighZ instruction with TLM selected is the same as the decoded output of the HighZ instruction with TLM not selected, except BR=0 and SEL 4 =1 to ensure that TLM is selected and the bypass register is deselected. Similarly, the decoded output of the Extest instruction with TLM not selected includes the same six logic levels as the conventional Extest instruction, plus a logic 0 on SEL 4 to ensure that TLM is not selected. The decoded output of the Extest instruction with TLM selected is the same as the decoded output of Extest with TLM not selected, except the BSR signal is at logic 0 to deselect BSR, and SEL 4 =1 to select TLM. Thus, the above-described instruction pairs and the other instruction pairs shown in FIG. 17A permit selection of either TLM or an internal data register (such as the bypass register or BSR) for scanning, but both instructions of each instruction pair otherwise provide the identical control signals provided by the corresponding conventional instructions illustrated in FIG. 16A . Thus, the instruction pairs of FIG. 17A permit TAP 4 to select for scanning either the external data path in TLM, or an internal data register such as the bypass register or BSR, while otherwise outputting control signals which are identical to those associated with the corresponding conventional instructions of FIG. 16A .
[0071] Execution of RunBist operations is improved by using the RunBist replacement instructions. The conventional RunBist instruction initiates a Bist (Built-In-Self-Test) operation when the TAP enters Run Test/Idle, but the conventional RunBist instruction selects a data register inside the TAP (boundary scan register in FIGS. 16-17 ) for scanning A first TAP can be enabled and scanned with the replacement RunBist instruction that selects the TLM and deselects the boundary scan register. After scanning the TLM to enable a second TAP, the first TAP gets disabled and automatically transitions into the Run Test/Idle state ( FIGS. 9-11 ) where the replacement RunBist instruction takes effect to initiate the Bist operation. While the first TAP is executing the Bist operation in Run Test/Idle, the second TAP can be scanned with the aforementioned replacement RunBist instruction that selects the TLM and deselects the boundary scan register. Scanning the TLM to enable a third TAP will force the second TAP to the Run Test/Idle state where the replacement RunBist instruction takes effect to initiate a Bist operation. This scheme can continue to sequentially select TAPs and initiate Bist testing in as many TAPs as desired. Thus, BIST operations in the selected megamodules can occur in time overlapping fashion rather than purely sequentially. This of course provides time savings.
[0072] To obtain the Bist result from BSR of FIG. 17 , TAP 4 can be enabled via TLM, and then loaded with the replacement RunBist instruction that deselects TLM and selects BSR. With BSR selected, the Bist result can be scanned out of BSR by a data register scan operation.
[0073] The architecture of FIG. 5 can also execute the above procedure to initiate multiple RunBist operations, or it could simply enable/link all or selected ones of the TAPs together, scan in a conventional RunBist instruction to each, then enter Run Test/Idle to concurrently execute the RunBist instructions. After linking a first group of TAPs together in FIG. 5 , each of them can be loaded with the replacement RunBist instruction that selects TLM 51 , and thereafter the first group can be unlinked via TLM 51 so the first group can execute Bist operations in Run Test/Idle while TLM 51 is linking a second group of TAPs to repeat the same procedure. So while the FIG. 2 architecture allows for enabling a TAP, loading RunBist, and then disabling the TAP to effect Bist operations in a megamodule, the FIG. 5 architecture allows enabling/linking a group of TAPs, loading RunBist, and then disabling/unlinking the group of TAPs to effect concurrent Bist operations in a group of megamodules. The capability of sequentially selecting groups of TAPs so that each group performs Bist operations concurrently within the group and in time-overlapping fashion relative to other groups provides additional flexibility to choose the most time-efficient approach for a given IC's megamodule layout.
[0074] Although providing a replacement instruction pair for each instruction will allow for leaving any instruction in effect after a TAP has been disabled, a single instruction can be defined to select the TLM if desired. When using a single TLM select instruction, the TAP cannot maintain the effect of a specific instruction on the IC when the TLM is accessed.
[0075] The TAP linking approach described herein could be accomplished on a substrate (e.g. multichip module or board) comprising individual circuits (e.g. die or IC), each having a TAP with externally accessible select and enable signals corresponding to SEL 1 - 4 and EN 1 - 4 . Also required on the substrate would be a TLM circuit (e.g. die or IC). Further, to support the plural TAP linking scheme of FIG. 5 , multiplexer circuits (e.g. die or IC) would be required on the TDI inputs of some or all of the TAP'ed circuits.
[0076] FIG. 18 shows an integrated circuit (IC) being designed from a library of first generation cores. The library contains circuit cores of many types such as DSPs, CPUs, Memories, I/O peripherals, A/D's, D/A's, etc. The first generation cores in the library can be selected and placed in the IC. The IC will serve as an application in a larger electronic system. In this example, each of the first generation cores is assumed to contain an 1149.1 TAP for test/emulation access. The IC contains a TLM, which has been previously described hereinabove, to provide access to one of more of the TAP'ed cores in the IC to facilitate test and emulation of the cores and IC. The use of pre-existing cores from the library allows highly complex IC applications to be designed quickly due to the reuse of the first generation core functions contained within the library.
[0077] If the IC application of FIG. 18 is popular, it may evolve into a second generation core as shown by the dotted line feeding into the larger library to allow its reuse within another IC. When the IC becomes a core, its TLM based test architecture will be maintained to enable reuse of the IC's test and emulation mechanisms at the core level. Further seen in FIG. 18 is the creation of an even more complex IC application which uses both first and second generation cores from the larger library. The IC also includes a TLM to provide access to the TAP'ed and TLM'ed cores. Additionally, it is seen that the more complex IC application may evolve into a third generation core which will go into an even larger core library.
[0078] What FIG. 18 indicates is a trend of how ICs designed from cores, will themselves become cores for use in larger, more complex ICs. This continuing generation of larger, more complex cores will put an increasing burden on test and emulation at the IC level. The TLM invention described hereinabove addresses test and emulation access of ICs designed from first generation cores, i.e. TAP'ed cores. The following description illustrates how the TLM described hereinabove can also provide hierarchical test and emulation access to second, third, and further core generations used inside an IC.
[0079] FIG. 19 shows an IC 190 with a TLM architecture including TAP domains 1 - 4 (as described previously in regard to FIG. 2 ). The term domain is used to indicate circuit regions within the IC where the TAPs provide test and/or emulation access and control. For example, TAP 1 provides control and access of circuitry within the IC domain, such as the IC's boundary scan register, test data registers, and built in self test circuitry (BIST), as described in IEEE standard 1149.1. TAP 2 provides control and access of circuitry within the MM 1 core domain. Similarly, TAPs 3 and 4 provide control and access of circuitry within the MM 2 and MM 3 core domains, respectively. The TAP accessible circuitry within each core domain can include; the core's boundary scan register, test data registers, and BIST circuitry, again as described in IEEE standard 1149.1. Further, all TAPs 1 - 4 may provide control and access of additional circuitry within each of their respective domains which is not described or anticipated by IEEE standard 1149.1. For example, a domain may contain emulation circuitry which is accessible via a TAP. According to the TAP connectivity arrangement made possible by the TLM of FIG. 19 , emulation circuitry residing within a given TAP domain may accessed and operated independently of emulation circuitry within other TAP domains, or in cooperation with emulation circuitry residing within other TAP domains.
[0080] For simplification, the TLM block of FIG. 19 has been expanded to include the TAP Linking Module, multiplexers and wiring interconnect of FIG. 2 . Also for simplification, the TCK, TMS, and TRST test bus signals of FIG. 2 are not shown in FIG. 19 . The operation of the TLM of FIG. 19 is otherwise the same as previously described in regard to FIG. 2 . That being that at power up, TAP 1 (the ICs BSR TAP) is enabled by the TLM while the other TAPs 2 - 4 (of cores MM 1 - 3 ) are disabled by the TLM. Following powerup, TAP 1 can select any other TAP to become the enabled TAP, and that TAP can likewise select another TAP to be enabled, and so on. If the IC of FIG. 19 will become a core, then the TLM is modified as follows to allow it to be used hierarchically inside an IC to control and access circuitry within its domain.
[0081] The changes to the IC 190 TLM architecture in FIG. 19 to produce the core 200 hierarchical TLM (HTLM) architecture of FIG. 20 includes; (1) TAP 1 is expanded to include an additional select output (S) 201 that passes through the HTLM as an external core output, (2) an external enable (E) 202 core input is added and input to the HTLM, and (3) an AND gate (&) 203 is added to the HTLM. The AND gate is inserted into the EN 1 signal path between the TAP Linking Module and TAP 1 of FIG. 2 . The AND gate receives as input the EN 1 signal from the Link Update Register of FIG. 3 and the enable input 202 of FIG. 20 . The AND gate output 204 is input to the enable input (E 1 ) of TAP 1 . The TAP 1 enable input E 1 is the same as the TAP 1 EN 1 input previously shown in FIG. 2 , with the exception that it now comes from the output of AND gate 203 , instead of directly from the EN 1 output of the Link Update Register of FIG. 3 .
[0082] At power up, the EN 1 signal from the Link Update Register is set high to enable TAP 1 , as previously described in regard to FIG. 2 . However in FIG. 20 it is seen that if enable 202 is low, TAP 1 will not be enabled since the enable 204 input to TAP 1 is gated low by enable 202 . So enable 202 provides an externally accessible input which can disable (if low) or enable (if high) TAP 1 . When using HTLM'ed cores within an IC, the ability to control the HTLM's externally accessible enable 202 input is key to providing hierarchical test and emulation access to HTLM'ed cores. For example, if the HTLM of core 200 is enabled (by enable input 202 ) it provides test and/or emulation access to its TAP circuit domains, as previously described in regard to FIG. 2 . When access of the HTLM's TAP circuit domains is complete, TAP 1 is selected as the enabled TAP. Scanning an instruction into TAP 1 can set the select signal 201 high to select scan access to an HTLM external to core 200 . Scanning data into the external HTLM can set the enable signal input 202 of FIG. 20 low which disables the internal HTLM of FIG. 20 , as described above.
[0083] The instruction scanned into TAP 1 to set the external select output 201 high must also set the internal select output 205 low, so that during the data scan operation, the internal HTLM of FIG. 20 will not be scanned while the external HTLM is being scanned. Likewise, instructions scanned into TAP 1 to set the internal select 205 output high to access the internal HTLM must also set the external select 201 low so that the external HTLM is not scanned during data scans to the internal HTLM.
[0084] FIGS. 21 through 23 illustrate the hierarchical access of HTLM'ed cores within ICs or cores using the additional externally accessible select and enable signals described above. FIG. 21 illustrates the IC or core design 200 of FIG. 20 . In the IC case, the externally accessible select (S) and enable (E) signals are not required to be pinned out, while they could be if the IC user desired their capabilities at the board or MCM level. If not pinned out, the enable signal (E) is wired or pulled high to force the HTLM to always be enabled, and the select signal (S) is not connected. In this case the HTLM operates as would the previously described TLM.
[0085] FIG. 22 illustrates a case where three copies of the FIG. 21 HTLM'ed core design 200 are used inside another IC or Core design 220 . In FIG. 22 , the select and enable signals of each HTLM core design 200 are shown connected to the HTLM of the IC or core design 220 . In this arrangement, the previously described method of accessing the core's HTLM by an external HTLM, using the select and enable signals, is made more clear. Again, if the FIG. 22 circuit is used as an IC, the externally accessible select signal is not connected and the enable signal is wired or pulled high. FIG. 23 illustrates a case where three copies of the FIG. 22 HTLM'ed core design 220 are used inside another IC or core design 230 . In FIG. 23 , the select and enable signals of the FIG. 22 HTLM's are shown connected to the HTLM of the IC or core design 230 .
[0086] It is clear from FIGS. 21 through 23 that the HTLM can be reused over and over again without modifying its basic interface to provide hierarchical test and emulation access to cores deeply embedded within ICs or cores. It is seen, in IC design 230 of FIG. 23 , that at power up, HTLM 302 enables TAP 1 301 and disables the three HTLM'ed cores. This allows access to the IC's boundary scan register upon power up, as required by IEEE standard 1149.1. Access to the HTLMs occurs as previously mentioned, wherein TAP 1 selects HTLM 302 for scanning to disable TAP 1 301 and enable an HTLM.
[0087] The following example is given to illustrate the hierarchical access steps that can be used to allow HTLM 302 of the IC of FIG. 23 to access the embedded core TAP 4 307 of FIG. 21 . At power up, TAP 1 301 of the IC of FIG. 23 is enabled (IC's enable (E) wired or pulled high as mentioned above). TAP 1 301 can be scanned with an instruction that selects, via SEL 1 240 , HTLM 302 for scanning Scanning data into HTLM 302 enables the core HTLM 303 domain, via E 241 , and disables TAP 1 301 , via E 1 242 . Enabling the core HTLM 303 domain enables TAP 1 304 , via E 1 243 . Scanning an instruction into TAP 1 304 selects, via SEL 1 244 , HTLM 303 for scanning Scanning data into HTLM 303 enables the core HTLM 305 domain, via E 202 , and disables TAP 1 304 , via E 1 243 . Enabling the core HTLM 305 domain enables TAP 1 306 , via E 1 204 . Scanning an instruction into TAP 1 306 selects HTLM 305 for scanning, via SEL 1 205 . Scanning data into HTLM 305 enables the core TAP 4 307 domain, via EN 4 246 , and disables TAP 1 306 , via E 1 204 . Following these steps, a hierarchical connection is formed such that the circuits within the TAP 4 307 domain can be accessed and controlled for test and/or emulation operations directly from the test interface of the IC 230 of FIG. 23 .
[0088] After all test and emulation access has been performed on circuits existing within the TAP 4 307 domain, an instruction can be scanned into TAP 4 307 to select HTLM 305 for scanning, via SEL 4 247 . Scanning data into HTLM 305 enables TAP 1 306 , via E 1 204 , and disables HTLM 307 , via EN 4 246 . Scanning an instruction into TAP 1 306 selects HTLM 303 for scanning, via S 201 . Scanning data into HTLM 303 enables TAP 1 304 , via E 1 243 and disables HTLM 305 , via E 202 . Scanning an instruction into TAP 1 304 selects HTLM 302 for scanning via S 248 . Scanning data into HTLM 302 enables TAP 1 301 , via E 1 242 , and disables HTLM 303 , via E 241 .
[0089] This example has demonstrated the ability to extend test access from HTLM 302 of the FIG. 231C up into the TAP 4 307 domain, execute test or emulation operations on circuits existing within the TAP 4 307 domain, then retract test access from the TAP 4 307 domain back down to the HTLM 302 of the FIG. 231C . The ability to hierarchically extend and retract test access in this manner provides a standard way to provide test and emulation operations on circuits/cores independently of how deeply they may be embedded within a complex IC or core design. The approach uses conventional 1149.1 instruction and data scan operations to achieve this hierarchical access methodology. ICs and cores designed with HTLM interfaces can therefore be reused efficiently. Additionally, since a direct test access mechanism is provided via the HTLMs, embedded cores that. evolved from ICs can reuse the test and emulation schemes and pattern sets previously developed and used for the ICs.
[0090] FIG. 24 illustrates an example of how the TAP of FIG. 7 can be modified to support the additional select output 201 of FIG. 20 without having to add instructions to the instruction register. The modifications include adding a scan cell 350 in series with the instruction register, but not the data registers, and inserting a demultiplexer 352 in the SEL signal path from the instruction register. Also, the TAP of FIG. 24 represents the TAP 1 of FIG. 20 , so SEL 4 output of FIG. 7 is renamed in FIG. 24 to be SEL 1 of FIG. 20 and the EN 4 input of FIG. 7 is renamed in FIG. 24 to be E 1 of FIG. 20 . The scan cell 350 is connected to the instruction scan control that operates the instruction register. In response to the instruction scan control, the scan cell 350 captures data when the instruction register captures data, shifts data when the instruction register shifts data, and updates and outputs data when the instruction register updates and outputs data. When data is being shifted through scan cell 350 , its output 351 remains unchanged until after the shift operation is complete and the update operation occurs. An example of the instruction register is shown in FIG. 17 . In reference to FIGS. 17 and 24 it is seen that the scan cell 350 output is not input to the decode logic of the instruction register. Therefore, scan cell 350 does not modify the decoded instructions contained within the instruction register.
[0091] FIG. 25 illustrates an example circuit for implementing demultiplexer 352 of FIG. 24 . The circuit has an input for receiving the SEL output from the instruction register, an input for receiving the address (A) output 351 from scan cell 350 , an output for providing the internal HTLM select output 205 (SEL 1 ) of FIG. 20 , and an output for providing the external HTLM select output 201 (S) of FIG. 20 . When the address input 351 is low, SEL 1 is driven by the state of SEL, while S is driven low. When the address input 351 is high, S is driven by the state of SEL, while SEL 1 is driven low. This circuit in combination with scan cell 350 allows either the internal or external HTLM to be selected for scanning, but never both at the same time. Also this circuit in combination with scan cell 350 allows the instruction used to set SEL high to be used for selecting either the internal or external HTLM.
[0092] Previous description regarding the operation and need for replacement instructions has been given in regard to FIGS. 17 and 17A . For example, in FIG. 17A a normal HighZ instruction produces an effect and selects the bypass register for scanning, while a replacement HighZ instruction produces the same effect but selects the TLM for scanning. Using the present invention as shown in FIG. 24 , a normal HighZ instruction continues to produce an effect and select the bypass register for scanning, while a replacement HighZ instruction can produce the same effect but, by the data value loaded into scan cell 350 , also selects either the internal HTLM for scanning via SEL 1 , or the external HTLM for scanning via S. Thus the same replacement instruction previously described is made reusable by scan cell 350 and demultiplexer 352 for either selecting the internal or external HTLM. Since the existing replacement instruction is reusable for accessing either the internal or external HTLM, no additional instruction is required for selecting the external HTLM.
[0093] Table 1 illustrates an example of how the HighZ, Clamp, and RunBist replacement instructions, previously described in regard to FIGS. 17 and 17A , can be reused for accessing either the internal HTLM or external HTLM. In Table 1, the address (A) column indicates the data bit value shifted into scan cell 350 , the instruction column indicates the data bit values shifted into the instruction shift register of FIG. 17 , and the SEL column indicates the value of the SEL output from the instruction register of FIG. 17 .
[0094] In the first row, A=X, instruction=0010, and SEL=0 and the instruction is a normal HighZ instruction with no HTLM selected. In the first row, notice that since the SEL 1 and S outputs of demultiplexer 352 are low when SEL is low, A can be a don't care value. In the second row, A=0, instruction=1010, and the instruction is a replacement HighZ instruction with the internal HTLM selected. In the third row, A=1, instruction=1010, and the instruction is a replacement HighZ instruction with the external HTLM selected. By inspection it is seen that if A=0, the replacement HighZ instruction 1010 is used to access the internal HTLM, and if A=1, the replacement HighZ instruction 1010 is used to access the external HTLM. Thus the 1010 HighZ replacement instruction code is reused for accessing either the internal or external HTLM, as determined by the value of the data bit shifted into scan cell 350 . The other two example instructions illustrate how the Clamp and RunBist replacement instruction codes, 1011 and 1100 respectively, are similarly made reusable by the value of the data bit shifted into scan cell 350 .
[0095] This instruction reuse approach provides a way to upgrade TAP 1 to support access to external HTLMs without having to modify the design of TAP l's instruction register. However, the present invention is not dependent upon this instruction reuse approach and it should be clearly understood that the instruction register may be redesigned to include additional instructions for accessing external HTLMs instead of using the instruction reuse approach described above.
[0096] While a single scan cell 350 is used in FIG. 24 to allow demultiplexing the SEL output into two output signals, SEL 1 and S, additional scan cells could be added in series with the instruction register and connected to a larger output demultiplexer to allow increasing the number of output signals. For example, two scan cells and a 1 to 4 demultiplexer would allow the SEL output to be connected to four outputs.
[0097] Some microprocessor and digital signal processor ICs utilize the 1149.1 TAP for performing scan based emulation and debug. During emulation and debug, serial data is communicated to the processor via the TAP pins. The data communicated to the processor can be used to establish various emulation and debug modes, breakpoint conditions, and non-intrusive system observation functions (for example, as described in “Pentium Pro Processor Design for Test and Debug”, Paper 12.3, 1997 IEEE International Test Conference Proceedings). As these ICs evolve into cores, it is important to maintain access to their TAPs so that emulation and debug can continue to be performed, even when the core is embedded deeply within an IC. The ability of the present invention to provide hierarchical connectivity between the IC pins and the TAPs of embedded cores provides for continued use of scan based emulation and debug.
[0098] Using the previous example described in regard to FIGS. 21 through 23 , it is clear that TAP 307 of FIG. 21 can be hierarchically connected to the test pins (TDI, TMS, TCK, TRST, and TDO) of the IC in FIG. 23 . TAP 307 could be part of a processor core that evolved from an IC. Further, the processor core could have reusable IC emulation and debug features available via TAP 307 . Further still, potentially many more TAP'ed cored embedded within the IC of FIG. 23 may have emulation and debug features available via their TAPs. The hierarchical connectivity of the present invention can be used advantageously to provide direct access between the IC test bus pins and core TAPs to enable scan-based emulation and debug features to be performed on embedded cores within an IC.
[0099] Although exemplary embodiments of the present invention are described above, this description does not limit the scope of the invention, which can be practiced in a variety of embodiments. | An integrated circuit can have plural core circuits, each having a test access port that is defined in IEEE standard 1149.1. Access to and control of these ports is though a test linking module. The test access ports on an integrated circuit can be arranged in a hierarchy with one test linking module controlling access to plural secondary test linking modules and test access ports. Each secondary test linking module in turn can also control access to tertiary test linking modules and test access ports. The test linking modules can also be used for emulation. | 6 |
FIELD OF THE INVENTION
The present invention relates to integrated circuits (ICs); more particularly, the present invention relates to the carrying and handling of ICs.
BACKGROUND
Pin grid arrays (PGAs) are integrated circuit packages that have pins arrayed in a series of square-within-square grids at the bottom. The square-pin design enables a computer hardware technician to smoothly plug the PGA into an associated socket on a computer system motherboard using little to no force.
Prior to a PGA being inserted into a socket for operation, PGAs are carried in a plastic tray with pocketed cavities. However, packing PGAs in such a tray during transportation and handling typically results in many of the pins at the bottom of the PGA being bent or broken, thus, ruining a particular PGA. PGAs are expensive, thus, being susceptible to pin bending or breakage often leads to higher manufacturing costs for replacements. In addition, bent PGAs may lead to the damage of sockets on a computer system motherboard on which a PGA is placed during operation.
Therefore, a PGA carrying mechanism is desired.
SUMMARY
According to one embodiment, an apparatus is disclosed. The apparatus comprises an integrated circuit (IC) having a plurality of connection pins, carrier socket configured to carry the IC. The carrier socket protects the pins of the IC from bending. In addition, the carrier socket straightens pins that have been bent prior to placing the IC into the carrier socket.
According to a further embodiment, the carrier socket includes a holder that secures the IC and a housing that secures the holder and the IC. The holder includes a plurality of tines to hold the plurality of pins of the IC. The tines are tapered to straighten one or more bent pins. Further, the housing includes a plurality of tapered holes to guide the tines and the pins into the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the invention. The drawings, however, should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding only.
FIG. 1 illustrates a top view of one embodiment of an integrated circuit (IC) mounted within an IC carrier socket;
FIG. 2 illustrates a side view of one embodiment of an IC mounted within a carrier socket;
FIG. 3 illustrates a detailed side view of one embodiment of an IC mounted within a carrier socket;
FIG. 4 illustrates another detailed side view of one embodiment of an IC mounted within a carrier socket;
FIG. 5 illustrates an exploded view of one embodiment of an IC with a carrier socket;
FIG. 6 illustrates one embodiment of a holder;
FIG. 7 illustrates an exploded view of one embodiment of an IC a holder and a housing; and
FIG. 8 illustrates another exploded view of one embodiment of an IC a holder and a housing.
DETAILED DESCRIPTION
An integrated circuit (IC) carrier socket is described. In the following description, numerous details are set forth. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present invention.
Reference in the 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 invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
FIG. 1 illustrates a top view of one embodiment of an IC 1 mounted within an IC carrier socket. According to one embodiment, the IC 1 is a micro-pin grid array (micro-PGA). In a further embodiment, IC 1 includes 959 pins arrayed in a series of square grids. In another embodiment, IC 1 may be implemented as a PGA, or other type of microprocessor or integrated circuit. However, one of ordinary skill in the art will appreciate that IC 1 may be implemented in other forms without departing from the true scope of the invention.
The IC carrier socket includes a holder 2 and a housing 3 . According to one embodiment, holder 2 and housing 3 protect against pins of IC 1 bending during handling and transport. FIG. 2 illustrates a side view of one embodiment of IC 1 mounted within holder 2 , which is in turn mounted within housing 3 . In one embodiment, the holder 2 and housing 3 assembly accommodates various types of pin diameters and lengths for IC 1 .
FIG. 3 illustrates a detailed side view of one embodiment of IC 1 mounted within holder 2 and housing 3 . In particular, FIG. 3 shows a holder 2 and a housing 3 interlocking mechanism. According to one embodiment, holder 2 includes one or more latches 7 at each end of holder 2 , while housing 3 includes latches 8 .
Upon inserting the IC 1 , holder 2 assembly into housing 3 , latch 8 of housing 3 interlocks with a latch 7 on holder 2 to hold IC 1 , holder 2 and housing 3 together. In a further embodiment, the interlocking mechanism provides for variable sizes of ICs 1 to be placed in housing 3 . For example, the larger the IC 1 , a lower latch 7 on holder 2 is used to engaged with latch 8 .
FIG. 4 illustrates another detailed side view of one embodiment of IC 1 mounted within holder 2 and housing 3 . FIG. 4 shows housing 3 having tabs 9 on each side that releases the holder 2 , housing 3 interlocking mechanism. For instance, a user may depress tabs 9 at each side of housing 3 with the thumbs to release the IC 1 , holder 2 combination. As a result, each latch 8 releases the interconnected latch 7 .
In addition, FIG. 4 shows holder 2 having tines 5 that hold pins 4 of IC 1 . FIG. 8 illustrates a reverse angle of IC 1 mounted in one embodiment of holder 2 . Thus, FIG. 6 provides greater detail of pins 4 secured within tines 5 . According to one embodiment, tines 5 are constructed of a flexible plastic material that is tapered to firmly grip pins 4 .
In a further embodiment, tines 5 are tapered to enable the straightening of pins 4 if one or more pins 4 are bent. Referring back to FIG. 4 , housing 3 includes holes 6 that are tapered to guide the pins 4 , tines 5 combination into housing 3 . FIG. 7 illustrates an exploded view of one embodiment of IC 1 , holder 2 and housing 3 , which shows a more detailed view of pins 4 , tines 5 and holes 6 .
FIG. 5 illustrates an exploded view of one embodiment of the IC 1 , holder 2 combination and housing 3 . This figure shows how holder 2 fits within housing 3 . In one embodiment, holder 2 has sides 13 that surround IC 1 once IC 1 is inserted within holder 2 . The sides 13 include a series of latches 17 that are used to secure holder 2 to housing 3 .
Similarly, housing 3 includes sides 14 that surround holder 2 once the IC 1 /holder 2 combination is inserted within housing 3 . The sides 14 include latches 18 that engage the latches 17 to secure holder 2 . As described above, variable sizes of ICs 1 to be placed in housing 3 . Thus, the series of latches account for the variance in IC 1 sizes. For example, the larger the IC 1 , a lower latch 17 on holder 2 is used to engaged with latch 18 on housing 3 .
FIG. 8 illustrates an exploded view of one embodiment of IC 1 , holder 2 and housing 3 . According to one embodiment, housing 2 includes snaps 15 to firmly hold IC 1 . Particularly, snaps 15 snap over a heatsink 16 of IC 1 . Additionally, holder 2 includes holes 20 . Holes 20 are large holes with rounded edges in order to facilitate the insertion of pins 4 into holder 2 . In a further embodiment, holder 2 and housing 3 include notches 11 and 12 , respectively that enable a used to easily remove IC 1 .
For insertion of an IC 1 into the carrier socket, the IC 1 is positioned in alignment with the large holes 20 of holder 2 . As discussed above, the holes 20 have rounded edges to enable the insertion of the IC 1 pins 4 . Subsequently, the snaps 25 engage the IC 1 , holding the IC 1 firmly. Next, the flexible tapered tines 5 of holder 2 firmly grip the pins 4 . The pins 4 and tines 5 are inserted into the tapered holes 6 to assist in the self-aligning and self-centering of the pins 4 . The latches 7 and 17 of holder 2 interlock with latches 8 and 18 , respectively, of housing to hold IC 1 , holder 2 and housing 3 together.
To remove the IC 1 from the carrier socket, a user presses thumb tabs 9 to unlatch housing 3 from holder 2 and use the reverse operations shown above. Finally, the user can remove the IC 1 by lifting the IC 1 at the notched edges 11 and 12 .
The above-described carrier socket protects the high pin count ICs with variable pin diameters and lengths from damage due to the handling and misusing at manufacturing sites. Moreover, the carrier socket straightens the pins of such ICs if one or more pins have been bent.
Whereas many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that any particular embodiment shown and described by way of illustration is in no way intended to be considered limiting. Therefore, references to details of various embodiments are not intended to limit the scope of the claims which in themselves recite only those features regarded as the invention. | According to one embodiment, an apparatus is disclosed. The apparatus comprises an integrated circuit (IC) having a plurality of connection pins, a carrier socket configured to carry the IC. The carrier socket protects the pins of the IC from bending. In addition, the carrier socket straightens pins that have been bent prior to placing the IC into the carrier socket. | 7 |
FIELD OF THE INVENTION
The present invention is directed generally to an ink fountain for use in a printing machine. More particularly, the present invention is directed to an ink fountain having a plurality of ink metering elements placed side by side in the ink fountain bottom. Most specifically, the present invention is directed to an ink fountain in which the ink metering elements are each pivotably adjustable about a pivot edge. The ink fountain bottom is provided with a longitudinal gap in which are carried a plurality of laterally placed ink metering elements. These elements are capable of pivotal movement within the gap about a pivot edge formed where a side wall of the gap and the fountain bottom intersect so that the ink metering slot formed between the ink metering elements and an ink roller is adjustable by pivotal movement of the ink metering elements. Each of the ink metering elements is secured to a pivotable arm which is caused to move by a crank arm that is carried in a slot in the arm. All the arms move in a similar fashion to provide a uniform ink metering slot along the length of the ink fountain roller.
DESCRIPTION OF THE PRIOR ART
Ink fountains for printing machines are generally well known in the art. Exemplary of such inking fountains is German Unexamined Published application No. 2,814,889 and corresponding U.S. Pat. No. 4,170,177 to Iida et al. This patent discloses an ink fountain roller which contacts printing ink in a reservoir. The patent further discloses a plurality of ink metering elements which are placed side by side in direct contact with each other. These ink metering elements are placed longitudinally along the axial length of, and spaced from the peripheral surface of, the ink fountain roller. These ink metering elements are pivotably mounted and supported in the ink fountain bottom and are rigidly secured to a pivotable arm. A controllable mechanism is provided to permit adjustment of an ink metering slot formed by the ink metering elements with the surface of the ink fountain roller.
A problem with ink fountains of this type is that the ink guiding surfaces of the ink fountain bottom and of the ink metering elements are always disposed at an angle of just greater than 90° which makes cleaning of the ink fountain quite difficult. A bottom plate of the ink fountain bottom removes printing ink from the ink guiding surfaces of the ink metering elements when the ink metering elements move in the "MORE INK" direction. As the metering elements move in this direction, it is the usual occurrence that ink particles get under the bottom plate. These ink particles can adversely effect the operation of the ink metering elements thereby making the adjustment of the ink metering slot difficult. As a result the slot is not uniform across its length and variations in thickness of the ink applied to the roller result.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an ink fountain for a printing machine.
Another object of the present invention is to provide an ink fountain having multiple side by side metering elements.
A further object of the present invention is to provide an ink fountain wherein each metering element is carried by a pivotable arm.
Yet another object of the present invention is to provide an ink fountain having an adjustable metering slot.
A still further object of the present invention is to provide an ink fountain having a longitudinal gap in the bottom of the ink fountain with the metering elements being pivotable in the gap.
As will be discussed in greater detail in the description of a preferred embodiment, as set forth hereinafter, the ink fountain in accordance with the present invention is comprised generally of a plurality of ink metering elements which are pivotably carried by spaced pivotable arms. The ink metering elements are placed side by side along the length of the ink roller and spaced from the surface of the roller to form a metering slot. A particular advantage of the present invention is that it permits the formation of an opening angle between the ink guiding surfaces of the ink metering elements and the ink fountain bottom of up to 180° so that the ink fountain can be thoroughly cleaned.
Another particular advantage of the ink fountain in accordance with the present invention is that is substantially reduces movement between the surfaces to be sealed against ink leakage of the ink metering elements and the ink fountain bottom so that ink leakage is substantially eliminated. Furthermore, the relative movement of the ink metering element and the ink fountain bottom does not cause any damage to the sealing means which prevent ink leakage.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the ink fountain for use in a printing machine in accordance with the present invention are set forth with particularity in the appended claims, a full and complete understanding of the invention may be had by referring to the description of a preferred embodiment as set forth hereinafter and as may be seen in the accompanying drawings in which:
FIG. 1 is a schematic side view of the ink fountain in accordance with the present invention with the ink fountain bottom and ink roller being shown in section and with the lateral end plates removed for clarity; and
FIG. 2 is a schematic front view of the ink fountain of FIG. 1 with the lateral end plates being shown.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning initially to FIG. 1, there may be seen an ink fountain generally at 1 with an ink fountain bottom member 2 provided therein. An inner bottom surface 3 of ink fountain bottom member 2 is covered with printing ink, when the ink fountain is filled with printing ink. A ceramic-coated ink fountain roller 4, which is driven in a conventional manner, plunges into the ink fountain 1. Ink metering extensions 5 of ink metering elements 6 form a slot with ink fountain roller 4 through which the printing ink passes. The ink fountain bottom 2 extends as an extension of the bottom surface 3 past all of the ink metering elements 6, thus forming a tail piece 7 having a tail face 8. A longitudinal gap 9 is provided in the ink fountain bottom 2, extending down into bottom 2 from the inner bottom surface 3. This longitudinal gap 9 preferably has a rhombus-shaped cross section and extends axially parallel to an axis of rotation of the ink fountain roller 4 near the point of closest proximity of the ink fountain roller 4 to the ink fountain bottom 2. A left guiding surface portion 12 of the longitudinal gap 9 abuts the bottom surface 3 at an angle α, which is preferably less than 90°, but which can be as great as 90°. An edge formed by the abutment of the left guiding surface 12 and the bottom surface 3 serves as a pivoting edge or pivoting line 21 for the ink metering elements 6. A right guiding surface 11 extends parallel to the left guiding surface 12 of the longitudinal gap 9, and a base surface 10 of the longitudinal gap 9 extends parallel to, and at a depth "a" below the bottom surface 3, of the ink fountain bottom 2. Vertical openings 13 in the ink fountain bottom 2 end in the base surface 10 of the longitudinal gap 9, these vertical openings 13 being spaced along the entire length "b" of the ink fountain bottom, for example, 30 mm from each other. The cross section of each of the openings 13 is dimensioned so that a pivotable arm 17 which is rigidly secured to each ink metering element 6 that extends horizontally in gap 9, is moveable in opening 13. The pivotable arm 17 can move in a preselectable pivoting motion. It is provided for this purpose with an elongated hole 18 in its lower portion. A crank pin 19 which is driven by an electric motor engages this elongated hole 18. The pivotable arm 17 pivots about the point of intersection 21 of the guiding surface 12 with the bottom surface 3 of the ink fountain bottom 2. The pivoting edge 21 for the pivotable arm 17 is also the pivoting edge for each ink metering element 6 which is rigidly secured to the upper end of a corresponding arm 17. The inner bottom surface 3 of the ink fountain bottom 2 adjoins an ink guiding surface 22 of the ink metering elements 6, so that no groove or ridge which might impede the passage of ink over both surfaces 3 and 22 is formed. Ink guiding surface 22 extends initially in a straight direction, then turns into a concave curvature, which ends in an ink metering extension 5.
A vertical surface 24 of the ink metering element forms an angle β of approximately 90° with the ink guiding surface 22 of the ink metering element 6 and ends in a first carrier extension 26. This carrier extension 26 projects downwardly approximately 1 mm below a curved rear surface 27 of the ink metering element 6. A collar 28 at the upper end of the pivotable arm 17 is rigidly and permanently joined to the rear surface 27. The rear surface 27 also includes a second carrier extension 29. The first carrier extension 26 rests upon the base surface 10, whereas the second carrier extension 29 rests upon the right guiding surface 11 of the longitudinal gap 9. The carrier extensions 26, 29 each extend preferably over the entire length "c" of the ink metering element 6 and define an angle γ of approximately 80°. The carrier extensions 26, 29 may have a rectangular cross section while their front faces or carrier surfaces 14, 15 should be as narrow as possible. The carrier extensions 26, 29 may, however, be blade-shaped, or they may have a plane front or a curved front.
A borehole 20 is positioned coaxially with each opening 13 and extends into the side opposite the bottom surface 3 of the ink fountain 1. A plane borehole bottom 31 of each extension borehole 30 forms a surface of action for a conical compression spring 32, which is slipped over the pivotable arm 17. This compression spring 32 is held between the borehole bottom 31 and a bolt 33, which projects through the cross section of the pivotable arm 17 and which bolt 33 is rigidly secured to this arm 17. Both carrier extensions 26, 29 and thus the ink metering element 6 are pulled by the compression spring 32 towards the base surface 10 or the right guiding surface 11 of the longitudinal gap 9, respectively.
An elastic sealing membrane 34 which may be, for example, convex, is inserted between the borehole bottom 31 and the compression spring 32. This sealing membrane 34 has an aperture which sealingly engages the pivotable arm 17, sealing it completely. A sealing effect for the ink fountain bottom 2 is secured by pressing the edge of the sealing membrane 34 against the borehole bottom 31 by means of the compression spring 32. A narrow longitudinal groove 36, which extends the whole length "c" of the ink metering elements 6, is provided in a rear part 16 of each of the ink metering elements 6, above the second carrier extension 29, and receives a first lateral edge 38 of an elastic sealing strip 37 to seal the vertical openings 13 from the ink fountain roller 4. A second lateral edge 35 of the elastic sealing strip 37 is secured to the tail surface 8 of the ink fountain 2 thereby sealing this tail surface 8 of the ink fountain 2. The sealing strip 37 extends as a single element over the entire length "b" of the ink fountain bottom 2, and thus over all the ink metering elements 6 of the ink fountain 1, which are disposed side by side.
An axial groove 39 which extends along the entire length "c" of the ink metering elements 6 and parallel to the axis of rotation of ink fountain roller 4 is located in the vertical surface 24 of the ink metering elements 6 approximately 1 mm below the ink guiding surface 22. This groove 39 receives an elastic sealing cord 41 having, for example, a rectangular cross section. This sealing cord 41 extends without breaks over the length "b" of gap 9. It is of a suitable size so that in every operating position of the ink metering elements 6, the left guiding surface 12 of the longitudinal gap 9 is safely sealed to the vertical surface 24 of the ink metering element 6.
A lubricant chamber 43 which is defined and sealed by the sealing strip 37, a right side face 40 of the opening 13, the sealing membrane 34, a left side face 42 of the opening 13, the base surface 10, the left guiding surface 12, the sealing cord 41, the surfaces 24 and 27 of the ink metering element 6 facing the longitudinal gap 9, and by two lateral end plates 49 and 50, as seen in FIG. 2, extends over the length "b" of the gap 9, and is completely filled with a lubricating means, for example, grease. Printing ink or dirt is thus prevented from penetrating the lubricating means chamber 43 and cannot handicap the operation of the ink metering elements 6.
Each ink metering element 6 is provided with a through borehole 44 in its center. This borehole 44 ends on either front side 45, 46 of ink metering element 6, in a lubricating groove 47, 48 respectively. Every lubricating groove 47, 48 extends within the surface limits of the front sides 45, 46 and is approximately 10 mm long, 2 mm wide, and 0.5 mm deep. A grease nipple 20 is provided on the lateral end plate 49, through which grease can be forced into the boreholes 44 of the ink metering elements 6. An outlet nipple 25, which is capable of being closed and opened, is provided on the second lateral end plate 50, through which waste grease can be forced out. Since all the boreholes 44 of the ink metering elements are in connection with each other, it is possible to press grease through them in a way that the grease is pressed out between the front sides 45, 46 of adjacent ink metering elements 6, and thus dirt and ink pigments which may have accumulated between adjacent elements 6 are simultaneously pressed out.
In operation, the crank pins 19 are all caused to rotate by the electric drive motor (not shown), such motion causing the solid pivot arms 17 to pivot about pivot edge 21 whereby the ink metering elements 6, which are rigidly connected to pivotable arms 17, also pivot about pivot edge or line 21 to adjust the spacing between ink metering extension 5 and ink fountain roller 4. The ink in the ink fountain flows smoothly along the inner bottom surface 3 of ink fountain bottom 2 and along the curving ink guiding surface 22. The lubricating means chamber 43 is sealed by seal 41, by elastic sealing strip 37 and by elastic sealing membrane 34 so that no dirt or ink can get into the longitudinal gap 9. Thus the several ink metering elements 6 which are disposed side by side in gap 9 can operate smoothly and in uniformity to meter the ink applied to roller 4. Similarly, the lubricant which is forced through lubricant hole 44 in each metering element 6 and out through the lubricant grooves 47 and 48 keeps particles of dirt and ink from between end faces 45 and 46 of adjacent ink metering elements 6. Accordingly, the ink fountain in accordance with the present invention includes a plurality of individual ink metering elements which cooperate to uniformly meter ink on an ink roller. Furthermore, the ink fountain in accordance with the present invention allows the ink metering elements to operate smoothly and to remain dirt and ink free.
While an ink fountain for printing machines having means to maintain smooth operation of the ink metering elements in accordance with the present invention has been fully and completely described hereinabove, it will be obvious to one of ordinary skill in the art that a number of changes in, for example, the number of metering elements, the means for pivoting the arms, the securement means for the spring and the like may be made without departing from the true spirit and scope of the invention and that the invention is to be limited only by the following claims. | An ink fountain for a printing machine is disclosed. A plurality of ink metering elements are placed side by side in a longitudinal gap in the bottom surface of an ink fountain with the gap being parallel to the axis of rotation of the ink roller. Each ink metering element includes an ink guiding surface which terminates in an ink metering extension that is adjustably spaced from the surface of the ink roller. Each of the ink metering elements is rigidly secured to a pivotable arm which extends through an opening in the ink fountain in a direction away from the inner bottom surface of the fountain. Pivoting of the arms causes the ink metering elements to pivot about a pivot line defined by the intersection of the inner bottom surface of the fountain bottom and a first edge of the longitudinal gap. Movement of the ink metering elements changes the space between the fountain roller and the ink metering extension thereby controlling the amount of ink carried out of the fountain by the ink fountain roller. | 1 |
RELATED APPLICATION
[0001] This application claims priority from co-pending provisional application Ser. No. 60/914,838, which was filed on Apr. 30, 2007, and which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of infectious diseases and, more particularly, to a pure culture of Mycobacterium which exhibits latency, including resistance to rifampicin and storage of increased lipids, and to a method for generating such a culture.
BACKGROUND OF THE INVENTION
[0003] Tuberculosis (TB) remains the leading cause of preventable deaths in the world with 100 million new infections and two million deaths each year. TB is caused by Mycobacterium tuberculosis (hereinafter also referred to by the abbreviation “Mtb”), an acid-fast bacillus that is transmitted primarily via the respiratory route. The aerosol containing the pathogen is released from people with active TB when they cough or sneeze. When a person breathes in the pathogen it enters the alveolar macrophages via a variety of receptors. Mtb multiplies within the vacuoles in the macrophage, avoids fusion with the acidic lysosomes and eludes the host defenses. As the host defense system senses the multiplying pathogen and mounts its immune defense, the pathogen goes into a non-replicating, drug-resistant, latent state. The protective response by the immune system at the site of infection results in the formation of a granuloma that contains the infection and prevents its spread. Live bacilli have reportedly been isolated from granulomas or tubercles in the lungs of persons with clinically inactive tuberculosis, regarded as the latent form of TB, indicating that the organism can persist in granulomatous lesions for decades. It is estimated that one-third of the world population has latent TB. These individuals are asymptomatic latent carriers who exhibit no signs of disease. Their risk for reactivation is estimated to be 2-23% over their life time. One study concluded that a 25 year old with latent TB has a 7.3% life time risk of reactivation. The risk increases dramatically for persons coinfected with HIV, more like 10% per year. Thus, the advent of AIDS greatly amplified the TB threat to human health. The deadly partnership between TB and AIDS, especially with multi- and extremely drug-resistant TB, is contributing to a dramatic rise in TB cases worldwide leading to a grave situation. The emergence and spread of multi-drug resistant and extremely drug-resistant TB is widely recognized as a major threat to public health.
[0004] The ability of the pathogen to go into the drug-resistant latent state is a major road block to the eradication of TB. It is known that latent Mtb persists in a non-replicating state. Antibiotics used to treat bacterial infection are usually active against growing bacteria but not against the dormant pathogen. Correlation between antibiotic activity and bacterial growth state in streptomycin-dependent Mtb was shown almost 30 years ago. The antibiotic-resistance of non-growing bacteria is due to changes in bacterial metabolism or physiological state and is described as phenotypic resistance. The phenotypic resistance has been classified into three types based on the physiological state of bacteria as stationary phenotyopic resistance, persister phenotypic resistance and phenotypic resistance in dormant bacteria. Mtb displays dormancy-related phenotypic resistance which is demonstrated by the Cornell mouse model. Traditionally, the phenotypic resistance is exemplified by resistance to the antibiotic Rifampicin (Rif) and is regarded as one of the hallmarks of latent TB. The mechanism of phenotypic resistance in dormant Mtb is not clearly understood.
[0005] Development of drugs that can effectively kill dormant Mtb is of vital importance for the eradication of TB. If such drugs would prevent the pathogen from surviving in a drug-resistant state, a combination of such drugs with currently used antibiotics could drastically shorten the period of treatment for complete cure and lead to global eradication of TB. For this purpose, we need to identify processes that are necessary for the pathogen to go into dormancy, survive under the nonreplicating drug-resistant state, and get reactivated when the immune system of the host is weakened. Such steps, essential for the latent pathogen, could offer ideal targets for novel antilatency drugs that can eliminate the dormant pathogen. To achieve these objectives we explored the biochemical processes that the pathogen uses to survive for such long periods under a latent state. It has been known for many decades that Mtb in the host uses fatty acids as the major source of energy. It is well known that glyoxylate cycle is used by organisms that live on fatty acids. In recent years the important role of isocitrate lyase, a key enzyme uniquely used in the glyoxylate cycle, was shown to be required for the persistence of Mtb in the host demonstrating the central role played by fatty acid catabolism in persistence. However, the source of fatty acids used by the pathogen remains unclear. We postulated that the pathogen probably stores energy as triacylglycerol (TG) as it goes into dormancy and uses this stored energy to survive the long dormant period at very low metabolic rates as many living organisms such as hibernating animals, seeds and spores do for similar purposes. We began to identify the likely gene products that the pathogen uses to store TG and to release the fatty acids for catabolism. We also initiated the development of an in vitro dormancy model to test the hypothesis that lipid storage and mobilization are of importance for latency, a model that can be adapted for screening antilatency drug candidates.
[0006] TG is an important storage form of lipid that accumulates in species belonging to the actinomycetes family, particularly Mtb. Intracellular TG inclusion bodies were detected in mycobacteria isolated from organ lesions and Mycobacterium bovis BCG was reported to preferentially use TG within macrophages indicating that TG is probably used as an energy source by Mtb during the course of the disease. We have shown that TG accumulates when Mtb is subjected to hypoxia or nitric oxide treatment that led to a dormancy-like state in culture. We identified fifteen members of a novel class of diacylglycerol acyltransferase genes which we designated as tgs (triacylglycerol synthase). Several of the tgs genes were significantly upregulated under hypoxic conditions and under nitric oxide treatment, particularly those that show the highest TG synthase activity when expressed in E. coli . We identified Rv3130c as the prime gene in the biosynthesis of TG in the bacterium under in vitro dormancy-like conditions. Our hypothesis was strongly supported by a important recent report on the W/Beijing lineage of Mtb strains which has been associated with the increasing incidence of multi-drug resistant (MDR) TB epidemic in Asia. The W/Beijing strains were shown to overproduce TG and the Rv3130c gene was constitutively upregulated along with the dormancy regulator protein DosR. The authors suggested that constitutive accumulation of TG by this strain may confer an adaptive advantage for growth in microaerophilic or anaerobic environments and thus be related to the epidemiological spread of this strain. Our hypothesis concerning the importance of Rv3130c is strongly supported by the remarkable finding by our collaborators. A recently developed two step multiplex and real time PCR method was adapted for reliable quantitative gene profiling of the small amount of latent Mtb expected to be found in infected animal and human host lung tissues. Remarkably, tgs1 (Rv3130c) was by far the most upregulated gene in the pathogen within the host, while dosR and aceAa that are well-known to be involved in dormancy, were much less induced. Many organisms use waxy esters (WE) as the major form of energy storage. Mtb also stores WE but the genes involved in the synthesis of WE and the growth conditions that cause its accumulation have not been identified. The basic mechanisms used for biosynthesis of WE were first elucidated in our laboratory several decades ago and the enzymatic strategy described more recently. We have recently shown that Rv3391 and Rv1543 encode acyl-CoA reductases involved in WE synthesis in Mtb. Rv3391 has been reported to be upregulated under nutrient stress conditions. We found that WE accumulates under stress conditions that lead to a dormancy-like state and the accumulated WE is utilized upon starvation. This utilization was reduced in lipY mutant, indicating the involvement of lipY in WE hydrolysis. Thus, Mtb can produce and use both major energy storage forms. TG and WE, and both forms are likely to be used for successfully going through dormancy. WE may also be a component of the cell wall lipids that control permeability.
SUMMARY OF THE INVENTION
[0007] With the foregoing in mind, the present invention advantageously provides a method of inducing latency in Mycobacterium , the method comprising growing a pure culture of Mycobacterium exposed to multiple stress conditions, the stress conditions including at least a low nutrient culture medium without glycerol, a low pH, a relatively high level of carbon dioxide and a relatively low gas phase oxygen level.
[0008] A latent culture of Mycobacterium growing in vitro is particularly useful in evaluating the effectiveness of antimicrobial compounds against this form of the organism, which is prevalent throughout the world in infected but asymptomatic persons. Before the present invention, it was difficult to test drug effectiveness against latent Mtb due to the lack of an easily reproducible model system. Accordingly, the present invention discloses an in vitro model of latent mycobacterial infection which is useful in testing antimicrobials for activity against the infection in its latent stage.
[0009] The method of the invention includes growing the Mtb in a low nutrient medium comprising approximately 10% Dubos medium, preferably at a pH of approximately 5 and in an atmosphere relatively high in level of carbon dioxide, at approximately 10%. Additionally, the atmosphere includes a relatively low oxygen level of approximately 5%. Preferably, in the method, the Mycobacterium is a strain of Mycobacterium tuberculosis.
[0010] Another embodiment of the present invention includes a method of inducing a pure culture of Mycobacterium to become rifampicin resistant and to store an increased lipid content, two hallmarks of latency, the method comprising growing the culture simultaneously exposed to multiple stress conditions, the stress conditions including at least a low nutrient culture medium without glycerol, a low pH, a relatively high level of carbon dioxide and a relatively low gas phase oxygen level.
[0011] The present invention also includes a pure culture, and even a single isolated cell of resistant Mycobacterium generated according to the method disclosed.
[0012] The invention includes an in vitro model of latent tuberculosis, the model comprising an isolated culture of THP1 derived macrophages containing ingested Mycobacterium tuberculosis bacteria and incubated under hypoxic conditions for a time sufficient for the bacteria to accumulate increased lipids therein. More broadly, the invention also provides an in vitro model of latent mycobacterial infection, the model comprising an isolated culture of THP1 derived macrophages containing ingested Mycobacterium spp. cells and incubated under hypoxic conditions for a time sufficient for the bacteria to accumulate increased lipids therein. More broadly still, the invention teaches an in vitro model of mycobacterial infection, the model comprising an isolated culture of THP1 derived macrophages containing ingested Mycobacterium spp. cells.
[0013] With regard to the various models disclosed in the invention, the teachings also comprise a method of making a model of latent tuberculosis, the method including inducing cultured THP1 cells to differentiate into macrophages; infecting the macrophages with Mycobacterium tuberculosis bacteria; and incubating the infected macrophages under hypoxia, particularly wherein incubating is for a time sufficient for the bacteria to accumulate increased lipids therein, a hallmark of latency. This method is, in general, should also be applicable to other Mycobacterium species as well.
[0014] The various in vitro models of latent tuberculosis and mycobacterial infection herein disclosed are useful in evaluating compounds for effectiveness against these bacterial pathogens.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Some of the features, advantages, and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, presented for solely for exemplary purposes and not with intent to limit the invention thereto, and in which:
[0016] FIG. 1 is a demonstration of the accumulation of storage lipids in Mtb cells treated for the indicated periods under the multiple stress conditions, according to an embodiment of the present invention; TLC was performed as described; the plates were charred and quantitation was done by densitometry;
[0017] FIG. 2 shows increasing lipid storage bodies in Mtb cells with increasing periods of multiple stress; non-acid fast staining cells (green) and lipid storage body staining (red) increased with time under multiple stresses; cells were stained with Auramine-O and Nile Red and examined by confocal laser scanning microscopy (Leica TCS SP5) with Z-stacking to get the depth of the scan field; scanned samples were analyzed by LAS AF software for image projection;
[0018] FIG. 3 shows an increase in the percentage of lipid-stained cells and decrease in percentage of acidfast stained cells in Mtb culture when subjected to multiple stresses in vitro;
[0019] FIG. 4 depicts TG accumulation by tgs1 (Rv3130c) and restoration of TG accumulation by complementation under 18 days of multiple stress; equal amounts of lipid were subjected to TLC as in FIG. 1 ; C-Δtgs1, is a complemented mutant;
[0020] FIG. 5 shows real-time PCR measurements of transcript levels of tgs and stress responsive genes in Mtb H37Rv under in vitro multiple stress for 9 days; comparative C T method (ΔΔC T ) was used to quantify and values obtained with starting aerated cells were used to calculate the fold induction;
[0021] FIG. 6 shows expression profiles of genes encoding proteins involved in the glyoxylate cycle during the multiple stress treatment;
[0022] FIG. 7 depicts a decrease in buoyant density of Mtb cells subjected to multiple stresses; Mtb cells subjected to the multiple stresses were placed on the preformed gradient and centrifuged at 400 g for 20 min; the center tube is a 3 day cell sample mixed with density marker beads; Percoll® gradients were self-formed by centrifugation from a starting solution with a density of 1.0925 gm/ml; the densities of selected bead layers (ρ, in gm/ml) are given on the right and the positions of one ml fractions collected for analyses are at the left; numbers below the tubes indicate the number of days under multiple stress:
[0023] FIG. 8 is a bar graph showing that Alamar Blue assay reveals development of Rif resistance by multiple-stressed Mtb cultures; Mtb cultures subjected to multiple stresses were assayed by the specially adapted Alamar Blue method described in text for resistance to Rif and INH; fluorescence readings above 0 h controls are depicted;
[0024] FIG. 9 shows real time PCR measurement of transcripts levels of a subset of selected dormancy metabolism and stress responsive genes in Mtb H37Rv under in vitro multiple stresses for 9 and 18 days; a relative quantitation method (ddCt) was used with the 7500 Fast real time system; samples of starter cultures were used as calibrator to calculate the fold induction:
[0025] FIG. 10 are photomicrographs where Oil Red-O staining reveals lipid droplet accumulation in TDM incubated for 3-days in 1% O 2 , 5% CO 2 (a) compared to 0-day control (b);
[0026] FIG. 11 indicates the increase in lipid bodies in TDM infected with Mtb and subjected to hypoxia for 0 and 3-days;
[0027] FIG. 12 shows Mtb within TDM stained with Auramine-O and Nile Red showing spherical fluorescent lipid bodies and lack of acid fast staining;
[0028] FIG. 13 shows that TG accumulated by TDM under hypoxia is utilized by Mtb; in A, lipids from uninfected (U) and infected (I) TDM, incubated in 20% O 2 or 1% O 2 for 7 days after infection, were resolved on TLC and visualized under UV light after spraying with 2′,7′-dichlorofluorescein; in B, lipids of Mtb recovered from TDM incubated in 20% O 2 (i) or 1% O 2 (ii); solvent was hexane-ether-formic acid (90:10:1, v/v/v) TG, triacylglycerol, FA, fatty acids;
[0029] FIG. 14 depicts the fatty acid composition of TG from Mtb recovered after TDM infection; after infection with Mtb, TDM were incubated under 1% O 2 for 7 days; TG from Mtb isolated from TDM was purified by preparative TLC. Fatty acid methyl esters were prepared from Mtb TG and analyzed using a Varian CP-TAP CB column attached to a Varian CP-3900 gas chromatograph under a temperature control program;
[0030] FIG. 15 depicts transcriptional profiling of genes in Mtb H37Rv from infected TDM under hypoxia;
[0031] FIG. 16 shows that Mtb inside [ 14 C]acetate-labeled lipid-loaded macrophages mobilizes host lipids and accumulates TG enriched in saturated fatty acids; in A, AgNO 3 -impregnated silica-TLC purified from [ 14 C]acetate-labeled lipids of infected macrophages (lane 1) and from Mtb recovered from such macrophages (lane 2); solvent system is 1% methanol in chloroform; in B, is shown reversed-phase TLC analysis of fatty acids methyl esters of TG from infected macrophages (lane 1) and from Mtb recovered from infected macrophages (lane 2); the solvent system is acetonitrile:methanol:water:acetic acid (30:70:5:1, by volume); in C. AgNO 3 -impregnated silica-TLC of fatty acids methyl esters of TG from infected macrophages (lane 1) and from Mtb recovered from infected macrophages (lane 2); the solvent system is hexane:diethyl ether:acetic acid, 94:4:2, v/v/v, (developed twice);
[0032] FIG. 17 shows TDM infected with Mtb and incubated under hypoxia appear to fuse together; TDM infected with Mtb at an MOI of 0.1 and incubated for 7 days under 1% O 2 were stained with carbolfuschin followed by hematoxylin and eosin (A) or carbolfuschin followed by methylene blue (B); arrows show Mtb; and
[0033] FIG. 18 shows Mtb inside TDM that accumulate neutral lipids lose acid-fastness; intact TDM harboring Mtb were fixed with 4% paraformaldehyde overnight and stained with the fluorescent mycolic acid staining dye Auramine-O (A) followed by the neutral lipid stain Nile Red (B); arrows indicate Mtb that stained strongly for Nile Red but weakly for Auramine-O.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. 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 invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. Any publications, patent applications, patents, or other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including any definitions, will control. In addition, the materials, methods and examples given are illustrative in nature only and not intended to be limiting. Accordingly, this invention may be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these illustrated 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. Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
[0035] With the foregoing in mind, an in vitro dormancy model that can be adapted to drug screening would help to discover antilatency drug candidates. in vitro models suitable for such screening are urgently needed. A number of different stresses have been applied to Mtb in vitro in an attempt to generate a dormant state and gene expression changes have been investigated. Most of these models involve single stress factors such as oxygen depletion, nutrient deprivation, NO treatment and acidic conditions. The gene expression changes during combined nutrient deprivation and 10% and 0.2% oxygen stress on stationary phase cultures were investigated. Some of these stress conditions such as prolonged nutrient starvation caused Mtb to become highly Rif-resistant but accumulation of storage lipids was not tested. On the other hand hypoxic conditions we used that caused TG accumulation did not develop resistance to 5 μg/ml Rif (unpublished). The NRP-1 condition was reported to cause resistance to a lower concentration of Rif (1 μg/ml) but lipid accumulation was not tested. We suggest that both Rif-resistance and lipid storage are hallmarks of dormancy. Since individual stress conditions do not allow the pathogen to fully meet these criteria, we attempted to mimic the in vivo conditions by applying multiple stresses thought to be encountered in vivo by Mtb and tested whether the pathogen would accumulate storage lipids and develop Rif-resistance. Bacilli within granulomas encounter low oxygen (5%) but not hypoxia, high CO 2 (10%) concentrations, low nutrient levels and acidic pH. Based on these reports, we used 5% O 2 , 10% CO 2 , pH 5.0 and 10% Dubos medium in a multiple stress in vitro model. Our preliminary results show that the combination of the four stress factors leads to accumulation of storage lipids (TG and WE), development of Rif-resistance and gene expression changes thought to be associated with dormancy. Some of the gene expression changes are similar to those found in the pathogen from infected lungs of hosts, including primates and a human TB patient.
[0036] Both Rif-resistance and storage lipid accumulation are associated with dormancy. However, the commonly used in vitro hypoxia model, does not show both of these characteristics. Therefore we developed a novel multiple stress model that applies four different stresses that the pathogen is thought to encounter in the host. We grew Mtb cultures in low pH (pH 5.0), low nutrient (10%) Dubos medium without glycerol, with high (10%) CO 2 and low (5%) oxygen gas phase.
[0037] Mtb cultures in 10% Dubos (Difco) medium at pH 5.0 at an OD 600 of 0.2 were maintained under 5% O 2 +10% CO 2 +85% N 2 by replacing the air phase every other day; oxygen levels did not change significantly during the two day period. After monitoring the progressive changes that happened to the pathogen, we chose to harvest cells at 3, 9 and 18 days under such conditions for more detailed studies. These studies included examination of storage lipids, antibiotic (Rif and INH)-resistance, gene expression changes directly relevant to storage lipid synthesis by quantitative real time PCR (qPCR), and gene expression profiles by microarray analyses. TLC showed that WE and TG accumulated under the multiple stress conditions reaching near maximal levels by 9 days FIG. 1 .
[0038] The major wax ester was oleyl oleate and the major fatty acids in the TG were C16 and C18 with less C26 (data not shown). Under these conditions more WE accumulated than TG in absolute amounts. Control samples at pH 7.0 or pH 5.0 without additional stress showed no increase in storage lipids.
[0039] Nile red staining revealed storage lipid accumulation under the multiple stress conditions. It is well known that Mtb cultures contain a heterogeneous population of cells under different physiological states. As the culture was subjected to multiple stress factors we observed decrease in acid fast staining cells with increasing lipid body staining cells from a barely detectable level to a significant percentage of the total cells by 18 days ( FIGS. 2 , 3 ).
[0040] Drug resistance was tested by treatment with 5 μg/ml Rif for 5 days followed by serial dilution and plating. By 9 days about 10% of the cells were found to be Rif resistant whereas the starting culture contained about 0.03% Rif-resistant cells. Rif-resistance increased up to 18 days, sometimes reaching up to 25% at 5 μg/ml Rif. The tgs1 (Rv3130c) disruption resulted in the loss of Rif-resistance which was restored in the complemented mutant (Table 1). Hypoxic conditions, that were previously found to cause accumulation of storage lipids, did not cause the cells to develop detectable Rif-resistance at 5 μg/ml. The tgs1 (Rv3130c) disruption resulted in loss of TG accumulation under multiple stress. However the complemented mutant showed a level of TG accumulation comparable to the wild type ( FIG. 4 ).
[0000]
TABLE 1
Development of Rif-resistance in wild type H37Rv but not in Rv3130c
mutant upon application of multiple stress: complementation restores
Rif-resistance. Aliquots were either untreated or
treated with Rif (5 μg/ml) or INH (0.8 μg/ml).
Mtb
Resistance to Antibiotics (%)
strains
Days
INH (0.8 μg/ml)
Rif (5.0 μg/ml)
WT-H37Rv
0 day
0.034 (±0.02)
0.037 (±0.027)
9 day
34.7 (±12)
4.7 (±1.9)
18 day
84.4 (±17.5)
12.5 (±3.4)
Δ-Rv3130c
0 day
0.011 (±0.01)
0.025 (±0.019)
(Δ-tgs1)
9 day
21.1 (±7.8)
1.16 (±0.87)
18 day
31.2 (±13.1)
1.89 (±0.9)
Comple-Δ-
0 day
0.041 (±0.02)
0.029 (±0.01)
Rv3130c
9 day
37.9 (±13.5)
5.2 (±2.1)
18 day
91 (±19)
11 (±4.5)
ND, Not determined;
d, day.
[0041] Gene expression changes directly relevant to storage lipid accumulation were examined by real-time PCR. Among all the tgs genes, induction of tgs1 (Rv3130c) was by far the highest at 9 days under the multiple stress condition, followed by Rv3371 and Rv3088 ( FIG. 5 ). Microarray analysis also indicated upregulation of Rv3371 under multiple stress condition (data not shown). Upregulation of Rv3088 probably resulted from the low pH as it has been previously reported to be induced under acidic stress. Up-regulation of Rv3371 is noteworthy as it was also shown to be up-regulated in human lung granuloma by microarray analysis. The degree of induction of tgs1 (Rv3130c) was comparable to that of icl and acr (hspX), genes previously reported to be induced during persistence. Our preliminary experimental results raise the possibility that lipid accumulation under different stress conditions might use different sets of tgs genes.
[0042] The TIGR Pathogen Functional Genomics Resource Center provided the Mtb genome microarray for this study. Under our multiple stress condition, genes that encode enzymes involved in glyoxylate cycle such as isocitrate lyase (aceA) and citrate synthase (gltA1) showed significant increase in expression for all time points examined ( FIG. 6 ). From these data we infer that the metabolic regulation of cells adapting to the multiple stresses was similar to that observed in persistent bacilli adapting to the phagosomal environment of a macrophage. Under multiple stresses, Mtb showed shutdown of both ATP/NAD energy regeneration systems. While gene expression for anaerobic respiration was continuously increased at the later time points, the aerobic respiration was significantly repressed at all the time points. All the subunits encoding NADH dehydrogenase and the ubiquinol-cytochrome C complex were repressed more than 2-fold. In addition, the expression of the genes encoding ATP synthase subunits was repressed. Slowdown of the transcription/translation apparatus was evident during the multiple stresses. Many genes related to transcription and translation apparatus were all consistently repressed. Genes involved in modification of chromosome and cell division were repressed by the multiple stresses. The expression level of the gene cluster, mas, fad28, mmpL7, and ppsA-E, associated with phthiocerol dimycocerosate (PDIM) synthesis and transport, that was repressed at the beginning of the multiple stress treatment, gradually increased more than two-fold and remained high throughout the period of in vitro multiple stress. Further, the mas-like gene pks2, which is responsible for encoding a hepta/octa-methyl branched fatty acid synthase, was highly expressed. These changes are consistent with the report that dormant cells have thickened walls. We also found significant induction of the genes classified as the stress response genes (eg. hspX) that has been suggested to play a role in maintaining long term survival within the host. The gene array analysis results were verified by qPCR analysis of selected test genes. Repressed and induced gene transcript level changes indicated by microarray analysis were found to be consistent with the changes indicated by the qPCR method (data not shown).
[0043] We investigated whether the lipid accumulation that occurs as a result of multiple stresses might be reflected in changes in buoyant density. We fractionated the culture on a Percoll® gradient in 10 ml Seton Easy-Seal polyallomer centrifuge tubes with Seton Noryl crown assembly. This procedure resolved cells based on buoyant density ( FIG. 7 ). The banding pattern changed as the cultures were subjected to multiple stresses for increasing duration. These changes are consistent with the conclusion that application of multiple stresses caused progressive changes in lipid accumulation resulting in increasing percentages of cells in the lighter fractions. Auramine-O/Nile Red staining of the different fractions showed that with increasing periods under the multiple stresses, increasing percentage of cells became lipid-loaded and lost acid-fast staining (presumably dormant cells). Staining of Percoll® fractions from 18 day stressed cultures showed that the lighter fractions were more enriched in, lipid loaded cells that lost acid-fastness. After this long stress period most cells were in the lighter fractions ( FIG. 7 ). Upon Percoll® density gradient fractionation of the 18-day multiple-stressed culture, the great majority of the cells were distributed in the lighter fractions. When Rif-resistance was assessed by the Alamar Blue dye method the lighter fractions showed a higher percentage of Rif-resistant cells (data not shown). The small number of heavier cells present in this culture showed Rif-susceptibility comparable to that of the starting culture.
[0044] Recent meta-analysis of Mtb microarray data from many in vitro and in vivo conditions that are thought to induce dormancy (Murphy and Brown, BMC Infect. Dis. I, 84 -100, 2007) indicated that a set of genes possibly involved in lipid storage and utilization are highly upregulated. We have determined the transcriptional profile of the genes, selected on the basis of the meta-analysis by real-time PCR using 7500 Fast system (Applied Biosystem). Detection of transcriptional upregulation of the known dormancy-responsive genes such as hspx, icl and dosR ( FIG. 1 ) is consistent with our conclusion that the multiple stress conditions induce dormancy. Seven of the 10 genes in the first priority group, such as Rv3130c along with a few other tgs genes (Rv3371, Rv1760), a few genes encoding potential hydrolases (lipX lipY, cut3), and fatty acyl-CoA reductase gene (Rv3391) showed upregulation. Three of the 21 genes in the next priority group showed upregulation under the multiple stress condition. One of them showed surprisingly high induction. The other two upregulated genes in this group were cut2 and lipZ. Only one gene (Rv2285, a tgs) in the third priority group showed upregulation. Among the tgs products that showed the highest enzymatic activity (when expressed in E. coli ) only this tgs showed a preference for oleoyl-CoA. We already have mutant for this gene and this mutant showed the second most impaired ability to accumulate TG under hypoxia as indicated in the preliminary results presented in the application.
[0045] It is noteworthy that 7 of the 10 genes in the first priority group and 3 out of 21 genes from the second priority group and only one out of 17 in the third priority group showed upregulation. Since the prioritization is based on meta-analysis of the degree of their upregulation under a variety of conditions thought to induce dormancy, our results suggest that the multiple stress model reflects real dormancy and adds validity to our approach.
[0046] The tuberculous granuloma, which is thought to be a hypoxic environment, consists of a core of Mtb-infected macrophages surrounded by lipid-loaded macrophages, mononuclear phagocytes and lymphocytes enclosed by a fibrous cuff. The differentiation of macrophages into lipid-loaded macrophages in tuberculous granulomas is a well-documented observation and the secretion of cytokines by the infected lipid-loaded macrophages probably helps to maintain the granuloma. Histological studies revealed the presence of lipid-loaded macrophages in the granulomas of immunocompetent and HIV-1 infected patients with TB. Lipid-loaded macrophages contain abundant cytosolic stores of TG and cholesterol esters. A recent study showed that exposure of human macrophages to hypoxia (1% O2) converted them into lipid-loaded cells and M. bovis BCG infection induced the conversion of macrophages into lipid-loaded cells but the nonpathogenic Mycobacterium smegmatis failed to induce lipid body formation. Thus lipid bodies within Mtb-infected macrophages may have important roles in pathogenesis and possibly in latency. Human THP-1 monocytic cell line-derived macrophages (TDM) are known to be converted into lipid-loaded macrophages. Therefore they can serve as a more convenient experimental model for studies on Mtb mutants, because their use can avoid the variability in responses encountered in the use of human peripheral blood monocyte-derived macrophages and provide a readily available uniformly reproducible cell model suitable for high throughput screening of drug candidates. Lipid bodies have been found in Mtb obtained from patients with active disease. However, the origin of these lipids remains unknown. The pathogen inside the lipid-loaded macrophages might utilize fatty acids derived from the lipid bodies in the host cells to store lipids within Mtb for later use. Such a possibility was raised by the recent finding that adipocytes might be a home for dormant Mtb in humans. In fact, Mtb inside adipocytes were found to accumulate lipid bodies while becoming dormant, as indicated by their resistance to killing by drugs. The lipid bodies found in the pathogen from patients probably originate from the lipid bodies in the macrophages. Our results indicate that Mtb within lipid-loaded macrophages can use the host's TG to accumulate TG within the pathogen and this Mtb becomes Rif resistant meeting our criteria for dormancy.
A New Lipid-Loaded Macrophage Model of Dormancy
[0047] Herein we disclose a newly developed THP-1 derived macrophage (TDM) system for infection with Mtb. THP-1 cells, differentiated into macrophages by treatment with 100 nM PMA for 3 days, were incubated for 3 days in 1% O2 and 5% CO2. Oil Red-O staining revealed lipid droplet accumulation in such macrophages ( FIG. 2 ). When the TDM were infected with Mtb at a multiplicity of infection (MOI) of 1.0 for 4 hr and incubated in 1% O 2 /5%/CO 2 for 3 days, lipid bodies accumulated in the host cells ( FIG. 3 ). Mtb cells within the macrophages showed Nile Red stained lipid bodies ( FIG. 4 ). Most Mtb cells showed loss of acid fast staining and thus stained only red; a few showed some acid fast and lipid staining (yellow).
[0048] We modified our experimental protocol to allow for longer incubation of infected macrophages. We infected TDM with Mtb at an MOI of 0.1 (1 bacillus per 10 macrophages) and extended the incubation of the infected TDM to 7 days under hypoxia. After 7 days, infected TDM were lysed and the cell debris was removed by centrifugation at 300 g for 10 min. The Mtb cells were pelleted by centrifugation at 3000 g for 10 min and washed. Lipids from the host-lipid bodies were extracted from the supernatant and the lipids from the pelleted To analyze fatty acid composition, host or Mtb TG was purified by preparative TLC and the methyl esters generated by BF3/methanol transesterification, were analyzed by capillary GC. The amount of fatty acids from the TG isolated from Mtb, recovered for TDM, is more than enough for such GC analysis ( FIG. 6 ) pathogens were extracted. TLC analysis of the lipids revealed that TG in the host cells was markedly increased by incubation under hypoxia for 7 days and the levels of TG were lower in infected TDM under hypoxia ( FIG. 5A ). Lipids extracted from Mtb recovered from infected TDM were also analyzed by TLC. We detected increased TG level in Mtb cells recovered from TDM incubated under hypoxic conditions ( FIG. 5B ).
[0049] The fatty acid composition of the TG from the pathogen was not identical to that of the host TG. C16:0, C18:0 and C18:1 fatty acids were the dominant components in both the pathogen and the host. Longer chain saturated fatty acids (C24. C26 and C28) that were present in the pathogen TG were absent in the host TG. We conclude that the TG that accumulated in the pathogen probably consisted of fatty acids from the host and some fatty acids generated within the pathogen.
[0050] Gene expression changes occurring in the pathogen within TDM were examined using a two-step real time PCR method. Briefly, total RNA was isolated and purified from a mixture of Mtb-infected TDM using Trizol (Invitrogen) and Qiagen RNeasy column purification method. Total RNA was DNase treated twice, purified through Qiagen mini elute RNeasy column, purity of RNA was checked at every step. Controls without reverse transcription (RT) verified lack of DNA contamination. First-strand cDNA, synthesized with exo-resistant random hexamers and Superscript III reverse transcriptase (Invitrogen) was used for multiplex PCR using many Mtb gene specific primer sets. All primers and Taqman probes were designed using VisualOMP6 software from DNA software, Inc (Ann Arbor, Mich.). The Taqman probes have a fluorescein reporter dye (FAM) at 5′-end and a Black Hole Quencher (BHQ) at 3′-end. Each multiplex and real-time PCR primer was checked for specificity and efficiency. Differences in Mtb specific gene transcripts were quantified by real-time PCR on generated multiplex-PCR products with nested Taqman primers and probes. The overall reliability and sensitivity of the two-step RT-PCR method to quantify gene expression profiling has been discussed in detail elsewhere. We have thus far done only a subset of genes thought to be relevant to lipid storage and metabolism ( FIG. 7 ); icl was by far the most induced gene, consistent with the idea that the pathogen in TDM grows on fatty acids. It is noteworthy that lipY, that was previously shown by us to be involved in TG mobilization, was highly induced and some of the other lip genes also showed induction. dosR and tgs genes were also induced probably indicating their involvement in the storage of fatty acids derived from host-lipids as TG resynthesized within the pathogen, consistent with our hypothesis. fatp, that might be involved in fatty acid transport into the pathogen was also induced. Putative fabp genes also showed some induction. These results indicate that our hypothesis concerning storage and mobilization of host lipids by the pathogen has real validity.
[0051] We analyzed the resistance of Mtb recovered from TDM after a 7 day incubation under 20% O 2 or 1% O 2 to Rif and INH by cfu determination. TDM were infected with Mtb at an MOI of 0.1. Mtb cells inside TDM were exposed to antibiotic for 2 days prior to lysis of TDM and recovery of the bacilli. The recovered Mtb cells were diluted and plated on agar plates without antibiotic and incubated for 4 weeks after which cfus were enumerated. Antibiotic resistance is expressed as percentage of control without antibiotic. As indicated in Table 2, Mtb recovered from TDM incubated under 20% O 2 showed resistance to both antibiotics. Others have found development of Rif resistance in host cells. We found that Rif resistance increased significantly in Mtb recovered from TDM incubated under 1% O 2 for 7 days compared to normoxic conditions. These results indicate support for our hypothesis that lipid-loading of macrophages favor the entry of Mtb into dormancy.
Lipid-Loaded Macrophage Model
[0052] In making further progress developing the macrophage dormancy model, we tested different MOI in the lipid loaded macrophage system. We assessed the viability of Mtb-infected lipid-loaded macrophages under hypoxia under different MOI. At MOI 1.0 or higher the host cell viability was seriously compromised. At MOI 0.1, after 7 days under 1% O 2 , 40% of the original TDM population remained intact as an adhered monolayer and were loaded with lipid droplets. About 94% of these lipid-loaded TDM cells in the adhered monolayer were viable. These results support the notion that these lipid-loaded TDMs provide a TG-enriched sanctuary for Mtb, favoring its entry into dormancy.
[0000]
TABLE 2
Increase in resistance of Mtb inside lipid-loaded macrophages to Rif
and INH. Mtb within TDM incubated for 7 days under 20% O 2 or 1% O 2
was exposed to antibiotic for 2 days. Mtb cells were then recovered by
lysis of TDM and plated on agar plates for cfu determination.
Mtb recovered from
Resistance to Antibiotic
TDM incubated
Rif
INH
7 days in
1 μg/ml
5 μg/ml
0.1 μg/ml
0.8 μg/ml
20% O 2
9%
4%
25%
12%
1% O 2
68 ± 14%
25 ± 2%
100%
68 ± 18%
[0053] We originally suspected that Mtb utilizes the macrophage lipid bodies to acquire fatty acids and store them as TG within the pathogen to enable it to go through dormancy. To test this hypothesis, we labeled TDM lipids by incubating the cells with [ 14 C]acetic acid or [ 14 C]oleic acid, under 1% O 2 for 2 days. These cells were washed three times with sterile phosphate-buffered saline (PBS) to remove unincorporated radiolabel. Thin-layer chromatographic (TLC) analysis of the labeled lipids extracted from TDM showed that major part (about 60%) of the radioactivity in the lipids derived from labeled acetate and oleate was in TG that accumulated in TDM under 1% O 2 . These pre-labeled cells were infected with Mtb at an MOI of 0.1 for 4 h under 1% O 2 . Following infection, extracellular Mtb were removed by thoroughly washing the TDM monolayer with sterile PBS. Infected TDM were incubated for 5 more days under 1% O 2 . The host lipids and lipids from Mtb recovered from the host cells were obtained and the lipids were analyzed by TLC. The fatty acid composition of the Mtb and host TG was analyzed by resolving the intact TG and fatty acid methyl esters derived from TG on reversed-phase silica-TLC and argentation-TLC. Analysis of intact TG from [ 14 C]acetate in TDM was composed of saturated and unsaturated fatty acids. However, the TG of Mtb was predominantly composed of saturated fatty acids as indicated by greater mobility on AgNO 3 -impregnated TLC ( FIG. 8 A). Analysis of fatty acid methyl esters prepared from TG isolated from TDM and Mtb indicated that the TG of Mtb, recovered from TDM labeled with [ 14 C]acetate, was composed primarily of saturated fatty acids, mostly 14 C-16:0 and a very small quantity of 14 C-18:0 fatty acids ( FIG. 8 B,C). See also Table 3, below.
[0000]
TABLE 3
Accumulation of radiolabeled TG by Mtb and mutants in
lipid-loaded macrophages under hypoxia:
DPM in TG
% of WT
14 C-Acetate
WT
210,000
100%
ΔRv3130c
22,600
11%
14 C-Oleate
WT
29,000
100%
ΔRv3130c
1470
5%
[0054] Mtb recovered from [ 14 C]oleic acid-labeled TDM had TG that was distinctly different in fatty acid composition from the TG in TDM. While the 14 C in TDM TG was predominantly in 18:0 (about 81% of total fatty acids), 14 C in Mtb TG was mainly in unsaturated fatty acids (about 70% of total fatty acids). The identity of these fatty acids is to be determined. These results clearly indicate that Mtb acquires fatty acids from TDM lipid bodies for synthesizing TG as a potential energy source. The TG stored within the pathogen probably includes the fatty acids from the host lipids and fatty acids generated by modification and/or catabolism and resynthesis. The biochemical processes involved can be deduced only after further characterization of the TG that accumulates in the host and in the pathogen.
[0055] We also postulated that the Mtb tgs gene products may be pivotally involved in synthesizing TG within the Mtb cell from fatty acids acquired from host TG. To test this hypothesis, we infected the pre-labeled TDM with wild-type Mtb and tgs1 (Rv3130c) deletion mutant (ΔRv3130c) as described in the methods section. About 1% of the radiolabel in the TG in TDM was found in the TG isolated from Mtb. We quantitated the radioactivity in the TG of Mtb and Δv3130c recovered from TDM. The results indicate that TG accumulation by the Δ3130c was decreased by 90-95% when compared to the wild-type (Table 3). These results additionally suggest that Rv3130c plays an essential role in the accumulation of TG by Mtb within lipid-loaded macrophages.
[0056] In order to visualize the Mtb inside lipid-loaded host cells, infected TDM after 7 days under hypoxia were fixed with 4% paraformaldehyde and stained for Mtb with carbolfuschin followed by methylene blue or hematoxylin and eosin to stain the host cell. Mtb inside TDM were also stained with the mycolic acid-specific fluorescent dye Auramine-O followed by Nile Red which stains neutral lipids. Interestingly, as seen in FIG. 9 , the Mtb-infected TDM which were incubated under hypoxia for 7 days appeared to be fusing together. It is probable that these TDM are in the process of forming multinucleate giant cells (asterisk in FIG. 9A ) which are known to be present in the hypoxic environment of the granuloma in close vicinity to lipid-loaded macrophages. These observations support the hypothesis that this lipid-loaded macrophage system is a good model for in vivo latency.
[0057] Individual Mtb cells inside TDM that accumulated neutral lipids, as indicated by Nile Red staining, lost acid-fastness as shown by weak or total loss of Auramine-O staining ( FIG. 10 ). Conversely, Mtb cells which stained strongly with Auramine-O did not accumulate neutral lipids. This accumulation of neutral lipids and loss of acid-fastness by a subset of Mtb cells within lipid-loaded TDM under hypoxia, correlates well with our data in the Preliminary Results, that demonstrated the development of Rif resistance by about 25% of the Mtb population and increase in TG within Mtb from TDM under the same conditions. Since then, we have reconfirmed these results with additional experiments.
[0058] Based on these results, the multiple stress in vitro latency model disclosed herein appears to be the best one available for screening chemicals to discover drug candidates that can eliminate latent pathogen. Accordingly, in the drawings and specification there have been disclosed typical preferred embodiments of the invention and although specific terms may have been employed, the terms are used in a descriptive sense only and not for purposes of limitation. The invention has been described in considerable detail with specific reference to these illustrated embodiments. It will be apparent, however, that various modifications and changes can be made within the spirit and scope of the invention as described in the foregoing specification and as defined in the appended claims. | A method of inducing latency in Mycobacterium permits preparation of an in vitro model system of latent mycobacterial infection. Latency is induced in a pure culture of Mycobacterium by exposing it to multiple stress conditions, including a low nutrient culture medium without glycerol, a low pH, a relatively high level of carbon dioxide and a relatively low gas phase oxygen level. An in vitro model of mycobacterial infection employs macrophages induced from THP1 cells which are then infected with Mycobacterium . The infected macrophages are grown under hypoxic conditions to induce latency in the mycobacteria. The in vitro model of infection is useful in evaluating compounds for activity against latent mycobacteria. | 2 |
[0001] This is a continuation-in-part of PCT/JP00/05061, filed Jul. 28, 2000, which claims priority to U.S. Provisional Application No. 60/159,590, filed Oct. 18, 1999, and No. 60/183,322, filed Feb. 17, 2000; and Japanese Patent Application Nos. 11-248036, filed Jul. 29, 1999; 2000-118776, filed Jan. 11, 2000; 2000-183767, filed May 2, 2000; and 2000-241899, filed Jun. 9, 2000.
TECHNICAL FIELD
[0002] The present invention relates to novel human protein kinases and protein phosphatases, as well as to genes encoding the proteins.
BACKGROUND
[0003] A variety of physiological functions of cells have to be regulated correctly and harmoniously according to need for cells to differtiate/proliferate into normal cells, and further to exert functions at the tissue level. It has been well known that the regulation of the state of protein phosphorylation by protein phosphorylation enzyme/protein kinase (hereinafter referred to as “kinase”) and protein dephosphorylation enzyme/protein phosphatase (hereinafter referred to as “phosphatase”) plays a central role in most of such regulatory mechanisms.
[0004] Many kinase and phosphatase genes have been identified to date. It has been clarified that they form a very large protein family with a well conserved structure (Semin. Cell Biol. 5(6):367-76, 1994; Cell 80(2): 225-36, 1995; Genes Cells 1(2): 147-69, 1996; Trends Biochem. Sci. 22(1):18-22, 1997; Proc Natl Acad Sci USA 96(24):13603-10, 1999). The presence of numerous types of kinases and phosphatases in cells suggests that many types of intracellular physiological functions are precisely regulated by kinases and phosphatases. Thus, there is a possibility that agents acting on kinase or phosphatase can more precisely control physiological functions as compared with known agents represented by receptor agonist or receptor antagonist. Therefore, it is expected that agents acting on kinase or phosphatase are agents, which undesirable side effects can be much easily separated from the main effects, and accordingly, may function as highly useful pharmaceuticals.
[0005] In order to develop such agents acting on kinase or phosphatase, first, it is required to specify the intracellular physiological function associated with each of the kinases and phosphatases, and gain some information indicating the medical usefulness of suppressing or activating the function. Many types of kinases and phosphatases have been already isolated and studied. However, there may exist many unidentified molecules. Furthermore, with respect to kinases and phosphatases the genes of which have been isolated, it can be stated that information on intracellular physiological functions related with each kinase or phosphatase still are poor and has to be clarified. The identification of new kinase and phosphatase as well as clarification of physiological functions thereof is expected to make significant progress in the development of new pharmaceuticals and therapies.
SUMMARY
[0006] The object of the present invention is to provide novel human protein kinase and protein phosphatase proteins, genes encoding the proteins, as well as production and uses of the same.
[0007] To accomplish the object described above, the present inventors strenuously carried out researches as follows. First, the present inventors tried to select clones having the kinase/phosphatase-like structure (KP clones) from clones which had been isolated and the structures of which had been determined in the Helix Research Institute (hereinafter referred to as “helix clones”; Japanese Patent Application No. Hei 11-248036; Japanese Patent Application No. 2000-118776; Japanese Patent Application No. 2000-183767). These helix clones are highly expected to have the full-length sequence, which were obtained by the combined use of; [1] preparation of a cDNA library containing sequences of full-length at a high rate achieved by the oligo-capping method; and [2] evaluation system for the completeness in cDNA length based on the 5′-end sequence (the selection is achieved based on the evaluation using ATGpr after eliminating non-full length clones as compared with an EST). In addition, they are highly advantageous since the cDNAs are already inserted into a mammalian expression vector, they can be used promptly in experiments for the expression in cells.
[0008] The present inventors carried out homology search for all the helix clones using the amino acid sequences of known kinases and phosphatases as queries, and selected 2 clones: “C-NT2RP3001938” and “C-OVARC1000945” (hereinafter referred to as “KP clones”). These KP clones contain full-length cDNAs encoding novel human proteins. It has been known that many of known kinases and phosphatases are associated with a variety of signal transduction pathways in cells. Therefore, there is the possibility that the newly found KP clones having the kinase/phosphatase-like structure are also associated with some signal transduction pathways. The potential of the KP clones as target molecules in drug discovery can be explored through evaluating these KP clones in various assay systems using reporter genes and deducing the physiological functions thereof.
[0009] As described above, the present inventors found novel kinase/phosphatase proteins, and thereby accomplished the present invention.
[0010] Specifically, the present invention relates to novel human protein kinase and protein phosphatase proteins, genes encoding the proteins, and production and uses of the proteins and genes. More specifically, the present invention provides the following:
[0011] [1] a DNA of any one of the following (a) to (d):
[0012] (a) a DNA encoding a protein consisting of the amino acid sequence of SEQ ID NO:2 or 4,
[0013] (b) a DNA comprising the coding region of the nucleotide sequence of SEQ ID NO:1 or 3,
[0014] (c) a DNA encoding a protein which (i) comprises the amino acid sequence of SEQ ID NO:2 or 4 in which one or more amino acids are substituted, deleted, inserted and/or added, and (ii) is functionally equivalent to the protein consisting of the amino acid sequence of SEQ ID NO:2 or 4, and
[0015] (d) a DNA hybridizing under a stringent condition to a DNA consisting of the nucleotide sequence of SEQ ID NO: 1 or 3, which encodes a protein functionally equivalent to the protein consisting of the amino acid sequence of SEQ ID NO:2 or 4;
[0016] [2] a DNA encoding a partial peptide of a protein consisting of the amino acid sequence of SEQ ID NO:2 or 4;
[0017] [3] a protein or peptide encoded by the DNA of [α]or [2];
[0018] [4] a vector into which the DNA of [α]or [2] has been inserted;
[0019] [5] a host cell containing the DNA of [1] or [2], or containing the vector of [4];
[0020] [6] a method for producing the protein or peptide of [3], which comprises the steps of culturing the host cell of [5], and recovering the expressed protein from the host cell or the culture supernatant;
[0021] [7] an antibody binding to the protein of [3];
[0022] [8] a polynucleotide containing at least 15 nucleotides complementary to a DNA consisting of the nucleotide sequence of SEQ ID NO: 1 or 3, or the complementary strand thereof, and
[0023] [9] a method of screening for compounds binding to the protein of [3], which comprises the steps of:
[0024] (a) contacting a test sample with the protein or a partial peptide thereof,
[0025] (b) detecting the binding activity of the test sample with the protein or partial peptide thereof, and
[0026] (c) selecting a compound having the activity of binding to the protein or partial peptide thereof.
[0027] The present invention provides human-derived genes “C-NT2RP3001938” and “C-OVARC1000945” encoding novel kinase/phosphatase. The nucleotide sequence of cDNA of the human-derived gene “C-NT2RP3001938” is shown in SEQ ID NO:1, and the amino acid sequence encoded by the cDNA is shown in SEQ ID NO:2. The nucleotide sequence of cDNA of the human-derived gene “C-OVARC1000945” is shown in SEQ ID NO:3, and the amino acid sequence encoded by the cDNA is shown in SEQ ID NO:4.
[0028] The gene “C-NT2RP3001938” shown in SEQ ID NO:1 and “C-OVARC1000945” shown in SEQ ID NO:3 has an ORF encoding a protein consisting of 418 amino acids and 865 amino acids, respectively.
[0029] Hereinafter, unless otherwise stated, the above-mentioned genes of the present invention, “C-NT2RP3001938” and “C-OVARC1000945” are collectively called “KP genes”, and proteins encoded by respective genes are collectively called “KP proteins”.
[0030] The inventive KP proteins were selected as clones having the kinase/phosphatase-like structure from the clones isolated and whose structures had been already determined in the Helix Research Institute. The regulation of the phosphorylation state of proteins by kinase and phosphatase plays central roles in normal differentiation and/or proliferation of cells, as well as in physiological functions at the cellular level. Thus, the inventive proteins are expected to share important functions in living body, and therefore, are useful as target molecules in drug development. In addition, the inventive KP proteins can be used as reagents for phosphorylating or dephosphorylating proteins.
[0031] The helix clones were prepared by a special method, and are expected to contain cDNA of full-length chains in high probability (Japanese Patent Application No. Hei 11-248036; Japanese Patent Application No. 2000-118776; Japanese Patent Application No. 2000-183767). Furthermore, because the cDNAs are already inserted in a mammalian expression vector, they can be used promptly in experiments for the expression in cells. Thus, information on physiological functions of the genes can be gained by successively testing these vectors with various assay systems using reporter genes. It has been known that many of known kinases and phosphatases are associated with a variety of signal transduction pathways in cells, and thus, the inventive KP genes can be also associated with signal transduction. Various potential physiological functions of the inventive genes can be thoroughly examined by functional screening using reporter gene assay systems in which known types of signal transduction can be detected.
[0032] Assay systems using reporter genes are excellent experimental systems which enable assessment of a variety of intracellular physiological functions simply in a single format. Specifically, the functional screening is preformed by the following reporter gene assay. A vector containing the inventive KP gene is introduced into the host cell with reporter genes having a variety of enhancer elements, and the KP gene is expressed in the cell. When the expression level of the reporter gene is altered as compared to that of the control cells in which no vector containing the KP gene had been introduced, it can be concluded that the protein encoded by the KP gene acted on the enhancer element. Useful information on physiological functions of the inventive KP gene is expected to be provided by testing whether the inventive KP gene acts on a variety of enhancer elements or not. Large amount of information on signal transduction systems acting on the elements, functional genes regulated by the enhancer elements, and so on, are known for many enhancer elements. Thus, when a KP gene being tested is proved to act on an enhancer element, it is possible to deduce physiological functions in which the KP gene participates based on known information on the enhancer element.
[0033] In the functional screening, it is also beneficial to study not only actions of a KP gene expressed alone, but also influences of the KP gene on the action after some stimuli. More specifically, even if the KP gene alone does not exhibit any activity, there is the possibility that the activation of a particular element by a known type of stimulus is enhanced or suppressed by the coexpressed KP gene. Such a known type of stimulus includes, for example, ligands of a cell surface receptor (interleukins, growth factors, TGF-β family, TNF-α family, hormones, low-molecular-weight compounds, etc.); expression of factors associated with intracellular signal transduction (various kinases, various phosphatases, low-molecular-weight G protein binding protein family, Smad family, STAT family, TRAF family, cell surface receptors, etc.); stress stimuli (oxidation stress, mechanical stress, heat stress, etc.); and so on.
[0034] The assays using reporter genes can be conducted by those skilled in the art by using a variety of commercially available kits that are used conventionally. For example, Mercury™ Pathway Profiling Systems from Clontech, PathDetectR Trans-Reporting System and PathDetectR Cis-Reporting System from Stratagene, and such are included. The assays can be conducted according to standard methods as described in the literature (“Overview of Genetic Reporter Systems” In Current Protocols in Molecular Biology, Ed. Ausubel, F. M. et al., (Wiley & Sons, NY) Unit 9.6 (1995); Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory Press (Cold Spring Harbor, N.Y. (1989)).
[0035] When the luciferase gene is used as the reporter gene, the luciferase activity can be measured, for example, by a standard method using Dual-Luciferase™ Reporter Assay System from Promega or the like.
[0036] Reporter genes that can be used in the above-mentioned functional screening include, for example, secretory alkaline phosphatase gene, chloramphenicol acetyltransferase (CAT) gene, α-galactosidase gene, and such in addition to luciferase gene. Further, enhancer elements that are used in the reporter assay can be exemplified by Serum Response Element (SRE), cAMP Response Element (CRE), TPA Response Element (TRE), NFκB (Nuclear factor of κB cell)-binding element, Heat shock Response Element (HRE), Glucocorticoid Response Element (GRE), AP 1 (Activator protein 1: c-jun/c-fos complex)-binding element, NFAT (Nuclear Factor of Activated T-cells)-binding element, p53-binding element, interferon-γ activated element (Interferon Gamma Activated Sequence: GAS), Interferon-Stimulated Response Element (ISRE), E2F-binding element, STAT family-binding element, Smad family-binding element, TCF/LEF-binding element, GATA family-binding element, Sterol Regulatory Element (SRE), IRF (Interferon Regulatory Factor) family-binding element, PPAR γ-binding element and AhR-binding element.
[0037] 293 cell, Hela, NIH3T3, CV-1, Jurkat, vascular smooth muscle cell, vascular endothelial cell, and cardiac muscle cell can be exemplified as host cells that are used in the reporter assay.
[0038] Functionally equivalent proteins to the human KP proteins (SEQ ID NOs:2 and 4) are encompassed in the present invention. Such proteins include, for example, mutants, homologues, variants, and so on, of human KP proteins. The term “functionally equivalent” herein means that the protein of interest has a function of phosphorylating proteins and/or dephosphorylating proteins like the KP proteins. According to the following procedure, it can be judged whether or not the protein of interest phosphorylates a protein.
[0039] A kinase protein and a substrate protein are combined together in an appropriate reaction solution. After the reaction is conduced in the presence of ATP, the phosphorylation state of the substrate protein is measured to judge the phosphorylation activity. The kinase protein to be used can be purified from appropriate cell lines or extracts from tissue by commonly used biochemical methods. It is also possible to use kinase proteins obtained by the overexpression of introduced genes encoding kinase proteins into mammalian cells (COS7, CV-1, HEK293, HeLa, Jurkat, NIH3T3, etc.), insect cells (Sf9, etc.), E. coli , yeast, and so on. The phosphorylation state of the substrate protein can be measured in a liquid scintillation counter, autoradiography, and such, by using ATP labeled with radioisotope, such as [γ- 32 P] ATP.
[0040] Further, the phosphorylation state of the substrate protein can be measured by ELISA (enzyme-linked immunosorbent assay), Western blotting, etc. using phosphorylated protein specific antibodies or the like. Such substrate proteins to be used include proteins specific to particular kinases, as well as a variety of proteins, such as casein, histone, and myelin basic protein (MBP), which are known to be phosphorylated by non-specific kinases. Alternatively, synthetic peptides and such containing sequences that are phosphorylated may be also used.
[0041] Furthermore, the phosphorylation activity can be assessed by measuring the phosphorylation of the kinase protein per se (autophosphorylation). More specifically, the assay can be performed according to conventional methods described in Protein Phosphorylation: A Practical Approach. First Edition (Hardie D G. et al., Oxford University Press, 1993) or others.
[0042] It can be judged whether a protein of interest dephosphorylates a protein or not by using the following procedure.
[0043] A phosphatase protein and a pre-phosphorylated substrate protein are combined together in an appropriate reaction solution. Then, the decrease in the extent of phosphorylation of the substrate protein or the amount of phosphate released from the substrate protein is measured to assess the dephosphorylation activity. Those phosphatase proteins prepared by the same method as those described above for the assessment of the phosphorylation activity can be used as the phosphatase protein in this method. The same substrate protein mentioned above for the judgment of the phosphorylation activity can be used as the substrate protein herein. In addition, phosphorylase, phosphorylase kinase, and such can be also used as substrate proteins. The pre-phosphorylation of the substrate protein can be achieved by using appropriate kinase such as phosphorylase kinase, protein kinase A, tyrosine kinases including EGF receptor and so on. The phosphorylation state of the substrate protein can be assayed by the same method described above for the assessment of the phosphorylation activity. More specifically, the assay can be performed according to conventional methods described in “Protein Phosphorylation: A Practical Approach. First Edition (Hardie et al., Oxford University Press, 1993)”, and so on.
[0044] Further, the substrate protein to be phosphorylated or dephosphorylated by a test protein can be identified by expressing a cDNA expression library composed of phage vectors or the like, and assessing whether a protein expressed from each clone can be a substrate for the test protein or not. More specifically, the identification can be carried out by referring to the method described in “EMBO J. (1997) 16:1921-1933”. Alternatively, the substrate protein can be identified through the identification of proteins binding to the test protein by the yeast two-hybrid screening or the like. More specifically, the identification can be carried out by referring to the method described in “EMBO J. (1997) 16:1909-1920”.
[0045] One method for preparing functionally equivalent proteins well known to those skilled in the art involves the introduction of mutations into the proteins. For example, one skilled in the art can prepare proteins functionally equivalent to the human KP protein (SEQ ID NO:2 or 4) by introducing appropriate mutations into the amino acid sequence of the protein using the site-directed mutagenesis method (Hashimoto-Gotoh et al., Gene 152:271-275, 1995; Zoller et al., Methods Enzymol. 100:468-500, 1983; Kramer et al., Nucleic Acids Res. 12:9441-9456, 1984; Kramer et al., Methods. Enzymol. 154:350-367, 1987; Kunkel, Proc. Natl. Acad. Sci. USA 82:488-492, 1985; Kunkel, Methods Enzymol. 85:2763-2766, 1988) and such. Mutation of amino acids may occur in nature, too. The proteins of the present invention include proteins comprising the amino acid sequence of human KP protein (SEQ ID NO:2 or 4) in which one or more amino acids are mutated, so long as the resulting mutant protein is functionally equivalent to the protein. In such a mutant protein, the number of the amino acids to be mutated is usually 50 residues or less, preferably 30 residues or less, and more preferably 10 residues or less (e.g., 5 residues or less).
[0046] The amino acid residue to be mutated is preferably mutated into a different amino acid that allows the properties of the amino acid side-chain to be conserved. Examples of properties of amino acid side chains include: hydrophobic amino acids (A, I, L, M, F, P, W, Y, V), hydrophilic amino acids (R, D, N, C, E, Q, G, H, K, S, T), and amino acids comprising the following side chains: an aliphatic side-chain (G, A, V, L, I, P); a hydroxyl group containing side-chain (S, T, Y); a sulfur atom containing side-chain (C, M); a carboxylic acid and amide containing side-chain (D, N, E, Q); a base containing side-chain (R, K, H); and an aromatic containing side-chain (H, F, Y, W) (The parenthetic letters indicate the one-letter codes of amino acids).
[0047] It is well known that a protein having deletion, addition, and/or substitution of one or more amino acid residues in the sequence of a protein can retain the original biological activity (Mark et al., Proc. Natl. Acad. Sci. USA 81:5662-5666, 1984; Zoller et al., Nucleic Acids Res. 10:6487-6500, 1982; Wang et al., Science 224:1431-1433; Dalbadie-McFarland et al., Proc. Natl. Acad. Sci. USA 79:6409-6413, 1982).
[0048] A protein having the amino acid sequence of human KP protein to which one or more amino acid residues have been added, is exemplified by a fusion protein containing the human KP protein. Fusion proteins, in which the human KP protein is fused to other peptides or proteins, are included in the present invention. Fusion proteins can be made using techniques well known to those skilled in the art, for example, by linking the DNA encoding the human KP protein (SEQ ID NO:2 or 4) in frame with the DNA encoding other peptides or proteins, followed by inserting the DNA into an expression vector and expressing it in a host. There is no restriction as to the peptides or proteins to be fused to the protein of the present invention.
[0049] For instance, known peptides which may be used for the fusion include the FLAG peptide (Hopp et al., BioTechnology 6:1204-1210, 1988), 6× His that is made up of six histidine residues, 10× His, influenza hemagglutinin (HA), human c-myc fragment, VSV-GP fragment, p18HIV fragment, T7-tag, HSV-tag, E-tag, SV40 T antigen fragment, lck tag, α-tubulin fragment, B-tag, and Protein C fragment. Also, glutathione-S-transferase (GST), influenza hemagglutinin (HA), the constant region of immunoglobulin, β-galactosidase, maltose binding protein (MBP), and the like may be used as a protein to be fused with the protein of this invention. Fusion proteins can be prepared by fusing the DNA encoding these peptides or proteins, which are commercially available, with the DNA encoding the protein of the invention, and expressing the fused DNA.
[0050] An alternative method for preparing functionally equivalent proteins known to those skilled in the art utilizes, for example, the hybridization technique (Sambrook et al., Molecular Cloning 2nd ed. 9.47-9.58, Cold Spring Harbor Lab. Press, 1989). Generally, one skilled in the art can isolate DNAs highly homologous to the whole or part of the DNA sequence encoding the human KP protein (SEQ ID NO: 1 or 3), and then isolate proteins functionally equivalent to the human KP protein based on those DNAs isolated. The present invention includes proteins that are (i) encoded by a DNA hybridizing to a DNA encoding the human KP protein and (ii) functionally equivalent to the human KP protein. Such proteins include, for example, homologues derived from human and other animals (for example, protein encoded by a DNA from mouse, rat, rabbit, cattle, etc.).
[0051] Those skilled in the art can properly select hybridization conditions to be used for the isolation of DNAs encoding proteins functionally equivalent to the human KP protein. Hybridization conditions include low stringent conditions. Low stringent conditions may be, for example, 42° C. in 2× SSC and 0.1% SDS, preferably 50° C. in 2× SSC and 0.1% SDS for washing after hybridization. More preferably, high stringent conditions such as 65° C. in 0.1× SSC and 0.1% SDS may be chosen. DNA with higher homology may be efficiently obtained at higher temperature under these conditions. However, several factors are thought to influence the stringency of hybridization, such as temperatures and salt concentrations, and one skilled in the art can suitably select these factors to accomplish a similar stringency. More guidelines for the hybridization condition are available in the art, for example, in a reference by Sambrook et al., (1989, Molecular Cloning, A Laboratory Manual, Cold Spring Harbor Press, N.Y.) and in unit 2.10 of the reference by Ausubel et al. (1995, Current Protocols in Molecular Biology, John Wiley & Sons, N.Y.).
[0052] Also, in lieu of hybridization, it is also possible to isolate functionally equivalent proteins by a gene amplification method, such as PCR, by synthesizing sequences based on the sequence information of the DNA encoding the human KP protein (SEQ ID NO: 1 or 3) and using them as primers.
[0053] The proteins functionally equivalent to the human KP proteins encoded by the DNA isolated by the hybridization or gene amplification techniques, usually are highly homologous to the human KP proteins (SEQ ID NO:2 or 4) at the amino acid sequence level. The proteins of the invention include proteins functionally equivalent to the human KP protein and are highly homologous to the amino acid sequence of SEQ ID NO:2 or 4. “Highly homologous” means typically 65% or higher, preferably 75% or higher, more preferably 85% or higher, and even more preferably 95% or higher identity at the amino acid level. Homology between proteins can be determined according to the algorithm described in the literature (Wilbur et al., Proc. Natl. Acad. Sci. USA 80:726-730, 1983).
[0054] The proteins of the present invention may have variations in the amino acid sequence, molecular weight, isoelectric point, presence or absence of sugar chains, or form, depending on the cell or host used to produce them or the purification method utilized as described below. Nevertheless, so long as the protein obtained has a function equivalent to the human KP protein, it is within the scope of the present invention. For example, when the inventive protein is expressed in prokaryotic cells, e.g., E. coli , a methionine residue is added at the N-terminus of the original protein. The present invention also includes such proteins.
[0055] The proteins of the present invention can be prepared as recombinant proteins or as naturally occurring proteins, using methods commonly known in the art. The recombinant protein can be, for example, prepared as follows. The DNA encoding the protein of this invention (e.g., DNA having the nucleotide sequence of SEQ ID NO: 1 or 3) is inserted into an appropriate expression vector, and introduced into suitable host cells. Subsequently, the resulting transformants, the host cell inserted with the expression vector, are recovered, extracted and then purified by chromatography utilizing ion exchange, reverse phase, or gel filtration, or by affinity chromatography with a column in which the antibodies against the protein of the present invention are fixed, or by a combination of these columns.
[0056] Alternatively, the protein of the invention can be prepared by expressing the protein in host cells (e.g., animal cells or E. coli ) as a fusion protein with glutathione S transferase protein, or as a recombinant protein with multiple histidine residues. The expressed protein can be purified using a glutathione column or nickel column. Subsequently, if necessary, regions of the fusion protein (apart from the desired protein) can be digested and removed with thrombin, factor Xa, etc.
[0057] The natural protein corresponding to the protein of the invention can be isolated by methods well known in the art, for example, by purifying tissue or cell extracts containing a protein of the invention with an affinity column to which the antibody that binds to the protein of the present invention described below is bound. The antibody may be a polyclonal antibody or monoclonal antibody.
[0058] The term “substantially pure” as used herein in reference to a given polypeptide means that the polypeptide is substantially free from other biological macromolecules. For example, the substantially pure polypeptide is at least 75%, 80, 85, 95, or 99% pure by dry weight. Purity can be measured by any appropriate standard method known in the art, for example, by column chromatography, polyacrylamide gel electrophoresis, or HPLC analysis.
[0059] Accordingly, the invention includes a polypeptide having a sequence shown as SEQ ID NO:2 or 4. The invention also includes a polypeptide, or fragment thereof, that differs from the corresponding sequence shown as SEQ ID NO:2 or 4. The differences are, preferably, differences or changes at a non-essential residue or a conservative substitution. In one embodiment, the polypeptide includes an amino acid sequence at least about 60% identical to a sequence shown as SEQ ID NO:2 or 4, or a fragment thereof. Preferably, the polypeptide is at least 65%, 70%, 75%, 80%, 85%, 90%, 95%, 98%, 99% or more identical to SEQ ID NO:2 or 4 and has at least one phosphorylation-related function or activity described herein, e.g., the polypeptide has a kinase or phosphatase activity. Preferred polypeptide fragments of the invention are at least 10%, preferably at least 20%, 30%, 40%, 50%, 60%, 70%, or more, of the length of the sequence shown as SEQ ID NO:2 or 4 and have at least one cell differentiation-related function or activity described herein. Or alternatively, the fragment can be merely an immunogenic fragment.
[0060] The present invention also includes partial peptides of the proteins of the present invention. The partial peptides of the present invention comprise at least 7 or more amino acids, preferably 8 or more amino acids, more preferably 9 or more amino acids. The partial peptides can be used, for example, for generating antibodies against the protein of the present invention, screening of compounds binding to the protein of the present invention, or screening of promoters or inhibitors for the protein of the present invention. The partial peptides can be used as antagonists or competitive inhibitors for the protein of this invention. The partial peptides of the invention can be produced by genetic engineering, known methods of peptide synthesis, or by digesting the protein of the invention with an appropriate peptidase. For peptide synthesis, for example, solid phase synthesis or liquid phase synthesis may be used.
[0061] DNA encoding an inventive protein can be used for the production of the inventive protein in vivo and in vitro as described above; it is also applicable to, for example, gene therapy for diseases caused by the abnormality in the gene encoding the inventive protein and for diseases that can be treated by the inventive protein. Any type of DNA, such as cDNA synthesized from mRNA, genomic DNA or synthetic DNA, can be used so long as the DNA encodes a protein of the present invention. Also so long as they can encode a protein of the present invention, DNAs comprising arbitrary sequences based on the degeneracy of the genetic code are also included.
[0062] As used herein, an “isolated nucleic acid” is a nucleic acid, the structure of which is not identical to that of any naturally occurring nucleic acid or to that of any fragment of a naturally occurring genomic nucleic acid spanning more than three genes. The term therefore covers, for example, (a) a DNA which has the sequence of part of a naturally occurring genomic DNA molecule but is not flanked by both of the coding sequences that flank that part of the molecule in the genome of the organism in which it naturally occurs; (b) a nucleic acid incorporated into a vector or into the genomic DNA of a prokaryote or eukaryote in a manner such that the resulting molecule is not identical to any naturally occurring vector or genomic DNA; (c) a separate molecule such as a cDNA, a genomic fragment, a fragment produced by polymerase chain reaction (PCR), or a restriction fragment; and (d) a recombinant nucleotide sequence that is part of a hybrid gene, i.e., a gene encoding a fusion protein. Specifically excluded from this definition are nucleic acids present in random, uncharacterized mixtures of different DNA molecules, transfected cells, or cell clones, e.g., as these occur in a DNA library such as a cDNA or genomic DNA library.
[0063] Accordingly, in one aspect, the invention provides an isolated or purified nucleic acid molecule that encodes a polypeptide described herein or a fragment thereof. Preferably, the isolated nucleic acid molecule includes a nucleotide sequence that is at least 60% identical to the nucleotide sequence shown in SEQ ID NO:1 or 3. More preferably, the isolated nucleic acid molecule is at least 65%, 70%, 75%, 80%, 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or more, identical to the nucleotide sequence shown in SEQ ID NO: 1 or 3. In the case of an isolated nucleic acid molecule which is longer than or equivalent in length to the reference sequence, e.g., SEQ ID NO: 1 or 3, the comparison is made with the full length of the reference sequence. Where the isolated nucleic acid molecule is shorter that the reference sequence, e.g., shorter than SEQ ID NO: 1 or 3, the comparison is made to a segment of the reference sequence of the same length (excluding any loop required by the homology calculation).
[0064] As used herein, “% identity” of two amino acid sequences, or of two nucleic acid sequences, is determined using the algorithm of Karlin and Altschul (PNAS USA 87:2264-2268, 1990), modified as in Karlin and Altschul, PNAS USA 90:5873-5877, 1993). Such an algorithm is incorporated into the NBLAST and XBLAST programs of Altschul et al. (J. Mol. Biol. 215:403-410, 1990). BLAST nucleotide searches are performed with the NBLAST program, score=100, wordlength=12. BLAST protein searches are performed with the XBLAST program, score=50, wordlength=3. To obtain gapped alignment for comparison purposes GappedBLAST is utilized as described in Altschul et al (Nucleic Acids Res. 25:3389-3402, 1997). When utilizing BLAST and GappedBLAST programs the default parameters of the respective programs (e.g., XBLAST and NBLAST) are used to obtain nucleotide sequences homologous to a nucleic acid molecule of the invention.
[0065] The DNA of the present invention can be prepared using methods known in the art. For example, a cDNA library can be constructed from the cells expressing the protein of the present invention, and hybridization can be conducted using a part of the DNA sequence of the present invention (for example, SEQ ID NO: 1 or 3) as a probe. cDNA libraries may be prepared by, for example, the method described in the literature (Sambrook et al., Molecular Cloning, Cold Spring Harbor Laboratory Press, 1989), and also, commercially available ones can be used. Alternatively, the DNA of the present invention can be obtained by preparing the RNA from the cells expressing the protein of the present invention, synthesizing cDNA by reverse transcriptase, synthesizing the oligo-DNAs based on the DNA sequence of the present invention (for example, SEQ ID NO: 1 or 3), and amplifying the cDNA encoding the protein of the present invention by PCR using the oligonucleotides as primers.
[0066] The nucleotide sequence of the obtained cDNA is determined to find an open reading frame, and thereby the amino acid sequence of the protein of the invention can be obtained. The cDNA obtained may also be used as a probe for screening a genomic library to isolate a genomic DNA.
[0067] More specifically, mRNAs may first be prepared from a cell, tissue, or organ in which the protein of the invention is expressed. Known methods can be used to isolate mRNAs; for instance, total RNA can be prepared by guanidine ultracentrifugation (Chirgwin et al., Biochemistry 18:5294-5299, 1979) or the AGPC method (Chomczynski et al., Anal. Biochem. 162:156-159, 1987). mRNA may then be purified from total RNA using mRNA Purification Kit (Pharmacia) and such; alternatively, mRNA may be directly purified by QuickPrep mRNA Purification Kit (Pharmacia).
[0068] The obtained mRNA is used to synthesize cDNA using reverse transcriptase. cDNA may be synthesized by using a kit such as the AMV Reverse Transcriptase First-strand cDNA Synthesis Kit (Seikagaku Kogyo). Alternatively, cDNA may be synthesized and amplified following the 5′-RACE method (Frohman et al., Proc. Natl. Acad. Sci. USA 85:8998-9002, 1988; Belyavsky et al., Nucleic Acids Res. 17:2919-2932, 1989) which uses primers described herein, the 5′-Ampli FINDER RACE Kit (Clontech), and polymerase chain reaction (PCR).
[0069] A desired DNA fragment is prepared from the PCR products and ligated with a vector DNA. The recombinant vectors are used to transform E. coli and such, and a desired recombinant vector is prepared from a selected colony. The nucleotide sequence of the desired DNA is verified by conventional methods, such as dideoxynucleotide chain termination.
[0070] A DNA of the invention may be designed to have a sequence that is expressed more efficiently by taking into account the frequency of codon usage in the host to be used for expression (Grantham et al., Nucleic Acids Res. 9:43-74, 1981). The DNA of the present invention may be altered by a commercially available kit or a conventional method. For instance, the DNA may be altered by digestion with restriction enzymes, insertion of a synthetic oligonucleotide or an appropriate DNA fragment, addition of a linker, or insertion of the initiation codon (ATG) and/or the stop codon (TAA, TGA, or TAG).
[0071] The inventive DNA includes, specifically, a DNA comprising a stretch from A at nucleotide residue 366 to C at nucleotide residue 1619 from the nucleotide sequence of SEQ ID NO:1 as well as a stretch from A at nucleotide residue 33 to A at nucleotide residue 2627 from the nucleotide sequence of SEQ ID NO:3.
[0072] The DNA of the present invention also include a DNA hybridizing to a DNA consisting of the nucleotide sequence of SEQ ID NO: 1 or 3 and encoding a protein functionally equivalent to the above-mentioned protein of the present invention. Those skilled in the art can properly select the appropriate hybridization conditions, and specifically the above-mentioned conditions can be used. Under these conditions, the higher the temperature, the higher the homology of the obtained DNA will be. The above-mentioned hybridizing DNA is preferably a naturally occurring DNA, for example, cDNA or chromosomal DNA.
[0073] The present invention also provides a vector into which a DNA of the present invention is inserted. The vectors of the present invention are useful for maintaining the DNA of the present invention within host cells or expressing the protein of the invention.
[0074] When the E. coli is used as a host cell, there is no limitation other than that the vector should have an “ori” to amplify and mass-produce the vector in E. coli (e.g., JM109, DH5α, HB101, or XL1Blue), and a marker gene for selecting the transformed E. coli (e.g., a drug-resistance gene selected by a drug such as ampicillin, tetracycline, kanamycin, or chloramphenicol). For example, M13-series vectors, pUC-series vectors, pBR322, pBluescript, pCR-Script, and such can be used. pGEM-T, pDIRECT, pT7, and so on can also be used for subcloning and excision of the cDNA as well as the vectors described above. When a vector is used to produce a protein of the present invention, an expression vector is especially useful. The expression vector, for example, to be expressed in E. coli should have the above characteristics to be amplified in E. coli . When E. coli , such as JM109, DH5α, HB101, or XL1 Blue, is used as the host cell, the vector should have a promoter such as lacZ promoter (Ward et al., Nature 341:544-546, 1989; FASEB J. 6:2422-2427, 1992), araB promoter (Better et al., Science 240:1041-1043, 1988), or T7 promoter that can efficiently promote the expression of the desired gene in E. coli . Other examples of the vectors are pGEX-5×-1 (Pharmacia), “QlAexpress system” (Qiagen), pEGFP, and pET (for this vector, BL21, a strain expressing T7 RNA polymerase, is preferably used as the host).
[0075] Further, the vector may contain a signal sequence for the secretion of polypeptides. The pelB signal sequence (Lei et al., J. Bacteriol. 169:4379, 1987) can be used as a signal sequence for secretion of proteins, when the proteins are intended to be produced in the periplasm of E. coli . Introduction of the vector into a host cell can be performed, for example, by the calcium chloride method or electroporation.
[0076] In addition to the vectors for E. coli , for example, the vector for producing the proteins of this invention may be a mammal-derived expression vector (e.g., pcDNA3 (Invitrogen), pEGF-BOS (Nucleic Acids Res. 18(17):5322, 1990), pEF, and pCDM8), an insect cell-derived expression vector (e.g., “Bac-to-BAC baculovairus expression system” (GibcoBRL) and pBacPAK8), a plant-derived expression vector (e.g., pMH1 and pMH2), an animal virus-derived expression vector (e.g., pHSV, pMV, and pAdexLcw), a retrovirus-derived expression vector (e.g., pZIPneo), an yeast-derived expression vector (e.g., “Pichia Expression Kit” (Invitrogen), pNV11, and SP—QO1), a Bacillus subtilis -derived expression vector (e.g., pPL608 and pKTH50).
[0077] In order to express proteins in animal cells, such as CHO, COS, and NIH3T3 cells, the vector should have a promoter necessary for expression in such cells, e.g., SV40 promoter (Mulligan et al., Nature 277:108, 1979), MMLV-LTR promoter, EF1α promoter (Mizushima et al., Nucleic Acids Res. 18:5322, 1990), CMV promoter, etc., and more preferably it has a marker gene for selecting transformants (for example, a drug resistance gene selected by a drug (e.g., neomycin, G418, etc.)). Examples of vectors with these characteristics include pMAM, pDR2, pBK-RSV, pBK-CMV, pOPRSV, pOP13, and so on.
[0078] The method using CHO cells deficient in nucleic acid synthetic pathways as the host, and incorporating a vector (such as PCHOI) with a DHFR gene that compensates for the deficiency and amplifying the vector with methotrexate (MTX) can be mentioned as an example method for stably expressing a gene and amplifying the copy number in cells. And as a method for transient expression, a method transforming the COS cells, which have the gene for SV40 T antigen on the chromosome, with a vector (such as pcD) having the SV40 replication origin can be mentioned. The origin used for replication may be those of polyomavirus, adenovirus, bovine papilloma virus (BPV), and the like. In addition, the expression vector may include a selection marker gene for amplification of the gene copies in host cells. Examples of such markers include, but are not limited to, the aminoglycoside transferase (APH) gene, the thymidine kinase (TK) gene, the E. coli xanthine-guanine phosphoribosyl transferase (Ecogpt) gene, and the dihydrofolate reductase (dhfr) gene.
[0079] The DNA of the present invention can be expressed in animals by, for example, inserting a DNA of the invention into an appropriate vector and introducing the vector into a living body by the retrovirus method, liposome method, cationic liposome method, adenovirus method, and so on. Thus, gene therapy can be conducted for diseases caused by mutations in the KP gene of this invention. The vectors used include, but are not limited to, adenoviral vectors (e.g., pAdexlcw) and retroviral vectors (e.g., pZIPneo). General techniques for gene manipulation, such as insertion of the DNA of the invention into a vector, can be performed according to conventional methods (Molecular Cloning, 5.61-5.63). The DNA of this invention can be administered to the living body by an ex vivo method or in vivo method.
[0080] The present invention also provides a host cell into which the vector of the present invention has been introduced. The host cell into which the vector of the invention is introduced is not particularly limited. E. coli and various animal cells can be used. The host cell of this invention can be used as, for example, a production system for producing or expressing the protein of the invention. The production system for producing a protein of the invention may be both in vitro or in vivo production system. For in vitro production, eukaryotic cells or prokaryotic cells can be used.
[0081] Useful eukaryotic host cells may be animal, plant, or fungi cells. As animal cells, mammalian cells such as CHO (J. Exp. Med. 108:945, 1995), COS, 3T3, myeloma, baby hamster kidney (BHK), HeLa, or Vero cells, amphibian cells such as Xenopus oocytes (Valle et al., Nature 291:340-358, 1981), or insect cells such as Sf9, Sf21, or Tn5 cells can be used. CHO cells lacking DHFR gene (dhfr-CHO) (Proc. Natl. Acad. Sci. USA 77:4216-4220, 1980) or CHO K-1 (Proc. Natl. Acad. Sci. USA 60:1275, 1968) may also be used. Among the animal cells, CHO cells are particularly preferable for high-level expression. The vector can be introduced into the host cell by, for example, the calcium phosphate method, the DEAE-dextran method, cationic liposome DOTAP (Boehringer Mannheim) method, electroporation, lipofection, etc.
[0082] As plant cells, for example, plant cells originating from Nicotiana tabacum are known as protein production system and may be used as callus cultures. As fungi cells, yeast cells such as Saccharomyces, including Saccharomyces cerevisiae , or filamentous fungi such as Aspergillus, including Aspergillus niger , are known.
[0083] Useful prokaryotic cells include bacterial cells, such as E. coli , for example, JM109, DH5 α, and HB101, or Bacillus subtilis.
[0084] These cells are transformed by a desired DNA, and the resulting transformants are cultured in vitro to obtain the protein. Transformants can be cultured using known methods. Culture medium such as DMEM, MEM, RPMI1640, or IMDM may be used for animal cells. The culture medium can be used with or without serum supplement such as fetal calf serum (FCS). The pH of the culture medium is preferably between about 6 and 8. Cells are typically cultured at about 30 to 40° C. for about 15 to 200 hr, and the culture medium may be replaced, aerated, or stirred if necessary.
[0085] Animal and plant hosts may be used for in vivo production. For example, a desired DNA can be introduced into an animal or plant host. Encoded proteins are produced in vivo, and then are recovered. These animal and plant hosts are included in host cells of the present invention.
[0086] Animals to be used for the production system described above include mammals and insects. Mammals such as goat, porcine, sheep, mouse, and bovine may be used (Vicki Glaser, SPECTRUM Biotechnology Applications, 1993). Alternatively, the mammals may be transgenic animals.
[0087] For instance, a desired DNA may be prepared as a fusion gene, fused with a gene such as goat β casein gene which encodes a protein specifically produced into milk. DNA fragments comprising the fusion gene are injected into goat embryos, which are then transplanted back to female goats. Proteins of interest can be recovered from milk produced by the transgenic goats (i.e., those born from the goats that had received the embryos) or from their offspring. To increase the amount of milk containing the proteins produced by transgenic goats, hormones may be appropriately administered to them (Ebert et al., Bio/Technology 12:699-702, 1994).
[0088] Alternatively, insects, such as the silkworm, may be used. Baculoviruses into which the DNA encoding the protein of interest is inserted can be used to infect silkworms, and the desired protein can be recovered from their body fluid (Susumu et al., Nature 315:592-594, 1985).
[0089] As plants, for example, tobacco can be used. In use of tobacco, DNA encoding the protein of interest may be inserted into a plant expression vector, such as pMON530, which is introduced into bacteria, such as Agrobacterium tumefaciens . Then the bacteria is used to infect tobacco, such as Nicotiana tabacum , and a desired polypeptide can be recovered from their leaves (Julian et al., Eur. J. Immunol. 24:131-138, 1994).
[0090] A protein of the present invention obtained as above may be isolated from inside or outside of the host cells (e.g., culture media), and purified as a substantially pure homogeneous protein. The method for protein isolation and purification is not limited to any specific method; in fact, any standard method may be used. For instance, column chromatography, filter, ultrafiltration, salt precipitation, solvent precipitation, solvent extraction, distillation, immunoprecipitation, SDS-polyacrylamide gel electrophoresis, isoelectric point electrophoresis, dialysis, recrystallization, and so on may be appropriately selected and combined to isolate and purify the protein.
[0091] For example, affinity chromatography, ion-exchange chromatography, hydrophobic chromatography, gel filtration, reverse phase chromatography, adsorption chromatography, and such may be used for chromatography (Strategies for Protein Purification and Characterization: A Laboratory Course Manual. Ed. Daniel R. Marshak et al., Cold Spring Harbor Laboratory Press, 1996). These chromatographies may be performed by liquid chromatography such as HPLC and FPLC. Thus, the present invention includes highly purified proteins, purified by the above methods.
[0092] A protein of the present invention may be optionally modified or partially deleted by treating it with an appropriate protein modification enzyme before or after purification. Useful protein modification enzymes include, but are not limited to, trypsin, chymotrypsin, lysylendopeptidase, protein kinase, glucosidase, and so on.
[0093] The present invention also provides antibodies that bind to the protein of the invention. The antibody of the invention may take any form, including monoclonal antibody, as well as polyclonal antibodies. Furthermore, antiserum obtained by immunizing an animal such as rabbit with the protein of the invention, all classes of polyclonal and monoclonal antibodies, human antibodies, and humanized antibodies produced by genetic recombination are included.
[0094] A protein of the invention used as the antigen to obtain antibodies may be derived from any animal species, but preferably it is derived from a mammal, such as a human, mouse, or rat, and more preferably from human. A human-derived protein may be obtained from the nucleotide or amino acid sequences disclosed herein.
[0095] Herein, a protein used as an antigen may be a complete protein or partial peptides thereof.
[0096] A partial peptide may be, for example, an amino (N)-terminal or carboxy (C)-terminal fragment of the protein. Herein, an antibody is defined as an antibody that reacts with either the full-length or a fragment of the protein.
[0097] A gene encoding a protein of the invention or its fragment may be inserted into a known expression vector, which is used to transform a host cell as described herein. The desired protein or its fragment may be recovered from the outside or inside of the host cell by any standard method, and may be used as an antigen. Alternatively, cells expressing the protein or their lysates, or a chemically synthesized protein may be used as an antigen. Short peptides are preferably used as antigens by appropriately combining them with carrier proteins such as keyhole limpet hemocyanin, bovine serum albumin, and ovalbumin.
[0098] Any mammalian animal may be immunized with the antigen, but preferably the compatibility with parental cells used for cell fusion is taken into account. In general, animals of Rodentia, Lagomorpha, or Primates are used.
[0099] Animals of Rodentia include, for example, mouse, rat, and hamster. Animals of Lagomorpha include, for example, rabbit. Animals of Primates include, for example, a monkey of Catarrhini (old world monkey) such as crab-eating monkey, rhesus monkey, sacred baboon, or chimpanzee.
[0100] Methods for immunizing animals with antigens are known in the art. For instance, intraperitoneal injection or subcutaneous injection of antigens is used as a standard method for immunization of mammals. More specifically, antigens may be diluted and suspended in an appropriate amount with phosphate buffered saline (PBS), physiological saline, etc. If desired, the antigen suspension may be mixed with an appropriate amount of a standard adjuvant, such as Freund's complete adjuvant, made into emulsion, and then administered to mammals. Preferably, it is followed by several administrations of antigen mixed with an appropriately amount of Freund's incomplete adjuvant every 4 to 21 days. An appropriate carrier may also be used for immunization. After immunization as above, serum is examined for increase of the amount of desired antibodies by a standard method.
[0101] Polyclonal antibodies against the proteins of the present invention may be prepared by collecting blood from the immunized mammal examined for the increase of desired antibodies in the serum, and by separating serum from the blood by any conventional method. Serum containing the polyclonal antibodies, or if necessary, a fraction containing the polyclonal antibodies may be isolated from the serum to be used as the polyclonal antibodies of the present invention. For example, immunoglobulin G or M can be prepared by using an affinity column coupled with the protein of the invention to obtain the fraction exclusively recognizing the protein of the invention, and then, purifying the fraction by using protein A or protein G column.
[0102] To prepare monoclonal antibodies, immune cells are collected from the mammal immunized with the antigen and checked for the increased level of desired antibodies in the serum as described above, and are subjected to cell fusion. The immune cells used for cell fusion are preferably obtained from spleen. The other parent cell which is fused with the above immune cell is preferably a mammalian myeloma cell, and more preferably a myeloma cell that has acquired a special feature that can be used for selection of fusion cells by drugs.
[0103] Cell fusion of the above immune cell and myeloma cell may be performed by any standard method, such as those described in the literature (Galfre et al., Methods Enzymol. 73:3-46, 1981).
[0104] Hybridomas obtained by the cell fusion may be selected by cultivating them in a standard selection medium, such as HAT medium (hypoxanthine, aminopterin, and thymidine containing medium). The cell culture is typically continued in the HAT medium for several days to several weeks, the time being sufficient to allow all the other cells, except desired hybridoma (non-fused cells), to die. Then, the standard limiting dilution is performed to screen and clone a hybridoma cell producing the desired antibody.
[0105] Besides the above method, in which a nonhuman animal is immunized with an antigen for preparing hybridoma, human lymphocytes such as that infected by EB virus may be immunized with a protein, protein expressing cells, or their lysates in vitro. Then, the immunized lymphocytes are fused with human-derived myeloma cells that is capable of indefinitely dividing, such as U266, to yield a hybridoma producing a desired human antibody, able to bind to the protein can be obtained (Unexamined Published Japanese Patent Application (JP-A) No. Sho 63-17688).
[0106] Subsequently, the hybridomas thus obtained are transplanted into the abdominal cavity of a mouse from which the ascites is collected. The monoclonal antibodies thus obtained can be purified by, for example, ammonium sulfate precipitation or by column chromatography using a protein A or protein G column, a DEAE ion exchange column, an affinity column to which the protein of the invention is coupled, and such. The antibody of the invention can be used not only for purifying and detecting the protein of the invention, but also as a candidate for an agonist or antagonist to the protein of the present invention. It is also expected to use the antibody for antibody therapy of diseases associated with the protein of this invention. When the antibody obtained is administered to the human body (antibody therapy), human antibodies or humanized antibodies are preferred to reduce immunogenicity.
[0107] For example, transgenic animals having a repertory of human antibody genes may be immunized with a protein, protein expressing cells, or their lysates as an antigen. Antibody producing cells are collected from the animals, and fused with myeloma cells to obtain hybridoma, from which human antibodies against the protein can be prepared (see WO92-03918, WO93-2227, WO94-02602, WO94-25585, WO96-33735, and WO96-34096).
[0108] Alternatively, an immune cell, such as an immunized lymphocyte, producing antibodies may be immortalized by an oncogene and used for preparing monoclonal antibodies.
[0109] Monoclonal antibodies thus obtained can also be recombinantly prepared using genetic engineering techniques (see, for example, Borrebaeck C. A. K. and Larrick J. W. Therapeutic Monoclonal Antibodies, published in the United Kingdom by MacMillan Publishers LTD (1990)). A DNA encoding an antibody may be cloned from an immune cell, such as hybridomas or immunized lymphocytes producing the antibody; inserted into an appropriate vector; and introduced into host cells to prepare a recombinant antibody. The present invention also includes recombinant antibodies prepared as described above.
[0110] The antibody of the present invention may be a fragment of an antibody or modified antibody, so long as it binds to the protein of the invention. For instance, the antibody fragment may be Fab, F(ab′) 2 , Fv, or single chain Fv (scFv), in which Fv fragments from H and L chains are ligated by an appropriate linker (Huston J. S. et al. Proc. Natl. Acad. Sci. USA 85:5879-5883, 1988). More specifically, an antibody fragment may be generated by treating an antibody with an enzyme such as papain or pepsin. Alternatively, a gene encoding the antibody fragment may be constructed; inserted into an expression vector; and expressed in an appropriate host cell (see, for example, Co et al., J. Immunol. 152:2968-2976, 1994; Better et al., Methods Enzymol. 178:476-496, 1989; Pluckthun et al., Methods Enzymol. 178:497-515, 1989; Lamoyi, Methods Enzymol. 121:652-663, 1986; Rousseaux et al. Methods Enzymol. 121:663-669, 1986; Bird et al., Trends Biotechnol. 9:132-137, 1991).
[0111] An antibody may be modified by conjugation with a variety of molecules, such as polyethylene glycol (PEG). The antibody of the present invention includes such modified antibodies. A modified antibody can be obtained by chemically modifying an antibody. These modification methods have been already established in the field.
[0112] Alternatively, the antibody of the present invention may be obtained as a chimeric antibody, between a variable region derived from nonhuman antibody and the constant region derived from human antibody, or as a humanized antibody, comprising the complementarity determining region (CDR) derived from nonhuman antibody, the frame work region (FR) derived from human antibody, and the constant region. Such antibodies can be prepared by using known technology.
[0113] Obtained antibodies may be purified to homogeneity. The antibodies can be separated and purified by using standard methods for protein separation and purification. For instance, column chromatography such as affinity chromatography, filter, ultrafiltration, salt precipitation, dialysis, SDS-polyacrylamide gel electrophoresis, isoelectric point electrophoresis, and so on may be appropriately selected and combined to isolate and purify the antibody (Antibodies: A Laboratory Manual. Ed Harlow and David Lane, Cold Spring Harbor Laboratory, 1988), but methods are not limited to them. The concentration of the antibody obtained as described above can be determined by the measurement of absorbance, enzyme-linked immunosorbent assay (ELISA), or others.
[0114] Columns for affinity chromatography include protein A column and protein G column.
[0115] For example, protein A column includes Hyper D, POROS, Sepharose F. F. (Pharmacia) and the like.
[0116] In addition to affinity chromatography, chromatographic methods include, for example, ion exchange chromatography, hydrophobic chromatography, gel filtration, reverse-phase chromatography, adsorption chromatography and others (“Strategies for Protein Purification and Characterization: A Laboratory Course Manual” Ed Daniel R. Marshak et al., Cold Spring Harbor Laboratory Press, 1996). These chromatographic methods can be conducted by using liquid chromatography such as HPLC and FPLC.
[0117] For example, absorbance measurement, enzyme-linked immunosorbent assay (ELISA), enzyme immunoassay (EIA), radioimmunoassay (RIA), or immunofluorescence may be used to measure the antigen binding activity of the antibody of the invention. In ELISA, the antibody of the present invention is immobilized on a plate; the protein of the invention is applied to the plate; and then a sample containing a desired antibody, such as culture supernatant of antibody producing cells or purified antibodies, is applied. Then, a secondary antibody that recognizes the primary antibody and which is labeled with an enzyme such as alkaline phosphatase is applied, and the plate is incubated. After washing, an enzyme substrate, such as p-nitrophenyl phosphate, is added to the plate, and the absorbance is measured to evaluate the antigen binding activity of the sample. A fragment of the protein, such as a C-terminal fragment, may be used as a protein. BIAcore (Pharmacia) may be used to evaluate the activity of the antibody according to the present invention.
[0118] The above methods allow for the detection or measurement of the protein of the invention, by exposing the antibody of the invention to a sample assumed to contain the protein of the invention, and detecting or measuring the immune complex formed by the antibody and the protein. Because the method of detection or measurement of the protein according to the invention can specifically detect or measure a protein, the method may be useful in a variety of experiments in which the protein is used.
[0119] The present invention also provides a polynucleotide containing at least 15 nucleotides complementary to the DNA (SEQ ID NO: 1 or 3) encoding the human KP protein or the complementary strand thereof.
[0120] Herein, the term “complementary strand” is defined as one strand of a double strand DNA composed of A:T and G:C base pair to the other strand. Also, “complementary” is defined as not only those completely matching within a continuous region of at least 15 nucleotides, but also having a homology of at least 70%, favorably 80% or higher, more favorably 90% or higher, and most favorably 95% or higher within that region. The homology may be determined using the algorithm described herein.
[0121] Such a nucleic acid includes probes and primers used for the detection and amplification of DNA encoding the inventive protein; probes and primers used for the detection of expression of the DNA; and nucleotide and nucleotide derivatives (e.g., antisense oligonucleotide and ribozyme, or DNAs encoding them, etc.) used for the regulation of expression of the inventive protein. In addition, such a nucleic acid can also be used for the preparation of DNA chip.
[0122] When used as primers, such nucleic acids are complementary at the 3′ end, and restriction enzyme recognition sequences or tags can be added to the 5′ end.
[0123] The antisense oligonucleotides include, for example, antisense oligonucleotides hybridizing to any region of the nucleotide sequence of SEQ ID NO: 1 or 3. The antisense oligonucleotide is preferably an antisense of a continuous sequence of a length of 15 nucleotides or longer within the nucleotide sequence of SEQ ID NO:1 or 3. More preferably, the above continuous sequence of a length of 15 nucleotides or longer contains the translation initiation codon.
[0124] A derivative or modified form of antisense oligonucleotide may also be used. The modified antisense oligonucleotides may be those modified with lower alkylphosphonate such as methylphosphonate and ethylphosphonate; phosphorothioate; phosphoroamidate; and so on.
[0125] Herein, an antisense oligonucleotide is not restricted to those in which all nucleotides are complementary to the corresponding nucleotides within a given region of a DNA or mRNA; so long as it can specifically hybridize with the nucleotide sequences of SEQ ID NO: 1 or 3, it may have one or more nucleotide mismatches.
[0126] A derivative of the antisense oligonucleotide of the present invention may act on cells producing the protein of the invention and may bind to a DNA or mRNA encoding the protein, whereby inhibiting the expression of the protein of the invention by inhibiting its transcription or translation, or by promoting the degradation of mRNA, and thereby inhibiting the function of the protein of the invention.
[0127] A derivative of the antisense oligonucleotide of the present invention may be mixed with appropriate carriers which are inactive against the derivative, and may be used as a medicine for externally application such as salve or poultice.
[0128] If necessary, it may be mixed with an excipient, isotonizing agent, solubilizing agent, stabilizer, preservative, pain-killer, or the like, and prepared as a tablet, powder, granule, capsule, liposome capsule, injectable solution, liquid formulation, nose drops, freeze-dried agent, etc. The above may be achieved according to standard methods.
[0129] For treating patients, a derivative of an antisense oligonucleotide of the present invention may be, for example, directly applied to the affected area of a patient, or administered into blood vessels so as to finally reach the affected area. Moreover, the derivative may be encapsulated in antisense-encapsulating materials such as liposome, poly-L-lysine, lipid, cholesterol, lipofectin, or their derivative in order to increase durability and/or membrane permeability.
[0130] Dose of the derivative of the antisense oligonucleotide of the present invention may be appropriately adjusted depending on the patient's conditions, and a favorable amount such as 0.1 to 100 mg/kg, or more preferably 0.1 to 50 mg/kg may be administered.
[0131] As the antisense oligonucleotides of the present invention inhibit expression of the protein of the invention, they find utility as inhibitors of the biological activity of the protein of the invention. An inhibitor of expression comprising the antisense oligonucleotide of the present invention is useful because it can inhibit the biological activity of the protein of the invention.
[0132] The protein of the invention may be used to screen for compounds that bind to the protein of the present invention. Specifically, the protein may be used in methods of screening for compounds, which method comprises the steps of exposing the protein of the present invention to a test sample in which a compound binding to the protein is expected to be contained; and selecting the compound having the activity of binding to the protein.
[0133] The proteins of the invention used for screening may be recombinant or natural proteins, or partial peptides. Alternatively, they may be expressed on the surface of cells or in the form of a membrane fraction. There is no particular restriction on the test sample as it includes, for example, cell extract, cell culture supernatant, product of fermentation microorganism, extract from marine organism, extract from plant, purified or crude protein, peptide, non-peptide compound, synthetic low-molecular-weight compound, natural compound, etc. The inventive protein to be contacted with a test sample can be contacted with the test sample, for example, as a purified protein, as a soluble protein, in a form of protein immobilized on carriers, as a fusion protein with other proteins, in a form of protein presented on cell membrane, as a membrane fraction.
[0134] Many methods known to those skilled in the art can be used to screen proteins capable of binding to the inventive protein. Such screening can be carried out, for example, by the immunoprecipitation method. Specifically, the method can be carried out as follows. The gene encoding a protein of this invention is expressed by inserting the gene into a vector for foreign gene expression in pSV2neo, pcDNA I, pCD8, and such, and expressing the gene in animal cells, etc. Any generally used promoters may be employed for the expression, including the SV40 early promoter (Rigby In Williamson (ed.), Genetic Engineering, Vol. 3. Academic Press, London, p.83-141 (1982)), EF-1 α promoter (Kim, et al. Gene 91:217-223, 1990), CAG promoter (Niwa et al., Gene 108:193-200, 1991), RSV LTR promoter (Cullen, Methods Enzymology 152:684-704, 1987), SR a promoter (Takebe et al., Mol. Cell. Biol. 8:466, 1988), CMV immediate early promoter (Seed et al., Proc. Natl. Acad. Sci. USA 84:3365-3369, 1987), SV40 late promoter (Gheysen et al., J. Mol. Appl. Genet. 1:385-394, 1982), Adenovirus late promoter (Kaufman et al., Mol. Cell. Biol. 9:946, 1989), HSV TK promoter, etc.
[0135] Transfer of a foreign gene into animal cells for its expression can be performed by any of the following methods, including the electroporation method (Chu et al., Nucl. Acid Res. 15:1311-1326, 1987), the calcium phosphate method (Chen et al., Mol. Cell. Biol. 7:2745-2752, 1987), the DEAE dextran method (Lopata et al., Nucl. Acids Res. 12:5707-5717, 1984; Sussman et al., Mol. Cell. Biol. 4:1642-1643, 1985), the lipofectin method (Derijard, Cell. 7:1025-1037, 1994; Lamb et al., Nature Genetics 5:22-30, 1993; Rabindran et al., Science 259:230-234, 1993), etc.
[0136] The protein of this invention can be expressed as a fusion protein having a recognition site for a monoclonal antibody by introducing the recognition site (epitope) for the monoclonal antibody, the specificity of which has been established, into the N- or C-terminus of the protein of this invention. For this purpose, commercial epitope-antibody systems can be utilized (Igaku, Experimental Medicine 13:85-90, 1995). Vectors which can express fusion proteins with the β-galactosidase, maltose-binding protein, glutathione S-transferase, green fluorescence protein (GFP), and such, via the multi-cloning site are commercially available.
[0137] There is also a report that a fusion protein may be prepared by introducing only small epitope portions consisting of several to a dozen amino acid residues so as not to change the property of the protein of the present invention by the fusion. For example, epitopes such as polyhistidine (His-tag), influenza hemagglutinin (HA), human c-myc, FLAG, Vesicular stomatitis virus glycoprotein (VSV-GP), T7 gene 10 protein (T7-tag), human herpes simplex virus glycoprotein (HSV-tag), E-tag (epitope on the monoclonal phage), and such, and monoclonal antibodies to recognize them can be utilized as the epitope-antibody system for screening proteins binding to the protein of this invention (Igaku, Experimental Medicine 13:85-90, 1995).
[0138] In immunoprecipitation, immune complexes are formed by adding these antibodies to the cell lysate prepared using suitable surfactants. The immune complex comprises a protein of this invention, a protein comprising the binding ability with the protein, and an antibody. Immunoprecipitation can be also performed by using antibodies against a protein of this invention, besides using antibodies against the above-described epitopes. An antibody to a protein of this invention can be prepared, for example, by inserting a gene encoding the protein of the invention into an appropriate expression vector of E. coli to express it in the bacterium, purifying the expressed protein, and immunizing rabbits, mice, rats, goats, chicken, and such against the purified protein. The antibody can be also prepared by immunizing the above-described animals against synthetic partial peptides of the protein of the present invention.
[0139] Immune complexes can be precipitated using, for example, Protein A Sepharose and Protein G Sepharose when the antibody is a murine IgG antibody. In addition, if a protein of this invention is prepared as a fusion protein with the epitope, such as GST, an immune complex can be formed by using a substance specifically binding to these epitopes, such as glutathione-Sepharose 4B, in the same manner as in the use of the antibody against the protein of the present invention.
[0140] Immune precipitation, in general, may be carried out according to, or following the method described in the literature (Harlow, E. and Lane, D.: Antibodies, pp.511-552, Cold Spring Harbor Laboratory publications, New York, 1988).
[0141] SDS-PAGE is generally used for the analysis of immunoprecipitated proteins. Bound proteins can be analyzed based on the molecular weights of proteins using a gel of an appropriate concentration. In this case, although proteins bound to a protein of this invention, in general, are hardly detectable by the usual protein staining method, such as Coomassie staining and silver staining, the detection sensitivity can be improved by culturing cells in a medium containing radioisotopes, such as 35 S-methionine and 35 S-cysteine, to label proteins inside the cells, and detecting the labeled proteins. Once the molecular weight of the protein is determined, the desired protein can be purified directly from the SDS-polyacrylamide gel and can be sequenced.
[0142] In addition, proteins binding to a protein of this invention can be isolated using the West-western blotting method (Skolnik et al., Cell 65:83-90, 1991) with the protein of this invention. Namely, cDNA is isolated from cells, tissues, and organs, in which the protein binding to a protein of this invention is expected to be expressed (e.g., liver and kidney), and transferred into a phage vector (for example, λgt11, ZAP, and such) to prepare a cDNA library, which is then expressed on LB-agarose plates. The protein thus expressed is fixed on a filter; reacted with the labeled, purified protein of this invention; and plaques expressing a protein bound to a protein of this invention can be detected by the label. Methods for labeling the proteins of this invention include methods using the binding activity of biotin and avidin; methods using antibodies specifically binding to the proteins of this invention, or peptides or polypeptides fused with the protein of this invention (e.g., GST); methods using the radioisotopes; methods using fluorescence; etc.
[0143] Alternatively, in another embodiment of the method for screening of the present invention, the two-hybrid system utilizing cells may be used (Fields et al., Trends Genet. 10:286-292, 1994; Dalton et al., Cell 68:597-612, 1992; “MATCHMAKER Two-Hybrid System”, “Mammalian MATCHMAKER Two-Hybrid Assay Kit”, “MATCHMAKER One-Hybrid System (all from Clontech), “HybriZAP Two-Hybrid Vector System” (Stratagene)). In the two-hybrid system, an inventive protein or a partial peptide thereof is fused with the SRF DNA-binding region or GAL4 DNA-binding region, and then is expressed in yeast cells; a cDNA library, which express proteins in the form of fusion protein with the VP 16 or GAL4 transcription activation region, is prepared from cells that are predicted to express a protein binding to an inventive protein; the resulting cDNA library is introduced into the above-mentioned yeast cells; and then a cDNA derived from the library is isolated from a detected positive clone (when a protein binding to the inventive protein is expressed in yeast cells, the reporter gene is activated by the binding of the two proteins, and thus positive clones are detectable). A protein encoded by the cDNA can be prepared after the isolated cDNA is introduced and expressed in E. coli . Thus it is possible to prepare a protein binding to an inventive protein or the encoding gene. Reporter genes to be used in the two-hybrid system include, but are not limited to, for example, Ade2 gene, LacZ gene, CAT gene, luciferase gene, PAI-1 (Plasminogen activator inhibitor type1) gene in addition to HIS3 gene. The screening by the two-hybrid method can be conduced by using mammalian cells or others in addition to yeast.
[0144] Compounds binding to a protein of the present invention can be screened by affinity chromatography. For example, a protein of the invention is immobilized on a carrier of an affinity column, and a test sample, in which a protein binding to the protein of the invention is supposed to be expressed, is applied to the column. A test sample herein may be, for example, cell extracts, cell lysates, etc. After loading the test sample, the column is washed, and proteins bound to a protein of the invention can be prepared.
[0145] The amino acid sequence of the resulting protein is then analyzed. Based on the result, an oligo-DNA is synthesized and used as the probe to screen a cDNA library. This can provide a DNA encoding the protein.
[0146] In the present invention, a biosensor on the basis of surface plasmon resonance phenomenon can be used as a means to detect or assay the bound compounds. By utilizing the biosensor on the basis of surface plasmon resonance phenomenon, the interaction between the inventive protein and a test compound can be observed as a surface plasmon resonance signal in real time using a small amount of protein without labeling (e.g., BIAcore, Pharmacia). Thus the binding between the inventive protein and the test compound can be assessed by using biosensor of BIAcore, or the like.
[0147] In addition, methods are known in the art for isolating compounds binding to a protein of the invention, which are not limited only to proteins (including agonists and antagonists). Such methods include, for example, the method of screening for a molecule binding to a protein of the invention by contacting a synthetic compound or natural substance bank, or a random phage peptide display library with an immobilized protein of the invention, and the high-throughput screening method using a combinatorial chemistry technique (Wrighton et al., Science 273:458-64, 1996; Verdine G. L., Nature 384:11-13, 1996; Hogan J. C. Jr., Nature 384:17-9, 1996).
[0148] Compounds isolated by the screening of this invention are candidates for agents to regulate the activity of a protein of this invention, and thought to be applied to treatments for disorders caused by expressional and functional abnormalities, and such of the protein, and diseases which can be treated by controlling the activity of the protein. Compounds which can be obtained by the screening method of this invention, the partial structure of which is modified by addition, deletion and/or substitution, are also included in the compounds binding to the protein of this invention.
[0149] When a protein of this invention or compounds isolated by the screening of this invention are used as drugs for humans and other animals, for example, mice, rats, guinea pigs, rabbits, chickens, cats, dogs, sheep, pigs, cattle, monkeys, baboons, and chimpanzees, they can be administered by directly administering the protein or isolated compound itself to a patient or by administering it after formulated according to known pharmaceutical methods. They can be administered, as the occasion demands, for example, orally, as sugar-coated tablets, capsules, elixirs and microcapsules, or parenterally, in the form of sterile solutions in water or other pharmaceutically acceptable liquids, or suspensions for injections. For example, they may be formulated by appropriately mixing with pharmaceutically acceptable carriers or media, specifically sterile water, physiological saline, plant oil, emulsifying agents, suspending agents, surfactants, stabilizers, seasonings, excipients, vehicles, anticeptics, binders, and such, in the unit dosage form required in a generally accepted pharmaceutical procedure. Amounts of effective ingredients in these pharmaceutical preparations are adjusted so as to obtain the appropriate dose in the specified range.
[0150] Additives which can be mixed in tablets and capsules include, for example, binders such as gelatin, corn starch, tragacanth gum and arabic gum; excipients such as crystalline cellulose; bulking agents such as corn starch, gelatin and alginic acid; lubricants such as magnesium stearate; sweetening agents such as sucrose, lactose or saccharine; and flavors such as peppermint, Gaultheria adenothrix oil or cherry. When the dispensing unit form is a capsule, liquid carriers, such as oil, can be further added to the above-described materials. Sterile compositions for injection can be prescribed using vehicles such as distilled water for injection according to standard pharmaceutical procedure.
[0151] Aqueous solutions for injections include, for example, physiological saline, and isotonic solutions containing: glucose and other supplements such as D-sorbitol, D-mannose, D-mannitol, sodium chloride, and such; and suitable solubilizers, for example, alcohols, more specifically, ethanol, polyalcohols such as propylene glycol, polyethylene glycol, non-ionic surfactants such as polysorbate 80 (TM) and HCO-50 may be used together.
[0152] Oily solutions, including sesame oil and soybean oil, and benzyl benzoate and benzyl alcohol may be used together as the solubilizer. Injections may be combined with buffers such as phosphate buffer and sodium acetate buffer; soothing agents such as procaine hydrochloride; stabilizers such as benzyl alcohol, phenols and antioxidants. Injections thus prepared are typically filled in suitable ampules.
[0153] The administration to patients is done by methods commonly known to those skilled in the art, such as intraarterial, intravenous, or subcutaneous injections, as well as intranasal, bronchial, intramuscular, percutaneous, or oral administrations. One skilled in the art can suitably select the dosage according to the body-weight or age of a patient, or the method of administration. If the compound can be encoded by DNA, the DNA may be used for gene therapy by incorporating the DNA into a vector for gene therapy. Dosages and administration methods vary depending on the body-weight, age, symptoms, and such of patients, but those skilled in the art can appropriately select them.
[0154] Although the specific dosage of the protein of the invention changes according to the subject to be treated, the target organs, symptoms, and administration methods, it is generally considered to be, for example, about 100 μg to 20 mg one day for an adult (as body-weight 60 kg) in the form of injections.
[0155] Though they vary depending on the symptoms, doses of compounds binding to a protein of this invention or compounds regulating the activity of such a protein may be generally in the range of about 0.1 to 100 mg, preferably about 1.0 to 50 mg, and more preferably about 1.0 to 20 mg per day for adults (based on the body weight 60 kg) in the case of oral administration.
[0156] Though it varies depending on the subject to be administered, target organ, symptom and method of administration, a single dose of the compounds for the parenteral administration is thought to be preferably administered, for example, when it is in the form of injection, intravenously to normal adults (based on the body weight 60 kg) in the range of about 0.01 to 30 mg, preferably about 0.1 to 20 mg, and more preferably about 0.1 to 10 mg or thereabout per day. Doses converted on the 60 kg body weight basis or the body surface area can be similarly administered to other animals.
[0157] All publications and patents cited herein are incorporated by reference in their entirety
DETAILED DESCRIPTION
[0158] The invention is illustrated more specifically with reference to the following examples, but is not to be construed as being limited thereto.
EXAMPLE 1
Construction of a cDNA Library by the Oligo-Capping Method
[0159] The NT-2 neuron progenitor cells (Stratagene), teratocarcinoma cells from human fetal testis, which can be differentiated into neurons by the treatment with retinoic acid were cultured for two weeks after induction treatment by the addition of retinoic acid according to the manufacturer's instructions.
[0160] After the culture, the respective cells were collected, and mRNA was extracted according to the method described in the literature (Sambrook et al., Molecular Cloning 2nd edition, Cold Spring harbor Laboratory Press, 1989). Then, poly(A) + RNA was purified by using oligo dT cellulose.
[0161] Similarly, human ovary cancer tissue (OVARC1) was used to extract mRNA by the method described in the literature (Sambrook et al., Molecular Cloning 2nd edition, Cold Spring Harbor Laboratory Press, 1989). Furthermore, poly(A) + RNA was purified from the mRNA using oligo-dT cellulose.
[0162] This poly(A) + RNA was used to construct a cDNA library by the oligo-capping method (Maruyama et al., Gene 138:171-174, 1994). Using the Oligo-cap linker (agcaucgagu cggccuuguu ggccuacugg/SEQ ID NO:5) and the Oligo-dT primer (gcggctgaag acggcctatg tggccttttt tttttttt tt/SEQ ID NO:6), bacterial alkaline phosphatase (BAP) treatment, tobacco acid phosphatase (TAP) treatment, RNA ligation, the first strand cDNA synthesis, and removal of RNA were performed according to the references (Suzuki et al., Protein, Nucleic acid and Enzyme, 41:197-201, 1996; Suzuki et al., Gene 200:149-156, 1997). Then, 5′- and 3′-PCR primers (agcatcgagt cggccttgtt g/SEQ ID NO:7, and gcggctgaag acggcctatg t/SEQ ID NO:8, respectively) were used for performing PCR to convert the cDNA into double stranded cDNA, which was then digested with SfiI. Then, the DraIII-cleaved vector pUC19FL3 or pME18SFL3 (GenBank AB009864, expression vector) (NT2RP3, OVARC1) was used for cloning the cDNA in a unidirectional manner, and cDNA libraries were obtained. The nucleotide sequence of the 5′- and 3′-ends of the cDNA clones was analyzed with a DNA sequencer (ABI PRISM 377, PE Biosystems) after sequencing reactions performed with the DNA sequencing reagents (Dye Terminator Cycle Sequencing FS Ready Reaction Kit, dRhodamine Terminator Cycle Sequencing FS Ready Reaction Kit, or BigDye Terminator Cycle Sequencing FS Ready Reaction Kit, PE Biosystems), according to the instructions. The obtained data were used for a database.
[0163] Oligo-cap high full-length ratio cDNA library of NT2RP3 was prepared by using an expression vector, pME18SFL3, which can be expressed in eukaryotic cells. pME18SFL3 vector contains the SRα promoter and SV40 small t intron in the upstream, as well as the SV40 polyA addition signal sequence downstream of the cloning site, respectively. As the cloning site of pME18SFL3 has asymmetrical DraIII sites, and the ends of cDNA fragments contain SfiI sites complementary to the DraIII sites, the cloned cDNA fragments can be unidirectionally inserted downstream of the SRα promoter. Therefore, clones containing full-length cDNA can be expressed transiently by introducing the obtained plasmid directly into COS cells. Thus, the clones can be analyzed very easily in terms of the proteins that are the gene products of the clones, or in terms of the biological activities of the proteins.
EXAMPLE 2
Estimation of the Completeness at the 5′-ends of the Clones Contained in the cDNA Libraries Constructed by the Oligo-Capping Method
[0164] The full-length ratio at the 5′-end sequence of respective clones in the human cDNA libraries constructed by the oligo-capping method was determined as follows. The clones whose 5′-end sequences were consistent with those of known human mRNA in the public database were judged to be “full-length” if they had a longer 5′-end sequence than that of the known human mRNA; or even though the 5′-end sequence was shorter, if it contained the translation initiation codon it was judged to have the “full-length” sequence. Clones which did not contain the translation initiation codon were judged to be “not-full-length”. The full-length ratio ((the number of full-length clones)/(the number of full-length and not-full-length clones)) at the 5′-end of the cDNA clones from each library was determined by comparing with known human mRNA. As a result, the full-length ratio of the 5′-ends was 63.5%. The result indicates that the full-length ratio at the 5′-end sequence was extremely high in the human cDNA clones obtained by the oligo-capping method.
EXAMPLE 3
Assessment of the Full-Length Ratio of the 5′-End of the cDNA by the ATGpr and the ESTiMateFL
[0165] The ATGpr, developed by Salamov A. A., Nishikawa T., and Swindells M. B. in the Helix Research Institute, is a program for prediction of the translation initiation codon based on the characteristics of the sequences in the vicinity of the ATG codon (Salamov et al., Bioinformatics 14:384-390, 1998; http://www.hri.cojp/atgpr/). The results are shown with expectations (also mentioned as ATGpr1 below) whether the ATG is a true initiation codon (0.05-0.94). When it was not considered that the sequence was the 5′-end of the cDNA or not, both of the sensitivity and specificity of analytical results by this program were estimated as 66%. When the program was applied to the 5′-end sequences of the clones from the cDNA library that was obtained by the oligo-capping method having 65% full-length ratio, the sensitivity and specificity of the estimation of the full-length clone (clone containing the N-terminus of the ORF) were improved to 82 to 83% by selecting only clones having an ATGpr1 score 0.6 or higher. The maximum ATGpr1 scores for 5′-end sequences of NT2RP3001938 and OVARC1000945 were 0.32 and 0.74, respectively.
[0166] Next, the ESTiMateFL was used for the assessment of the clones. The ESTiMateFL, developed by Nishikawa and Ota in the Helix Research Institute, is a method for selecting clones expected to have a full-length cDNA by comparing with the 5′-end or 3′-end sequences of ESTs in the public database.
[0167] By this method, a cDNA clone is judged to be most likely not to be full-length if there exist any ESTs which have longer 5′-end or 3′-end sequences than the clone. The method is systematized for high throughput analysis. A clone is judged to be full-length if the clone has a longer 5′-end sequence than the ESTs in the public database corresponding thereto. Even if a clone has a shorter 5′-end, the clone is judged to be full-length if the difference in length is within 50 bases, and otherwise judged not to be full-length, for convenience. Those clones whose 5′-end sequence is matching with the known mRNA, about 80% of the clones judged to be full-length by the comparison with ESTs were also judged to be full-length by the assessment of the 5′-end sequence by comparing with known mRNA. Also, about 80% of the clones judged to be not full-length in the 5′-end sequence by comparing with ESTs were also judged to be not full-length in the 5′-end sequence by comparison with known mRNA. The precision of the estimation by comparing with ESTs is improved with increasing numbers of ESTs to be compared. However, in case with limited numbers of ESTs, the reliability becomes low. Thus, the method is effective in excluding clones with high probability of being not-full-length from the cDNA clones that is synthesized by the oligo-capping method having a 5′-end sequence full-length ratio of about 60%. In particular, the ESTiMateFL is efficiently used in estimating the full-length ratio at the 3′-end sequence of cDNA of a human unknown mRNA, a significant number of which are deposited in the public database as EST deposits.
[0168] Results of the above assessment for the full-length ratio showed that the clone “C-OVARC1000945” was a novel clone with a high probability of being full-length and also which shares no sequence identity with any of human EST sequences at least either at the 5′-end sequence or 3′-end sequence, or both ends.
[0169] Furthermore, “C-NT2RP3001938” is also a full-length clone; the number of human EST sequences that shared a common sequence to each of these clones at the 5′-end was 20 or less (clones which do not share sequences with certain human EST sequences at least either at the 5′-end or at 3′-end, or at both ends of the clone; excluding clones in which the number of human EST sequences that shared a common sequence to each of the clones at both of the 5′- and 3-end was 1 or more and 5 or less). Accordingly, they were concluded to be novel clones.
EXAMPLE 4
Selection of Clones having a Kinase/Phosphatase-Like Sequence
[0170] Clones having a kinase/phosphatase-like sequence were selected from the helix clones. All the helix clones were searched for homology by NCBI TBLASTN2.0 by using the following 31 amino acid sequences of known kinases and phosphatases (also including phospholipid kinases) as queries. Clones with a expectation value (Expect) 1.0e-05 or lower were selected.
[0171] The query sequences used in the homology search as well as their SEQ ID NOs and GenBank accession numbers are as follows.
Query sequence No. SEQ ID NO: GenBank accession No. hLKB1 9 gi|3024670 hVRK1 10 gi|4507903 hCDC2 11 gi|4502709 hAuroraK1 12 gb|AAC12708.1 hAuroraK2 13 gi|4759178 hIKKA 14 gb|AAC51662.1 hMKK3 15 gb|AAB40653.1 hERK1 16 pir|A48082 hRAF1 17 gi|4506401 hAKT 18 gi|4885061 hPIKP85 19 sp|P27986 hATM 20 gi|4502267 hc-src 21 gi|4758078 hJAK1 22 ref|NP_002218.1 hFLT1 23 gb|AAC16449.1 hPP2A 24 gi|4506017 hMKP2 25 gb|AAC50452.1 hVHR 26 gi|4758208 hPTP-SL 27 gi|4506325 hSTEP 28 sp|P54829 hPTEN 29 gi|4506249 Cdc14B1 30 gb|AAD15415.1 DUSP12 31 gi|6005956 AK000449 32 gi|8923413 DUS7 33 sp|Q16829 calcineurin A alpha 34 gi|6715568 PNP1 35 emb|CAA56124.1 TPTE 36 gi|7019559 PPP1CC 37 gi|4506007 PP-1 gamma 38 gb|AAA19823.1 PP2A 39 gi|4506017
[0172] The results of homology search were shown in Table 1.
TABLE 1 Search score Expectation Query Helix clone (score) value (expect) hAuroraK1 C-NT2RP3001938 55 4e-08 hAuroraK2 C-NT2RP3001938 51 5e-07 hMKK3 C-NT2RP3001938 80 7e-16 hRAF1 C-NT2RP3001938 62 4e-10 PNP1 C-OVARC1000945 93 5e-19
[0173] Based on the result, non-overlapping 2 clones, C-NT2RP3001938 and C-OVARC 1000945, were selected as clones having kinase/phosphatase-like structure (KP clones). The clones encode novel human proteins, and each of the proteins was deduced to function as a protein kinase and/or a protein phosphatase.
EXAMPLE 5
Gene Expression Analysis by Hybridization using High Density DNA Filter
[0174] DNA for spotting onto the nylon membranes was prepared according to the following procedure. E. coli was cultured in each well of a 96-well plate (in a LB medium at 37° C. for 16 hours). A part of each culture was suspended in 10 μl of sterile water in the well of a 96-well plate. The plate was heated at 100° C. for 10 minutes. Then the samples were analyzed by PCR. PCR was performed in a 20 μl solution per one reaction by using TaKaRa PCR Amplification Kit (Takara) according to the supplier's protocol. A pair of sequencing primers, ME761FW (5′ tacggaagtgttacttctgc 3′/SEQ ID NO:40) and ME1250RV (5′ tgtgggaggffttttctcta 3′/SEQ ID NO:41), or a pair of primers, M13M4 (5′ gttttcccagtcacgac 3′/SEQ ID NO:42) and M13RV (5′ caggaaacagctatgac 3′/SEQ ID NO:43) were used for the amplification of the insert cDNA in the plasmid. PCR was performed in a thermal cycler, GeneAmp System 9600 (PE Biosystems). The cycling profile consisted of pre-heating at 95° C. for 5 minutes; 10 cycles of denaturation at 95° C. for 10 seconds, and annealing/extension at 68° C. for 1 minute; 20 cycles of denaturation at 98° C. for 20 seconds and annealing/extension at 60° C. for 3 minutes; and final extension at 72° C. for 10 minutes. After the PCR, 2 μl of the reaction solution was electrophoresed on a 1% agarose gel. DNA on the gel was stained with ethidium bromide to confirm the amplification of cDNA. When cDNAs were not amplified by PCR, plasmids containing the corresponding insert cDNAs were prepared by the alkali-extraction method (Sambrook et al., Molecular Cloning, A laboratory manual, 2nd edition, Cold Spring Harbor Laboratory Press, 1989).
[0175] DNA array was prepared by the following procedure. An Aliquot of the DNA solution was added to each well of a 384-well plate. DNA was spotted onto a nylon membrane (Boehringer) by using a 384-pin tool of Biomek 2000 Laboratory Automation System (Beckman-Coulter). More specifically, the 384-well plate containing the DNA was placed under the 384-pin tool. The independent 384 needles of the pin tool were simultaneously dipped into the DNA solution to fix the DNA on the needles. The needles were gently pressed onto a nylon membrane, and the DNA fixed on the needles was spotted onto the membrane. Denaturation of the spotted DNA and immobilization of the DNA on the nylon membrane were carried out according to conventional methods (Sambrook et al., Molecular Cloning, A laboratory manual, 2nd edition, Cold Spring Harbor Laboratory Press, 1989).
[0176] 1 st strand cDNA labeled with radioisotope was used as the hybridization probe. The 1 st strand cDNA was synthesized by using Thermoscript ™ RT-PCR System (GIBCO). More specifically, the 1st strand cDNA was synthesized by using 1.5 μg mRNAs from various human tissues (Clontech), 1 μl 50 μM Oligo(dT)20, and 50 μCi [α 33 P]dATP according to the attached protocol. Purification of the probe was carried out by using ProbeQuant™ G-50 micro column (Amersham-Pharmacia Biotech) according to the attached protocol. In the next step, 2 units of E. coli RNaseH were added to the reaction mixture. The mixture was incubated at room temperature for 10 minutes, and then 100 μg of human COT-1 DNA (GIBCO) was added thereto. The mixture was incubated at 97° C. for 10 minutes, and then was allowed to stand on ice to give the hybridization probe.
[0177] Hybridization of the radioisotope-labeled probe to the DNA array was performed in a usual manner (Sambrook et al., Molecular Cloning, A laboratory manual, 2nd edition, Cold Spring Harbor Laboratory Press, 1989). The membrane was washed as follows: the nylon membrane was washed three times by incubating in the Washing solution 1 (2× SSC, 1% SDS) at room temperature (about 26° C.) for 20 minutes; then the membrane was washed 3 times by incubating it in the Washing solution 2 (0.1× SSC, 1% SDS) at 65° C. for 20 minutes. Autoradiography was performed by using an image plate for BAS2000 (Fuji Photo Film Co., Ltd.). Specifically, the nylon membrane used for the hybridization was wrapped with a piece of Saran Wrap, and was contacted with the light-sensitive surface of the image plate. The membrane with the image plate was placed in an imaging cassette for radioisotope and was allowed to stand in dark for 4 hours. The radioactivity recorded on the image plate was analyzed by BAS2000 (Fuji Photo Film Co., Ltd.) and was recorded as an image file of the autoradiogram by electronic conversion. The signal intensity of each DNA spot was analyzed by using Visage High Density Grid Analysis Systems (Genomic Solutions Inc.). The signal intensity was converted into numerical data. The data were taken by duplicated measurements. The reproducibility was assessed by comparing the signal intensities of the corresponding spots on the duplicated DNA filters that were hybridized to a single DNA probe. The ratio between the corresponding spots falls within a range of 2-folds or less in 95% of entire spots, and the correlation coefficient was r=0.97. Thus, the reproducibility was assumed to be satisfactory.
[0178] The detection sensitivity in gene expression analysis was estimated by examining increases in the signal intensity of the probe concentration-dependent spot of the hybridization using a probe complementary to the DNA spotted on the nylon membrane. PLACE1008092 (the same DNA as that deposited in GenBank Accession No. AF107253) was used as the DNA. The DNA array with the DNA of PLACE1008092 was prepared according to the above-mentioned method. The probe was prepared as follows: mRNA was synthesized in vitro from the clone, PLACE1008092; using this mRNA as the template, radioisotope-labeled 1st strand cDNA was synthesized in the same manner as the probe preparation method described above; and the cDNA was used as the probe. The cDNA PLACE1008092 was inserted into pBluescript SK(−), so that the 5′-end of the PLACE1008092 is ligated to the T7 promoter of the pBluescript SK(−) to give a recombinant plasmid for in vitro synthesis of the mRNA from PLACE1008092. Specifically, the PLACE1008092 inserted at the DraIII site of the pME18SFL3 was cut out by XhoI digestion. The resulting PLACE1008092 fragment was ligated to XhoI-predigested pBluescript SK(−) by using the DNA ligation kit ver.2 (Takara). The in-vitro mRNA synthesis from PLACE1008092 inserted in pBluescript SK(−) was carried out by using the Ampliscribe™ T7 high yield transcription kit (Epicentre technologies). The hybridization and analysis of signal intensity of each DNA spot were conducted using the same methods described above. When the probe concentration was 1×10 7 μg/ml or less, there was no increase of signal intensity proportional to the probe concentration. Therefore it was assumed to be difficult to compare the signals with one another in this concentration range. Thus, spots with a intensity of 40 or less were indiscriminately taken as low-level signals. Within a concentration of the probe ranging from 1×10 7 μg/ml to 0.1 μg/ml, signals were found to increase in a probe concentration-dependent manner. The detection sensitivity is 1:100,000 in a ratio of mRNA expression level in a sample.
[0179] Table 2 shows the expression of each cDNA in human normal tissues (heart, lung, pituitary gland, thymus, brain, kidney, liver and spleen). The expression levels are indicated by numerical values of 0 to 10,000. Each of the “C-NT2RP3001938” and “C-OVARC1000945” was expressed in at least one tissue.
TABLE 2 Pituitary Clone name Heart Lung gland Thymus Brain Kidney Liver Spleen GAPDH 38.210 32.670 23.820 13.580 11.230 21.120 24.910 22.440 β-actin 279.280 368.870 111.100 117.500 92.880 114.650 82.990 256.790 NT2RP3001938 40.274 25.723 28.062 7.496 13.890 31.768 21.367 10.885 OVARC1000945 72.670 66.756 35.734 31.061 28.439 44.288 57.299 34.609
EXAMPLE 6
Analysis of Disease-Associated Genes
[0180] Non-enzymic protein glycation reaction is believed to be a cause of a variety of chronic diabetic complications. Accordingly, genes of which expression is elevated or decreased in a glycated protein-specific manner are associated with diabetic complications caused by glycated proteins. Vascular endothelial cells are affected with glycated proteins present in blood.
[0181] Reaction products of non-enzymic protein glycation include amadori compound (glycated protein) as a mildly glycated protein and advanced glycation endproduct as a heavily glycated protein. Hence, whether or not the expression of the KP genes of this invention was varied depending on the presence of these proteins in endothelial cells was examined.
[0182] The mRNAs were extracted from endothelial cells that were cultured in the presence or absence of glycated protein. The mRNAs were converted into radiolabeled first strand cDNAs for preparing probes. The probes were hybridized to the above-mentioned DNA array. Signal of each DNA spot was detected by BAS2000 and analyzed by ArrayGauge (Fuji Photo Film Co., Ltd.).
[0183] Advanced glycation endproduct of bovine serum albumin was prepared as follows: bovine serum albumin (BSA; Sigma) was incubated in a phosphate buffer solution containing 50 mM glucose at 37° C. for 8 weeks; and the resulting brownish BSA was dialyzed against a phosphate buffer solution.
[0184] Human normal pulmonary arterial endothelial cells (Cell Applications) were cultured in an Endothelial Cell Growth Medium (Cell Applications). The culture dish (Falcon) with the cells was incubated in a CO 2 incubator (37° C., 5% CO 2 , in a humid atmosphere). When the cells were grown to be confluent in the dish, 250 μg/ml of bovine serum albumin (sigma), glycated bovine serum albumin (Sigma) or advanced glycation endproduct of serum albumin was added thereto and the cells were incubated for 33 hours. The mRNA was extracted from the cells by using a FastTrack ™ 2.0 kit (Invitrogen). The labeling of hybridization probe was carried out by using the mRNA according to the same procedure as described above.
[0185] Table 3 shows the expression level of each cDNA in human pulmonary arterial endothelial cells cultured in a medium containing bovine serum albumin, glycated bovine serum albumin or advanced glycation endproduct of bovine serum albumin. The expression of “C-NT2RP3001938” was detected in the endothelial cell.
TABLE 3 Advanced Glycated Advanced glycation glycation bovine albumin endproduct of bovine endproduct of addition/ serum albumin/ Bovine serum Glycated bovine serum Bovine serum Bovine serum Clone name albumin bovine albumin albumin albumin ratio albumin ratio GAPDH(Cr1) 100.81 134.21 115.16 1.33 1.14 βactin(Cr2) 1101.9 1092.57 997.36 0.99 0.91 NT2RP3001938 44.42 42.62 38.19 0.96 0.9
Example 7
Analysis of Ultraviolet Radiation Damage-Associated Genes
[0186] It is known that ultraviolet rays give considerably adverse influence on health. In recent years, the risks of tissue damage by ultraviolet rays has been increased due to the destruction of the ozone layer, and ultraviolet radiation has been recognized as a risk factor for diseases such as skin cancers (United States Environmental Protection Agency: Ozone Depletion Home Page, http://www.epa.gov/ozone/). Genes whose expression levels change with exposure of the skin epidermal cells to ultraviolet rays are considered to be associated with skin damage caused by ultraviolet radiation. Culturing primary cultured skin fibroblast cells irradiated with ultraviolet ray, it was examined whether the expression of KP genes of this invention varies depending on the irradiation of ultraviolet ray. First, after culturing to confluence in a culture dish, the primary cultured skin fibroblast cells (Cell Applications) were exposed to 10,000 PJ/cm 2 of 254-nm ultraviolet light. Thereafter, messenger RNAs were extracted by using a FastTrack™ 2.0 mRNA Isolation kit (Invitrogen) from the unexposed cells and from the cells that were exposed to the ultraviolet light and then cultured for 4 or 24 hours. The labeling of the hybridization probe was carried out by using 1.5 μg of each mRNA in the same manner as described above. The data were obtained in triplicate (n=3). The hybridization signals were compared between the cells exposed to the ultraviolet light and the unexposed cells. The comparison was preformed by statistical treatment with two-sample t-test. Clones with significant differences in the signal distribution were selected under the condition of p<0.05. According to the analysis, the difference in the signal values can be also detected statistically even when the signal values are low. Accordingly, clones with signal value of 40 or lower were also assessed.
[0187] Table 4 shows the expression of each cDNA in skin-derived fibroblast cells exposed and unexposed to ultraviolet light.
[0188] Averaged signal values (M 1 , M 2 ) and sample variances (s 1 2 , s 2 2 ) were calculated for each gene in each of the cells, and then, pooled sample variances s were obtained from the sample variances of the two types of cells to be compared. The t values were determined according to the following formula: t=(M 1 −M 2 )/s/(1/3+1/3) 1/2 . When the determined t-value was greater than a t-value at P, probability of significance level, of 0.05 or 0.01 in the t-distribution table with 4 degrees of freedom, it was judged that a difference exists in the expression level of the gene between the two types of cells at P<0.05 or P<0.01, respectively. The table also includes the information of an increase (+) or decrease (−) in the average expression level of a signal in the clones compared with that of undifferentiated cells.
[0189] The results showed that the expression level of “C-OVARC1000945” was reduced 4 hours or 24 hours after ultraviolet ray irradiation, suggesting that it is a clone associated with ultraviolet ray disorders.
TABLE 4 UV_0 h UV_4 h UV_24 h t test 4 h 24 h Clone Exp. 1 Exp. 2 Exp. 3 Exp. 1 Exp. 2 Exp. 3 Exp. 1 Exp. 2 Exp. 3 0/4 0/24 +/− +/− GAPDH(Cr1) 0 1.29 0.1 0.9 0.06 1.18 1.49 0.47 0 βactin(Cr2) 256.82 283.53 414.29 388.38 117.29 329.8 189.18 190.26 157.87 * − OVARC1000945 15 14.98 13.39 5.71 5.62 7.78 3.1 4.11 2.76 ** ** − −
INDUSTRIAL APPLICABILITY
[0190] The present invention provides novel human protein kinase and protein phosphatase proteins, as well as genes encoding the proteins. The regulation of the phosphorylation state of proteins by kinase and/or phosphatase plays central roles in normal differentiation and/or proliferation of cells, as well as in physiological functions at the cellular level. The novel kinases and phosphatases of the present invention can be assumed to be closely associated with intracellular physiological functions, and thus, the inventive proteins are useful as target molecules of agents in the development of pharmaceuticals. Furthermore, agents acting on the inventive proteins are expected to be effective pharmaceuticals which can control intracellular physiological functions more precisely than agents represented by previous receptor agonists and antagonists.
1
43
1
2174
DNA
Homo sapiens
CDS
(366)..(1619)
1
ccccgccttc tcgctgccca gccccgggga gggaggcggg gccgcgaccc cggcgcgggt 60
ggggcgaatg cgttcccagc gggtagcctg gggctggtgc agagttccaa gcccacggcc 120
ccggtcgcgg cctcgccgcc ctcccgcgcc ccgcgccggg agcgggccta gagcgctcgc 180
ctcgcccctc cgcgagcagg gctctggcgc ccgcccctgt ccgcaccgct ggcagcctga 240
agagagtcgc tggccgtggt cgccgctagg taggatatat ctgcatcttg aaaggaagat 300
aaaacaaaag ccttctttgg aatagatgga tttttgtcac tttctgtgtg aactaaagtg 360
attca atg tct ctt ttg gat tgc ttc tgc act tca aga aca caa gtt gaa 410
Met Ser Leu Leu Asp Cys Phe Cys Thr Ser Arg Thr Gln Val Glu
1 5 10 15
tca ctc aga cct gaa aaa cag tct gaa acc agt atc cat caa tac ttg 458
Ser Leu Arg Pro Glu Lys Gln Ser Glu Thr Ser Ile His Gln Tyr Leu
20 25 30
gtt gat gag cca acc ctt tcc tgg tca cgt cca tcc act aga gcc agt 506
Val Asp Glu Pro Thr Leu Ser Trp Ser Arg Pro Ser Thr Arg Ala Ser
35 40 45
gaa gta cta tgt tcc acc aac gtt tct cac tat gag ctc caa gta gaa 554
Glu Val Leu Cys Ser Thr Asn Val Ser His Tyr Glu Leu Gln Val Glu
50 55 60
ata gga aga gga ttt gac aac ttg act tct gtc cat ctt gca cgg cat 602
Ile Gly Arg Gly Phe Asp Asn Leu Thr Ser Val His Leu Ala Arg His
65 70 75
act ccc aca gga aca ctg gta act ata aaa att aca aat ctg gaa aac 650
Thr Pro Thr Gly Thr Leu Val Thr Ile Lys Ile Thr Asn Leu Glu Asn
80 85 90 95
tgc aat gaa gaa cgc ctg aaa gct tta cag aaa gcc gtg att cta tcc 698
Cys Asn Glu Glu Arg Leu Lys Ala Leu Gln Lys Ala Val Ile Leu Ser
100 105 110
cac ttt ttc cgg cat ccc aat att aca act tat tgg aca gtt ttc act 746
His Phe Phe Arg His Pro Asn Ile Thr Thr Tyr Trp Thr Val Phe Thr
115 120 125
gtt ggc agc tgg ctt tgg gtt att tct cca ttt atg gcc tat ggt tca 794
Val Gly Ser Trp Leu Trp Val Ile Ser Pro Phe Met Ala Tyr Gly Ser
130 135 140
gca agt caa ctc ttg agg acc tat ttt cct gaa gga atg agt gaa act 842
Ala Ser Gln Leu Leu Arg Thr Tyr Phe Pro Glu Gly Met Ser Glu Thr
145 150 155
tta ata aga aac att ctc ttt gga gcc gtg aga ggg ttg aac tat ctg 890
Leu Ile Arg Asn Ile Leu Phe Gly Ala Val Arg Gly Leu Asn Tyr Leu
160 165 170 175
cac caa aat ggc tgt att cac agg agt att aaa gcc agc cat atc ctc 938
His Gln Asn Gly Cys Ile His Arg Ser Ile Lys Ala Ser His Ile Leu
180 185 190
att tct ggt gat ggc cta gtg acc ctc tct ggc ctg tcc cat ctg cat 986
Ile Ser Gly Asp Gly Leu Val Thr Leu Ser Gly Leu Ser His Leu His
195 200 205
agt ttg gtt aag cat gga cag agg cat agg gct gtg tat gat ttc cca 1034
Ser Leu Val Lys His Gly Gln Arg His Arg Ala Val Tyr Asp Phe Pro
210 215 220
cag ttc agc aca tca gtg cag ccg tgg ctg agt cca gaa cta ctg aga 1082
Gln Phe Ser Thr Ser Val Gln Pro Trp Leu Ser Pro Glu Leu Leu Arg
225 230 235
cag gat tta cat ggg tat aat gtg aag tca gat att tac agt gtt ggg 1130
Gln Asp Leu His Gly Tyr Asn Val Lys Ser Asp Ile Tyr Ser Val Gly
240 245 250 255
att aca gca tgt gaa tta gcc agt ggg cag gtg cct ttc cag gac atg 1178
Ile Thr Ala Cys Glu Leu Ala Ser Gly Gln Val Pro Phe Gln Asp Met
260 265 270
cat aga act cag atg ctg tta cag aaa ctg aaa ggt cct cct tat agc 1226
His Arg Thr Gln Met Leu Leu Gln Lys Leu Lys Gly Pro Pro Tyr Ser
275 280 285
cca ttg gat atc agt att ttc cct caa tca gaa tcc aga atg aaa aat 1274
Pro Leu Asp Ile Ser Ile Phe Pro Gln Ser Glu Ser Arg Met Lys Asn
290 295 300
tcc cag tca ggt gta gac tct ggg att gga gaa agt gtg ctt gtc tcc 1322
Ser Gln Ser Gly Val Asp Ser Gly Ile Gly Glu Ser Val Leu Val Ser
305 310 315
agt gga act cac aca gta aat agt gac cga tta cac aca cca tcc tca 1370
Ser Gly Thr His Thr Val Asn Ser Asp Arg Leu His Thr Pro Ser Ser
320 325 330 335
aaa act ttc tct cct gcc ttc ttt agc ttg gta cag ctc tgt ttg caa 1418
Lys Thr Phe Ser Pro Ala Phe Phe Ser Leu Val Gln Leu Cys Leu Gln
340 345 350
caa gat cct gag aaa agg cca tca gca agc agt tta ttg tcc cat gtt 1466
Gln Asp Pro Glu Lys Arg Pro Ser Ala Ser Ser Leu Leu Ser His Val
355 360 365
ttc ttc aaa cag atg aaa gaa gaa agc cag gat tca ata ctt tca ctg 1514
Phe Phe Lys Gln Met Lys Glu Glu Ser Gln Asp Ser Ile Leu Ser Leu
370 375 380
ttg cct cct gct tat aac aag cca tca ata tca ttg cct cca gtg tta 1562
Leu Pro Pro Ala Tyr Asn Lys Pro Ser Ile Ser Leu Pro Pro Val Leu
385 390 395
cct tgg act gag cca gaa tgt gat ttt cct gat gaa aaa gac tca tac 1610
Pro Trp Thr Glu Pro Glu Cys Asp Phe Pro Asp Glu Lys Asp Ser Tyr
400 405 410 415
tgg gaa ttc tagggctgcc aaatcatttt atgtcctata tacttgacac 1659
Trp Glu Phe
tttctccttg ctgctttttc ttctgtattt ctaggtacaa ataccagaat tatacttgaa 1719
aatacagttg gtgcactgga gaatctatta tttaaaacca ctctgttcaa aggggcacca 1779
gtttgtagtc cctctgtttc gcacagagta ctatgacaag gaaacatcag aattactaat 1839
ctagctagtg tcatttattc tggaattttt ttctaagctg tgactaactc tttttatctc 1899
tcaatataat ttttgagcca gttaattttt ttcagtattt tgctgtccct tgggaatggg 1959
ccctcagagg acagtgcttc caagtacatc ttctcccaga ttctctggcc tttttaatga 2019
gctattgtta aaccaacagg ctagtttatc ttacatcaga cccttttctg gtagagggaa 2079
aatgtttgtg ctttcccttt ttcttctgtt aatacttatg gtaacaccta actgagcctc 2139
actcacatta aatgattcac ttgaaatata tacag 2174
2
418
PRT
Homo sapiens
2
Met Ser Leu Leu Asp Cys Phe Cys Thr Ser Arg Thr Gln Val Glu Ser
1 5 10 15
Leu Arg Pro Glu Lys Gln Ser Glu Thr Ser Ile His Gln Tyr Leu Val
20 25 30
Asp Glu Pro Thr Leu Ser Trp Ser Arg Pro Ser Thr Arg Ala Ser Glu
35 40 45
Val Leu Cys Ser Thr Asn Val Ser His Tyr Glu Leu Gln Val Glu Ile
50 55 60
Gly Arg Gly Phe Asp Asn Leu Thr Ser Val His Leu Ala Arg His Thr
65 70 75 80
Pro Thr Gly Thr Leu Val Thr Ile Lys Ile Thr Asn Leu Glu Asn Cys
85 90 95
Asn Glu Glu Arg Leu Lys Ala Leu Gln Lys Ala Val Ile Leu Ser His
100 105 110
Phe Phe Arg His Pro Asn Ile Thr Thr Tyr Trp Thr Val Phe Thr Val
115 120 125
Gly Ser Trp Leu Trp Val Ile Ser Pro Phe Met Ala Tyr Gly Ser Ala
130 135 140
Ser Gln Leu Leu Arg Thr Tyr Phe Pro Glu Gly Met Ser Glu Thr Leu
145 150 155 160
Ile Arg Asn Ile Leu Phe Gly Ala Val Arg Gly Leu Asn Tyr Leu His
165 170 175
Gln Asn Gly Cys Ile His Arg Ser Ile Lys Ala Ser His Ile Leu Ile
180 185 190
Ser Gly Asp Gly Leu Val Thr Leu Ser Gly Leu Ser His Leu His Ser
195 200 205
Leu Val Lys His Gly Gln Arg His Arg Ala Val Tyr Asp Phe Pro Gln
210 215 220
Phe Ser Thr Ser Val Gln Pro Trp Leu Ser Pro Glu Leu Leu Arg Gln
225 230 235 240
Asp Leu His Gly Tyr Asn Val Lys Ser Asp Ile Tyr Ser Val Gly Ile
245 250 255
Thr Ala Cys Glu Leu Ala Ser Gly Gln Val Pro Phe Gln Asp Met His
260 265 270
Arg Thr Gln Met Leu Leu Gln Lys Leu Lys Gly Pro Pro Tyr Ser Pro
275 280 285
Leu Asp Ile Ser Ile Phe Pro Gln Ser Glu Ser Arg Met Lys Asn Ser
290 295 300
Gln Ser Gly Val Asp Ser Gly Ile Gly Glu Ser Val Leu Val Ser Ser
305 310 315 320
Gly Thr His Thr Val Asn Ser Asp Arg Leu His Thr Pro Ser Ser Lys
325 330 335
Thr Phe Ser Pro Ala Phe Phe Ser Leu Val Gln Leu Cys Leu Gln Gln
340 345 350
Asp Pro Glu Lys Arg Pro Ser Ala Ser Ser Leu Leu Ser His Val Phe
355 360 365
Phe Lys Gln Met Lys Glu Glu Ser Gln Asp Ser Ile Leu Ser Leu Leu
370 375 380
Pro Pro Ala Tyr Asn Lys Pro Ser Ile Ser Leu Pro Pro Val Leu Pro
385 390 395 400
Trp Thr Glu Pro Glu Cys Asp Phe Pro Asp Glu Lys Asp Ser Tyr Trp
405 410 415
Glu Phe
3
2718
DNA
Homo sapiens
CDS
(33)..(2627)
3
ttgaggtcac accttcagtc cttcgagcaa at atg cct ctt cat gtt cga cgc 53
Met Pro Leu His Val Arg Arg
1 5
agt agt gac cca gct cta att ggc ctc tcc act tct gtc agt gat agt 101
Ser Ser Asp Pro Ala Leu Ile Gly Leu Ser Thr Ser Val Ser Asp Ser
10 15 20
aat ttt tcc tct gaa gag cct tca agg aaa aat ccc aca cgc tgg tca 149
Asn Phe Ser Ser Glu Glu Pro Ser Arg Lys Asn Pro Thr Arg Trp Ser
25 30 35
aca aca gct ggc ttc ctc aag cag aac act gct ggg agt cct aaa gcc 197
Thr Thr Ala Gly Phe Leu Lys Gln Asn Thr Ala Gly Ser Pro Lys Ala
40 45 50 55
tgc gac agg aag aaa gat gaa aac tac aga agc ctc ccg cgg gat act 245
Cys Asp Arg Lys Lys Asp Glu Asn Tyr Arg Ser Leu Pro Arg Asp Thr
60 65 70
agt aac tgg tct aac caa ttt cag aga gac aat gct cgc tcg tct ctg 293
Ser Asn Trp Ser Asn Gln Phe Gln Arg Asp Asn Ala Arg Ser Ser Leu
75 80 85
agt gcc agt cac cca atg gtg ggc aag tgg cag gag aaa caa gaa cag 341
Ser Ala Ser His Pro Met Val Gly Lys Trp Gln Glu Lys Gln Glu Gln
90 95 100
gat gag gat ggg aca gaa gag gat aac agt cgt gtt gaa cct gtt gga 389
Asp Glu Asp Gly Thr Glu Glu Asp Asn Ser Arg Val Glu Pro Val Gly
105 110 115
cat gct gac acg ggt ttg gag cat ata ccc aac ttt tct ctg gat gat 437
His Ala Asp Thr Gly Leu Glu His Ile Pro Asn Phe Ser Leu Asp Asp
120 125 130 135
atg gta aag ctc gta gaa gtc ccc aac gat gga ggg cct ctg gga atc 485
Met Val Lys Leu Val Glu Val Pro Asn Asp Gly Gly Pro Leu Gly Ile
140 145 150
cat gta gtg cct ttc agt gct cga ggc ggc aga acc ctg ggg tta tta 533
His Val Val Pro Phe Ser Ala Arg Gly Gly Arg Thr Leu Gly Leu Leu
155 160 165
gta aaa cga ttg gag aaa ggt ggt aaa gct gaa cat gaa aat ctt ttt 581
Val Lys Arg Leu Glu Lys Gly Gly Lys Ala Glu His Glu Asn Leu Phe
170 175 180
cgt gag aat gat tgc att gtc agg att aat gat ggc gac ctt cga aat 629
Arg Glu Asn Asp Cys Ile Val Arg Ile Asn Asp Gly Asp Leu Arg Asn
185 190 195
aga aga ttt gaa caa gca caa cat atg ttt cgc caa gcc atg cgt aca 677
Arg Arg Phe Glu Gln Ala Gln His Met Phe Arg Gln Ala Met Arg Thr
200 205 210 215
ccc atc att tgg ttc cat gtg gtt cct gca gca aat aaa gag cag tat 725
Pro Ile Ile Trp Phe His Val Val Pro Ala Ala Asn Lys Glu Gln Tyr
220 225 230
gaa caa cta tcc caa agt gag aag aac aat tac tat tca agc cgt ttt 773
Glu Gln Leu Ser Gln Ser Glu Lys Asn Asn Tyr Tyr Ser Ser Arg Phe
235 240 245
agc cct gac agc cag tat att gac aac agg agt gtg aac agt gca ggg 821
Ser Pro Asp Ser Gln Tyr Ile Asp Asn Arg Ser Val Asn Ser Ala Gly
250 255 260
ctt cac acg gtg cag aga gca ccc cga ctg aac cac ccg cct gag cag 869
Leu His Thr Val Gln Arg Ala Pro Arg Leu Asn His Pro Pro Glu Gln
265 270 275
ata gac tct cac tca aga cta cct cat agc gca cac ccc tcg gga aaa 917
Ile Asp Ser His Ser Arg Leu Pro His Ser Ala His Pro Ser Gly Lys
280 285 290 295
cca cca tcc gct cca gcc tcg gca cct cag aat gta ttt agt acg act 965
Pro Pro Ser Ala Pro Ala Ser Ala Pro Gln Asn Val Phe Ser Thr Thr
300 305 310
gta agc agt ggt tat aac acc aaa aaa ata ggc aag agg ctt aat atc 1013
Val Ser Ser Gly Tyr Asn Thr Lys Lys Ile Gly Lys Arg Leu Asn Ile
315 320 325
cag ctt aag aaa ggt aca gaa ggt ttg gga ttc agc atc act tcc aga 1061
Gln Leu Lys Lys Gly Thr Glu Gly Leu Gly Phe Ser Ile Thr Ser Arg
330 335 340
gat gta aca ata ggt ggc tca gct cca atc tat gtg aaa aac att ctc 1109
Asp Val Thr Ile Gly Gly Ser Ala Pro Ile Tyr Val Lys Asn Ile Leu
345 350 355
ccc cgg ggg gcg gcc att cag gat ggc cga ctt aag gca gga gac aga 1157
Pro Arg Gly Ala Ala Ile Gln Asp Gly Arg Leu Lys Ala Gly Asp Arg
360 365 370 375
ctt ata gag gta aat gga gta gat tta gtg ggc aaa tcc caa gag gaa 1205
Leu Ile Glu Val Asn Gly Val Asp Leu Val Gly Lys Ser Gln Glu Glu
380 385 390
gtt gtt tcg ctg ttg aga agc acc aag atg gaa gga act gtg agc ctt 1253
Val Val Ser Leu Leu Arg Ser Thr Lys Met Glu Gly Thr Val Ser Leu
395 400 405
ctg gtc ttt cgc cag gaa gac gcc ttc cac cca agg gaa ctg aat gca 1301
Leu Val Phe Arg Gln Glu Asp Ala Phe His Pro Arg Glu Leu Asn Ala
410 415 420
gag cca agc cag atg cag att cca aaa gaa acg aaa gca gaa gat gag 1349
Glu Pro Ser Gln Met Gln Ile Pro Lys Glu Thr Lys Ala Glu Asp Glu
425 430 435
gat att gtt ctt aca cct gat ggc acc agg gaa ttt ctg aca ttt gaa 1397
Asp Ile Val Leu Thr Pro Asp Gly Thr Arg Glu Phe Leu Thr Phe Glu
440 445 450 455
gtc cca ctt agt gat tca gga tct gca ggc ctt ggt gtc agt gtc aaa 1445
Val Pro Leu Ser Asp Ser Gly Ser Ala Gly Leu Gly Val Ser Val Lys
460 465 470
ggt aac cgg tca aaa gag aac cac gca gat ttg gga atc ttt gtc aag 1493
Gly Asn Arg Ser Lys Glu Asn His Ala Asp Leu Gly Ile Phe Val Lys
475 480 485
tcc att att aat gga gga gca gca tct aaa gat gga agg ctt cgg gtg 1541
Ser Ile Ile Asn Gly Gly Ala Ala Ser Lys Asp Gly Arg Leu Arg Val
490 495 500
aat gat caa ctg ata gca gta aat gga gaa tcc ctg ttg ggc aag aca 1589
Asn Asp Gln Leu Ile Ala Val Asn Gly Glu Ser Leu Leu Gly Lys Thr
505 510 515
aac caa gat gcc atg gaa acc cta aga agg tct atg tct act gaa ggc 1637
Asn Gln Asp Ala Met Glu Thr Leu Arg Arg Ser Met Ser Thr Glu Gly
520 525 530 535
aat aaa cga gga atg atc cag ctt att gtt gca agg aga ata agc aag 1685
Asn Lys Arg Gly Met Ile Gln Leu Ile Val Ala Arg Arg Ile Ser Lys
540 545 550
tgc aat gag ctg aag tca cct ggg agc ccc cct gga cct gag ctg ccc 1733
Cys Asn Glu Leu Lys Ser Pro Gly Ser Pro Pro Gly Pro Glu Leu Pro
555 560 565
att gaa aca gcg ttg gat gat aga gaa cga aga att tcc cat tcc ctc 1781
Ile Glu Thr Ala Leu Asp Asp Arg Glu Arg Arg Ile Ser His Ser Leu
570 575 580
tac agt ggg att gag ggg ctt gat gaa tcg ccc agc aga aat gct gcc 1829
Tyr Ser Gly Ile Glu Gly Leu Asp Glu Ser Pro Ser Arg Asn Ala Ala
585 590 595
ctc agt agg ata atg ggt aaa tac cag ctg tcc cct aca gtg aat atg 1877
Leu Ser Arg Ile Met Gly Lys Tyr Gln Leu Ser Pro Thr Val Asn Met
600 605 610 615
ccc caa gat gac act gtc att ata gaa gat gac agg ttg cca gtg ctt 1925
Pro Gln Asp Asp Thr Val Ile Ile Glu Asp Asp Arg Leu Pro Val Leu
620 625 630
cct cca cat ctc tct gac cag tcc tct tcc agc tcc cat gat gat gtg 1973
Pro Pro His Leu Ser Asp Gln Ser Ser Ser Ser Ser His Asp Asp Val
635 640 645
ggg ttt gtg acg gca gat gct ggt act tgg gcc aag gct gca atc agt 2021
Gly Phe Val Thr Ala Asp Ala Gly Thr Trp Ala Lys Ala Ala Ile Ser
650 655 660
gat tca gcc gac tgc tct ttg agt cca gat gtt gat cca gtt ctt gct 2069
Asp Ser Ala Asp Cys Ser Leu Ser Pro Asp Val Asp Pro Val Leu Ala
665 670 675
ttt caa cga gaa gga ttt gga cgt cag act gac gag act aaa ctc aat 2117
Phe Gln Arg Glu Gly Phe Gly Arg Gln Thr Asp Glu Thr Lys Leu Asn
680 685 690 695
aca gtg gat gac cag aaa gca ggt tct ccc agc aga gat gtg ggt cct 2165
Thr Val Asp Asp Gln Lys Ala Gly Ser Pro Ser Arg Asp Val Gly Pro
700 705 710
tcc ctg ggt ctg aag aag tca agc tca ttg gag agt ctg cag acc gca 2213
Ser Leu Gly Leu Lys Lys Ser Ser Ser Leu Glu Ser Leu Gln Thr Ala
715 720 725
gtt gcc gag gtg act ttg aat ggg gat att cct ttc cat cgt cca cgg 2261
Val Ala Glu Val Thr Leu Asn Gly Asp Ile Pro Phe His Arg Pro Arg
730 735 740
ccg cgg ata atc aga ggc agg gga tgc aat gag agc ttc aga gct gcc 2309
Pro Arg Ile Ile Arg Gly Arg Gly Cys Asn Glu Ser Phe Arg Ala Ala
745 750 755
atc gac aaa tct tat gat aaa ccc gcg gta gat gat gat gat gaa ggc 2357
Ile Asp Lys Ser Tyr Asp Lys Pro Ala Val Asp Asp Asp Asp Glu Gly
760 765 770 775
atg gag acc ttg gaa gaa gac aca gaa gaa agt tca aga tca ggg aga 2405
Met Glu Thr Leu Glu Glu Asp Thr Glu Glu Ser Ser Arg Ser Gly Arg
780 785 790
gag tct gta tcc aca gcc agt gat cag cct tcc cac tct ctg gag aga 2453
Glu Ser Val Ser Thr Ala Ser Asp Gln Pro Ser His Ser Leu Glu Arg
795 800 805
caa atg aat gga aac caa gag aaa ggt gat aag act gat aga aaa aag 2501
Gln Met Asn Gly Asn Gln Glu Lys Gly Asp Lys Thr Asp Arg Lys Lys
810 815 820
gat aaa act gga aaa gaa aag aag aaa gat aga gat aag gag aag gat 2549
Asp Lys Thr Gly Lys Glu Lys Lys Lys Asp Arg Asp Lys Glu Lys Asp
825 830 835
aaa atg aaa gcc aag aag gga atg ctg aag ggc ttg gga gac atg ttc 2597
Lys Met Lys Ala Lys Lys Gly Met Leu Lys Gly Leu Gly Asp Met Phe
840 845 850 855
agc ctt gcc aaa ctg aag ccc gag aag aga tgaacaacaa agcgattcaa 2647
Ser Leu Ala Lys Leu Lys Pro Glu Lys Arg
860 865
aacatgtctt gaacagcaca tattgcacag ttgttgtttt ttttaaacaa acaataaatt 2707
tacttttaat g 2718
4
865
PRT
Homo sapiens
4
Met Pro Leu His Val Arg Arg Ser Ser Asp Pro Ala Leu Ile Gly Leu
1 5 10 15
Ser Thr Ser Val Ser Asp Ser Asn Phe Ser Ser Glu Glu Pro Ser Arg
20 25 30
Lys Asn Pro Thr Arg Trp Ser Thr Thr Ala Gly Phe Leu Lys Gln Asn
35 40 45
Thr Ala Gly Ser Pro Lys Ala Cys Asp Arg Lys Lys Asp Glu Asn Tyr
50 55 60
Arg Ser Leu Pro Arg Asp Thr Ser Asn Trp Ser Asn Gln Phe Gln Arg
65 70 75 80
Asp Asn Ala Arg Ser Ser Leu Ser Ala Ser His Pro Met Val Gly Lys
85 90 95
Trp Gln Glu Lys Gln Glu Gln Asp Glu Asp Gly Thr Glu Glu Asp Asn
100 105 110
Ser Arg Val Glu Pro Val Gly His Ala Asp Thr Gly Leu Glu His Ile
115 120 125
Pro Asn Phe Ser Leu Asp Asp Met Val Lys Leu Val Glu Val Pro Asn
130 135 140
Asp Gly Gly Pro Leu Gly Ile His Val Val Pro Phe Ser Ala Arg Gly
145 150 155 160
Gly Arg Thr Leu Gly Leu Leu Val Lys Arg Leu Glu Lys Gly Gly Lys
165 170 175
Ala Glu His Glu Asn Leu Phe Arg Glu Asn Asp Cys Ile Val Arg Ile
180 185 190
Asn Asp Gly Asp Leu Arg Asn Arg Arg Phe Glu Gln Ala Gln His Met
195 200 205
Phe Arg Gln Ala Met Arg Thr Pro Ile Ile Trp Phe His Val Val Pro
210 215 220
Ala Ala Asn Lys Glu Gln Tyr Glu Gln Leu Ser Gln Ser Glu Lys Asn
225 230 235 240
Asn Tyr Tyr Ser Ser Arg Phe Ser Pro Asp Ser Gln Tyr Ile Asp Asn
245 250 255
Arg Ser Val Asn Ser Ala Gly Leu His Thr Val Gln Arg Ala Pro Arg
260 265 270
Leu Asn His Pro Pro Glu Gln Ile Asp Ser His Ser Arg Leu Pro His
275 280 285
Ser Ala His Pro Ser Gly Lys Pro Pro Ser Ala Pro Ala Ser Ala Pro
290 295 300
Gln Asn Val Phe Ser Thr Thr Val Ser Ser Gly Tyr Asn Thr Lys Lys
305 310 315 320
Ile Gly Lys Arg Leu Asn Ile Gln Leu Lys Lys Gly Thr Glu Gly Leu
325 330 335
Gly Phe Ser Ile Thr Ser Arg Asp Val Thr Ile Gly Gly Ser Ala Pro
340 345 350
Ile Tyr Val Lys Asn Ile Leu Pro Arg Gly Ala Ala Ile Gln Asp Gly
355 360 365
Arg Leu Lys Ala Gly Asp Arg Leu Ile Glu Val Asn Gly Val Asp Leu
370 375 380
Val Gly Lys Ser Gln Glu Glu Val Val Ser Leu Leu Arg Ser Thr Lys
385 390 395 400
Met Glu Gly Thr Val Ser Leu Leu Val Phe Arg Gln Glu Asp Ala Phe
405 410 415
His Pro Arg Glu Leu Asn Ala Glu Pro Ser Gln Met Gln Ile Pro Lys
420 425 430
Glu Thr Lys Ala Glu Asp Glu Asp Ile Val Leu Thr Pro Asp Gly Thr
435 440 445
Arg Glu Phe Leu Thr Phe Glu Val Pro Leu Ser Asp Ser Gly Ser Ala
450 455 460
Gly Leu Gly Val Ser Val Lys Gly Asn Arg Ser Lys Glu Asn His Ala
465 470 475 480
Asp Leu Gly Ile Phe Val Lys Ser Ile Ile Asn Gly Gly Ala Ala Ser
485 490 495
Lys Asp Gly Arg Leu Arg Val Asn Asp Gln Leu Ile Ala Val Asn Gly
500 505 510
Glu Ser Leu Leu Gly Lys Thr Asn Gln Asp Ala Met Glu Thr Leu Arg
515 520 525
Arg Ser Met Ser Thr Glu Gly Asn Lys Arg Gly Met Ile Gln Leu Ile
530 535 540
Val Ala Arg Arg Ile Ser Lys Cys Asn Glu Leu Lys Ser Pro Gly Ser
545 550 555 560
Pro Pro Gly Pro Glu Leu Pro Ile Glu Thr Ala Leu Asp Asp Arg Glu
565 570 575
Arg Arg Ile Ser His Ser Leu Tyr Ser Gly Ile Glu Gly Leu Asp Glu
580 585 590
Ser Pro Ser Arg Asn Ala Ala Leu Ser Arg Ile Met Gly Lys Tyr Gln
595 600 605
Leu Ser Pro Thr Val Asn Met Pro Gln Asp Asp Thr Val Ile Ile Glu
610 615 620
Asp Asp Arg Leu Pro Val Leu Pro Pro His Leu Ser Asp Gln Ser Ser
625 630 635 640
Ser Ser Ser His Asp Asp Val Gly Phe Val Thr Ala Asp Ala Gly Thr
645 650 655
Trp Ala Lys Ala Ala Ile Ser Asp Ser Ala Asp Cys Ser Leu Ser Pro
660 665 670
Asp Val Asp Pro Val Leu Ala Phe Gln Arg Glu Gly Phe Gly Arg Gln
675 680 685
Thr Asp Glu Thr Lys Leu Asn Thr Val Asp Asp Gln Lys Ala Gly Ser
690 695 700
Pro Ser Arg Asp Val Gly Pro Ser Leu Gly Leu Lys Lys Ser Ser Ser
705 710 715 720
Leu Glu Ser Leu Gln Thr Ala Val Ala Glu Val Thr Leu Asn Gly Asp
725 730 735
Ile Pro Phe His Arg Pro Arg Pro Arg Ile Ile Arg Gly Arg Gly Cys
740 745 750
Asn Glu Ser Phe Arg Ala Ala Ile Asp Lys Ser Tyr Asp Lys Pro Ala
755 760 765
Val Asp Asp Asp Asp Glu Gly Met Glu Thr Leu Glu Glu Asp Thr Glu
770 775 780
Glu Ser Ser Arg Ser Gly Arg Glu Ser Val Ser Thr Ala Ser Asp Gln
785 790 795 800
Pro Ser His Ser Leu Glu Arg Gln Met Asn Gly Asn Gln Glu Lys Gly
805 810 815
Asp Lys Thr Asp Arg Lys Lys Asp Lys Thr Gly Lys Glu Lys Lys Lys
820 825 830
Asp Arg Asp Lys Glu Lys Asp Lys Met Lys Ala Lys Lys Gly Met Leu
835 840 845
Lys Gly Leu Gly Asp Met Phe Ser Leu Ala Lys Leu Lys Pro Glu Lys
850 855 860
Arg
865
5
30
RNA
Artificial Sequence
Artificially Synthesized Sequence
5
agcaucgagu cggccuuguu ggccuacugg 30
6
42
DNA
Artificial Sequence
Artificially Synthesized Primer Sequence
6
gcggctgaag acggcctatg tggccttttt tttttttttt tt 42
7
21
DNA
Artificial Sequence
Artificially Synthesized Primer Sequence
7
agcatcgagt cggccttgtt g 21
8
21
DNA
Artificial Sequence
Artificially Synthesized Primer Sequence
8
gcggctgaag acggcctatg t 21
9
433
PRT
Homo sapiens
9
Met Glu Val Val Asp Pro Gln Gln Leu Gly Met Phe Thr Glu Gly Glu
1 5 10 15
Leu Met Ser Val Gly Met Asp Thr Phe Ile His Arg Ile Asp Ser Thr
20 25 30
Glu Val Ile Tyr Gln Pro Arg Arg Lys Arg Ala Lys Leu Ile Gly Lys
35 40 45
Tyr Leu Met Gly Asp Leu Leu Gly Glu Gly Ser Tyr Gly Lys Val Lys
50 55 60
Glu Val Leu Asp Ser Glu Thr Leu Cys Arg Arg Ala Val Lys Ile Leu
65 70 75 80
Lys Lys Lys Lys Leu Arg Arg Ile Pro Asn Gly Glu Ala Asn Val Lys
85 90 95
Lys Glu Ile Gln Leu Leu Arg Arg Leu Arg His Lys Asn Val Ile Gln
100 105 110
Leu Val Asp Val Leu Tyr Asn Glu Glu Lys Gln Lys Met Tyr Met Val
115 120 125
Met Glu Tyr Cys Val Cys Gly Met Gln Glu Met Leu Asp Ser Val Pro
130 135 140
Glu Lys Arg Phe Pro Val Cys Gln Ala His Gly Tyr Phe Cys Gln Leu
145 150 155 160
Ile Asp Gly Leu Glu Tyr Leu His Ser Gln Gly Ile Val His Lys Asp
165 170 175
Ile Lys Pro Gly Asn Leu Leu Leu Thr Thr Gly Gly Thr Leu Lys Ile
180 185 190
Ser Asp Leu Gly Val Ala Glu Ala Leu His Pro Phe Ala Ala Asp Asp
195 200 205
Thr Cys Arg Thr Ser Gln Gly Ser Pro Ala Phe Gln Pro Pro Glu Ile
210 215 220
Ala Asn Gly Leu Asp Thr Phe Ser Gly Phe Lys Val Asp Ile Trp Ser
225 230 235 240
Ala Gly Val Thr Leu Tyr Asn Ile Thr Thr Gly Leu Tyr Pro Phe Glu
245 250 255
Gly Asp Asn Ile Tyr Lys Leu Phe Glu Asn Ile Gly Lys Gly Ser Tyr
260 265 270
Ala Ile Pro Gly Asp Cys Gly Pro Pro Leu Ser Asp Leu Leu Lys Gly
275 280 285
Met Leu Glu Tyr Glu Pro Ala Lys Arg Phe Ser Ile Arg Gln Ile Arg
290 295 300
Gln His Ser Trp Phe Arg Lys Lys His Pro Pro Ala Glu Ala Pro Val
305 310 315 320
Pro Ile Pro Pro Ser Pro Asp Thr Lys Asp Arg Trp Arg Ser Met Thr
325 330 335
Val Val Pro Tyr Leu Glu Asp Leu His Gly Ala Asp Glu Asp Glu Asp
340 345 350
Leu Phe Asp Ile Glu Asp Asp Ile Ile Tyr Thr Gln Asp Phe Thr Val
355 360 365
Pro Gly Gln Val Pro Glu Glu Glu Ala Ser His Asn Gly Gln Arg Arg
370 375 380
Gly Leu Pro Lys Ala Val Cys Met Asn Gly Thr Glu Ala Ala Gln Leu
385 390 395 400
Ser Thr Lys Ser Arg Ala Glu Gly Arg Ala Pro Asn Pro Ala Arg Lys
405 410 415
Ala Cys Ser Ala Ser Ser Lys Ile Arg Arg Leu Ser Ala Cys Lys Gln
420 425 430
Gln
10
396
PRT
Homo sapiens
10
Met Pro Arg Val Lys Ala Ala Gln Ala Gly Arg Gln Ser Ser Ala Lys
1 5 10 15
Arg His Leu Ala Glu Gln Phe Ala Val Gly Glu Ile Ile Thr Asp Met
20 25 30
Ala Lys Lys Glu Trp Lys Val Gly Leu Pro Ile Gly Gln Gly Gly Phe
35 40 45
Gly Cys Ile Tyr Leu Ala Asp Met Asn Ser Ser Glu Ser Val Gly Ser
50 55 60
Asp Ala Pro Cys Val Val Lys Val Glu Pro Ser Asp Asn Gly Pro Leu
65 70 75 80
Phe Thr Glu Leu Lys Phe Tyr Gln Arg Ala Ala Lys Pro Glu Gln Ile
85 90 95
Gln Lys Trp Ile Arg Thr Arg Lys Leu Lys Tyr Leu Gly Val Pro Lys
100 105 110
Tyr Trp Gly Ser Gly Leu His Asp Lys Asn Gly Lys Ser Tyr Arg Phe
115 120 125
Met Ile Met Asp Arg Phe Gly Ser Asp Leu Gln Lys Ile Tyr Glu Ala
130 135 140
Asn Ala Lys Arg Phe Ser Arg Lys Thr Val Leu Gln Leu Ser Leu Arg
145 150 155 160
Ile Leu Asp Ile Leu Glu Tyr Ile His Glu His Glu Tyr Val His Gly
165 170 175
Asp Ile Lys Ala Ser Asn Leu Leu Leu Asn Tyr Lys Asn Pro Asp Gln
180 185 190
Val Tyr Leu Val Asp Tyr Gly Leu Ala Tyr Arg Tyr Cys Pro Glu Gly
195 200 205
Val His Lys Glu Tyr Lys Glu Asp Pro Lys Arg Cys His Asp Gly Thr
210 215 220
Ile Glu Phe Thr Ser Ile Asp Ala His Asn Gly Val Ala Pro Ser Arg
225 230 235 240
Arg Gly Asp Leu Glu Ile Leu Gly Tyr Cys Met Ile Gln Trp Leu Thr
245 250 255
Gly His Leu Pro Trp Glu Asp Asn Leu Lys Asp Pro Lys Tyr Val Arg
260 265 270
Asp Ser Lys Ile Arg Tyr Arg Glu Asn Ile Ala Ser Leu Met Asp Lys
275 280 285
Cys Phe Pro Glu Lys Asn Lys Pro Gly Glu Ile Ala Lys Tyr Met Glu
290 295 300
Thr Val Lys Leu Leu Asp Tyr Thr Glu Lys Pro Leu Tyr Glu Asn Leu
305 310 315 320
Arg Asp Ile Leu Leu Gln Gly Leu Lys Ala Ile Gly Ser Lys Asp Asp
325 330 335
Gly Lys Leu Asp Leu Ser Val Val Glu Asn Gly Gly Leu Lys Ala Lys
340 345 350
Thr Ile Thr Lys Lys Arg Lys Lys Glu Ile Glu Glu Ser Lys Glu Pro
355 360 365
Gly Val Glu Asp Thr Glu Trp Ser Asn Thr Gln Thr Glu Glu Ala Ile
370 375 380
Gln Thr Arg Ser Arg Thr Arg Lys Arg Val Gln Lys
385 390 395
11
297
PRT
Homo sapiens
11
Met Glu Asp Tyr Thr Lys Ile Glu Lys Ile Gly Glu Gly Thr Tyr Gly
1 5 10 15
Val Val Tyr Lys Gly Arg His Lys Thr Thr Gly Gln Val Val Ala Met
20 25 30
Lys Lys Ile Arg Leu Glu Ser Glu Glu Glu Gly Val Pro Ser Thr Ala
35 40 45
Ile Arg Glu Ile Ser Leu Leu Lys Glu Leu Arg His Pro Asn Ile Val
50 55 60
Ser Leu Gln Asp Val Leu Met Gln Asp Ser Arg Leu Tyr Leu Ile Phe
65 70 75 80
Glu Phe Leu Ser Met Asp Leu Lys Lys Tyr Leu Asp Ser Ile Pro Pro
85 90 95
Gly Gln Tyr Met Asp Ser Ser Leu Val Lys Ser Tyr Leu Tyr Gln Ile
100 105 110
Leu Gln Gly Ile Val Phe Cys His Ser Arg Arg Val Leu His Arg Asp
115 120 125
Leu Lys Pro Gln Asn Leu Leu Ile Asp Asp Lys Gly Thr Ile Lys Leu
130 135 140
Ala Asp Phe Gly Leu Ala Arg Ala Phe Gly Ile Pro Ile Arg Val Tyr
145 150 155 160
Thr His Glu Val Val Thr Leu Trp Tyr Arg Ser Pro Glu Val Leu Leu
165 170 175
Gly Ser Ala Arg Tyr Ser Thr Pro Val Asp Ile Trp Ser Ile Gly Thr
180 185 190
Ile Phe Ala Glu Leu Ala Thr Lys Lys Pro Leu Phe His Gly Asp Ser
195 200 205
Glu Ile Asp Gln Leu Phe Arg Ile Phe Arg Ala Leu Gly Thr Pro Asn
210 215 220
Asn Glu Val Trp Pro Glu Val Glu Ser Leu Gln Asp Tyr Lys Asn Thr
225 230 235 240
Phe Pro Lys Trp Lys Pro Gly Ser Leu Ala Ser His Val Lys Asn Leu
245 250 255
Asp Glu Asn Gly Leu Asp Leu Leu Ser Lys Met Leu Ile Tyr Asp Pro
260 265 270
Ala Lys Arg Ile Ser Gly Lys Met Ala Leu Asn His Pro Tyr Phe Asn
275 280 285
Asp Leu Asp Asn Gln Ile Lys Lys Met
290 295
12
403
PRT
Homo sapiens
12
Met Asp Arg Ser Lys Glu Asn Cys Ile Ser Gly Pro Val Lys Ala Thr
1 5 10 15
Ala Pro Val Gly Gly Pro Lys Arg Val Leu Val Thr Gln Gln Phe Pro
20 25 30
Cys Gln Asn Pro Leu Pro Val Asn Ser Gly Gln Ala Gln Arg Val Leu
35 40 45
Cys Pro Ser Asn Ser Ser Gln Arg Ile Pro Leu Gln Ala Gln Lys Leu
50 55 60
Val Ser Ser His Lys Pro Val Gln Asn Gln Lys Gln Lys Gln Leu Gln
65 70 75 80
Ala Thr Ser Val Pro His Pro Val Ser Arg Pro Leu Asn Asn Thr Gln
85 90 95
Lys Ser Lys Gln Pro Leu Pro Ser Ala Pro Glu Asn Asn Pro Glu Glu
100 105 110
Glu Leu Ala Ser Lys Gln Lys Asn Glu Glu Ser Lys Lys Arg Gln Trp
115 120 125
Ala Leu Glu Asp Phe Glu Ile Gly Arg Pro Leu Gly Lys Gly Lys Phe
130 135 140
Gly Asn Val Tyr Leu Ala Arg Glu Lys Gln Ser Lys Phe Ile Leu Ala
145 150 155 160
Leu Lys Val Leu Phe Lys Ala Gln Leu Glu Lys Ala Gly Val Glu His
165 170 175
Gln Leu Arg Arg Glu Val Glu Ile Gln Ser His Leu Arg His Pro Asn
180 185 190
Ile Leu Arg Leu Tyr Gly Tyr Phe His Asp Ala Thr Arg Val Tyr Leu
195 200 205
Ile Leu Glu Tyr Ala Pro Leu Gly Thr Val Tyr Arg Glu Leu Gln Lys
210 215 220
Leu Ser Lys Phe Asp Glu Gln Arg Thr Ala Thr Tyr Ile Thr Glu Leu
225 230 235 240
Ala Asn Ala Leu Ser Tyr Cys His Ser Lys Arg Val Ile His Arg Asp
245 250 255
Ile Lys Pro Glu Asn Leu Leu Leu Gly Ser Ala Gly Glu Leu Lys Ile
260 265 270
Ala Asp Phe Gly Trp Ser Val His Ala Pro Ser Ser Arg Arg Thr Thr
275 280 285
Leu Cys Gly Thr Leu Asp Tyr Leu Pro Pro Glu Met Ile Glu Gly Arg
290 295 300
Met His Asp Glu Lys Val Asp Leu Trp Ser Leu Gly Val Leu Cys Tyr
305 310 315 320
Glu Phe Leu Val Gly Lys Pro Pro Phe Glu Ala Asn Thr Tyr Gln Glu
325 330 335
Thr Tyr Lys Arg Ile Ser Arg Val Glu Phe Thr Phe Pro Asp Phe Val
340 345 350
Thr Glu Gly Ala Arg Asp Leu Ile Ser Arg Leu Leu Lys His Asn Pro
355 360 365
Ser Gln Arg Pro Met Leu Arg Glu Val Leu Glu His Pro Trp Ile Thr
370 375 380
Ala Asn Ser Ser Lys Pro Ser Asn Cys Gln Asn Lys Glu Ser Ala Ser
385 390 395 400
Lys Gln Ser
13
344
PRT
Homo sapiens
13
Met Ala Gln Lys Glu Asn Ser Tyr Pro Trp Pro Tyr Gly Arg Gln Thr
1 5 10 15
Ala Pro Ser Gly Leu Ser Thr Leu Pro Gln Arg Val Leu Arg Lys Glu
20 25 30
Pro Val Thr Pro Ser Ala Leu Val Leu Met Ser Arg Ser Asn Val Gln
35 40 45
Pro Thr Ala Ala Pro Gly Gln Lys Val Met Glu Asn Ser Ser Gly Thr
50 55 60
Pro Asp Ile Leu Thr Arg His Phe Thr Ile Asp Asp Phe Glu Ile Gly
65 70 75 80
Arg Pro Leu Gly Lys Gly Lys Phe Gly Asn Val Tyr Leu Ala Arg Glu
85 90 95
Lys Lys Ser His Phe Ile Val Ala Leu Lys Val Leu Phe Lys Ser Gln
100 105 110
Ile Glu Lys Glu Gly Val Glu His Gln Leu Arg Arg Glu Ile Glu Ile
115 120 125
Gln Ala His Leu His His Pro Asn Ile Leu Arg Leu Tyr Asn Tyr Phe
130 135 140
Tyr Asp Arg Arg Arg Ile Tyr Leu Ile Leu Glu Tyr Ala Pro Arg Gly
145 150 155 160
Glu Leu Tyr Lys Glu Leu Gln Lys Ser Cys Thr Phe Asp Glu Gln Arg
165 170 175
Thr Ala Thr Ile Met Glu Glu Leu Ala Asp Ala Leu Met Tyr Cys His
180 185 190
Gly Lys Lys Val Ile His Arg Asp Ile Lys Pro Glu Asn Leu Leu Leu
195 200 205
Gly Leu Lys Gly Glu Leu Lys Ile Ala Asp Phe Gly Trp Ser Val His
210 215 220
Ala Pro Ser Leu Arg Arg Lys Thr Met Cys Gly Thr Leu Asp Tyr Leu
225 230 235 240
Pro Pro Glu Met Ile Glu Gly Arg Met His Asn Glu Lys Val Asp Leu
245 250 255
Trp Cys Ile Gly Val Leu Cys Tyr Glu Leu Leu Val Gly Asn Pro Pro
260 265 270
Phe Glu Ser Ala Ser His Asn Glu Thr Tyr Arg Arg Ile Val Lys Val
275 280 285
Asp Leu Lys Phe Pro Ala Ser Val Pro Thr Gly Ala Gln Asp Leu Ile
290 295 300
Ser Lys Leu Leu Arg His Asn Pro Ser Glu Arg Leu Pro Leu Ala Gln
305 310 315 320
Val Ser Ala His Pro Trp Val Arg Ala Asn Ser Arg Arg Val Leu Pro
325 330 335
Pro Ser Ala Leu Gln Ser Val Ala
340
14
745
PRT
Homo sapiens
14
Met Glu Arg Pro Pro Gly Leu Arg Pro Gly Ala Gly Gly Pro Trp Glu
1 5 10 15
Met Arg Glu Arg Leu Gly Thr Gly Gly Phe Gly Asn Val Cys Leu Tyr
20 25 30
Gln His Arg Glu Leu Asp Leu Lys Ile Ala Ile Lys Ser Cys Arg Leu
35 40 45
Glu Leu Ser Thr Lys Asn Arg Glu Arg Trp Cys His Glu Ile Gln Ile
50 55 60
Met Lys Lys Leu Asn His Ala Asn Val Val Lys Ala Cys Asp Val Pro
65 70 75 80
Glu Glu Leu Asn Ile Leu Ile His Asp Val Pro Leu Leu Ala Met Glu
85 90 95
Tyr Cys Ser Gly Gly Asp Leu Arg Lys Leu Leu Asn Lys Pro Glu Asn
100 105 110
Cys Cys Gly Leu Lys Glu Ser Gln Ile Leu Ser Leu Leu Ser Asp Ile
115 120 125
Gly Ser Gly Ile Arg Tyr Leu His Glu Asn Lys Ile Ile His Arg Asp
130 135 140
Leu Lys Pro Glu Asn Ile Val Leu Gln Asp Val Gly Gly Lys Ile Ile
145 150 155 160
His Lys Ile Ile Asp Leu Gly Tyr Ala Lys Asp Val Asp Gln Gly Ser
165 170 175
Leu Cys Thr Ser Phe Val Gly Thr Leu Gln Tyr Leu Ala Pro Glu Leu
180 185 190
Phe Glu Asn Lys Pro Tyr Thr Ala Thr Val Asp Tyr Trp Ser Phe Gly
195 200 205
Thr Met Val Phe Glu Cys Ile Ala Gly Tyr Arg Pro Phe Leu His His
210 215 220
Leu Gln Pro Phe Thr Trp His Glu Lys Ile Lys Lys Lys Asp Pro Lys
225 230 235 240
Cys Ile Phe Ala Cys Glu Glu Met Ser Gly Glu Val Arg Phe Ser Ser
245 250 255
His Leu Pro Gln Pro Asn Ser Leu Cys Ser Leu Ile Val Glu Pro Met
260 265 270
Glu Asn Trp Leu Gln Leu Met Leu Asn Trp Asp Pro Gln Gln Arg Gly
275 280 285
Gly Pro Val Asp Leu Thr Leu Lys Gln Pro Arg Cys Phe Val Leu Met
290 295 300
Asp His Ile Leu Asn Leu Lys Ile Val His Ile Leu Asn Met Thr Ser
305 310 315 320
Ala Lys Ile Ile Ser Phe Leu Leu Pro Pro Asp Glu Ser Leu His Ser
325 330 335
Leu Gln Ser Arg Ile Glu Arg Glu Thr Gly Ile Asn Thr Gly Ser Gln
340 345 350
Glu Leu Leu Ser Glu Thr Gly Ile Ser Leu Asp Pro Arg Lys Pro Ala
355 360 365
Ser Gln Cys Val Leu Asp Gly Val Arg Gly Cys Asp Ser Tyr Met Val
370 375 380
Tyr Leu Phe Asp Lys Ser Lys Thr Val Tyr Glu Gly Pro Phe Ala Ser
385 390 395 400
Arg Ser Leu Ser Asp Cys Val Asn Tyr Ile Val Gln Asp Ser Lys Ile
405 410 415
Gln Leu Pro Ile Ile Gln Leu Arg Lys Val Trp Ala Glu Ala Val His
420 425 430
Tyr Val Ser Gly Leu Lys Glu Asp Tyr Ser Arg Leu Phe Gln Gly Gln
435 440 445
Arg Ala Ala Met Leu Ser Leu Leu Arg Tyr Asn Ala Asn Leu Thr Lys
450 455 460
Met Lys Asn Thr Leu Ile Ser Ala Ser Gln Gln Leu Lys Ala Lys Leu
465 470 475 480
Glu Phe Phe His Lys Ser Ile Gln Leu Asp Leu Glu Arg Tyr Ser Glu
485 490 495
Gln Met Thr Tyr Gly Ile Ser Ser Glu Lys Met Leu Lys Ala Trp Lys
500 505 510
Glu Met Glu Glu Lys Ala Ile His Tyr Ala Glu Val Gly Val Ile Gly
515 520 525
Tyr Leu Glu Asp Gln Ile Met Ser Leu His Ala Glu Ile Met Glu Leu
530 535 540
Gln Lys Ser Pro Tyr Gly Arg Arg Gln Gly Asp Leu Met Glu Ser Leu
545 550 555 560
Glu Gln Arg Ala Ile Asp Leu Tyr Lys Gln Leu Lys His Arg Pro Ser
565 570 575
Asp His Ser Tyr Ser Asp Ser Thr Glu Met Val Lys Ile Ile Val His
580 585 590
Thr Val Gln Ser Gln Asp Arg Val Leu Lys Glu Leu Phe Gly His Leu
595 600 605
Ser Lys Leu Leu Gly Cys Lys Gln Lys Ile Ile Asp Leu Leu Pro Lys
610 615 620
Val Glu Val Ala Leu Ser Asn Ile Lys Glu Ala Asp Asn Thr Val Met
625 630 635 640
Phe Met Gln Gly Lys Arg Gln Lys Glu Ile Trp His Leu Leu Lys Ile
645 650 655
Ala Cys Thr Gln Ser Ser Ala Arg Ser Leu Val Gly Ser Ser Leu Glu
660 665 670
Gly Ala Val Thr Pro Gln Thr Ser Ala Trp Leu Pro Pro Thr Ser Ala
675 680 685
Glu His Asp His Ser Leu Ser Cys Val Val Thr Pro Gln Asp Gly Glu
690 695 700
Thr Ser Ala Gln Met Ile Glu Glu Asn Leu Asn Cys Leu Gly His Leu
705 710 715 720
Ser Thr Ile Ile His Glu Ala Asn Glu Glu Gln Gly Asn Ser Met Met
725 730 735
Asn Leu Asp Trp Ser Trp Leu Thr Glu
740 745
15
318
PRT
Homo sapiens
15
Met Ser Lys Pro Pro Ala Pro Asn Pro Thr Pro Pro Arg Asn Leu Asp
1 5 10 15
Ser Arg Thr Phe Ile Thr Ile Gly Asp Arg Asn Phe Glu Val Glu Ala
20 25 30
Asp Asp Leu Val Thr Ile Ser Glu Leu Gly Arg Gly Ala Tyr Gly Val
35 40 45
Val Glu Lys Val Arg His Ala Gln Ser Gly Thr Ile Met Ala Val Lys
50 55 60
Arg Ile Arg Ala Thr Val Asn Ser Gln Glu Gln Lys Arg Leu Leu Met
65 70 75 80
Asp Leu Asp Ile Asn Met Arg Thr Val Asp Cys Phe Tyr Thr Val Thr
85 90 95
Phe Tyr Gly Ala Leu Phe Arg Glu Gly Asp Val Trp Ile Cys Met Glu
100 105 110
Leu Met Asp Thr Ser Leu Asp Lys Phe Tyr Arg Lys Val Leu Asp Lys
115 120 125
Asn Met Thr Ile Pro Glu Asp Ile Leu Gly Glu Ile Ala Val Ser Ile
130 135 140
Val Arg Ala Leu Glu His Leu His Ser Lys Leu Ser Val Ile His Arg
145 150 155 160
Asp Val Lys Pro Ser Asn Val Leu Ile Asn Lys Glu Gly His Val Lys
165 170 175
Met Cys Asp Phe Gly Ile Ser Gly Tyr Leu Val Asp Ser Val Ala Lys
180 185 190
Thr Met Asp Ala Gly Cys Lys Pro Tyr Met Ala Pro Glu Arg Ile Asn
195 200 205
Pro Glu Leu Asn Gln Lys Gly Tyr Asn Val Lys Ser Asp Val Trp Ser
210 215 220
Leu Gly Ile Thr Met Ile Glu Met Ala Ile Leu Arg Phe Pro Tyr Glu
225 230 235 240
Ser Trp Gly Thr Pro Phe Gln Gln Leu Lys Gln Val Val Glu Glu Pro
245 250 255
Ser Pro Gln Leu Pro Ala Asp Arg Phe Ser Pro Glu Phe Val Asp Phe
260 265 270
Thr Ala Gln Cys Leu Arg Lys Asn Pro Ala Glu Arg Met Ser Tyr Leu
275 280 285
Glu Leu Met Glu His Pro Phe Phe Thr Leu His Lys Thr Lys Lys Thr
290 295 300
Asp Ile Ala Ala Phe Val Lys Lys Ile Leu Gly Glu Asp Ser
305 310 315
16
379
PRT
Homo sapiens
16
Met Ala Ala Ala Ala Ala Gln Gly Gly Gly Gly Gly Glu Pro Arg Arg
1 5 10 15
Thr Glu Gly Val Gly Pro Gly Val Pro Gly Glu Val Glu Met Val Lys
20 25 30
Gly Gln Pro Phe Asp Val Gly Pro Arg Tyr Thr Gln Leu Gln Tyr Ile
35 40 45
Gly Glu Gly Ala Tyr Gly Met Val Ser Ser Ala Tyr Asp His Val Arg
50 55 60
Lys Thr Arg Val Ala Ile Lys Lys Ile Ser Pro Phe Glu His Gln Thr
65 70 75 80
Tyr Cys Gln Arg Thr Leu Arg Glu Ile Gln Ile Leu Leu Arg Phe Arg
85 90 95
His Glu Asn Val Ile Gly Ile Arg Asp Ile Leu Arg Ala Ser Thr Leu
100 105 110
Glu Ala Met Arg Asp Val Tyr Ile Val Gln Asp Leu Met Glu Thr Asp
115 120 125
Leu Tyr Lys Leu Leu Lys Ser Gln Gln Leu Ser Asn Asp His Ile Cys
130 135 140
Tyr Phe Leu Tyr Gln Ile Leu Arg Gly Leu Lys Tyr Ile His Ser Ala
145 150 155 160
Asn Val Leu His Arg Asp Leu Lys Pro Ser Asn Leu Leu Ser Asn Thr
165 170 175
Thr Cys Asp Leu Lys Ile Cys Asp Phe Gly Leu Ala Arg Ile Ala Asp
180 185 190
Pro Glu His Asp His Thr Gly Phe Leu Thr Glu Tyr Val Ala Thr Arg
195 200 205
Trp Tyr Arg Ala Pro Glu Ile Met Leu Asn Ser Lys Gly Tyr Thr Lys
210 215 220
Ser Ile Asp Ile Trp Ser Val Gly Cys Ile Leu Ala Glu Met Leu Ser
225 230 235 240
Asn Arg Pro Ile Phe Pro Gly Lys His Tyr Leu Asp Gln Leu Asn His
245 250 255
Ile Leu Gly Ile Leu Gly Ser Pro Ser Gln Glu Asp Leu Asn Cys Ile
260 265 270
Ile Asn Met Lys Ala Arg Asn Tyr Leu Gln Ser Leu Pro Ser Lys Thr
275 280 285
Lys Val Ala Trp Ala Lys Leu Phe Pro Lys Ser Asp Ser Lys Ala Leu
290 295 300
Asp Leu Leu Asp Arg Met Leu Thr Phe Asn Pro Asn Lys Arg Ile Thr
305 310 315 320
Val Glu Glu Ala Leu Ala His Pro Tyr Leu Glu Gln Tyr Tyr Asp Pro
325 330 335
Thr Asp Glu Pro Val Ala Glu Glu Pro Phe Thr Phe Ala Met Glu Leu
340 345 350
Asp Asp Leu Pro Lys Glu Arg Leu Lys Glu Leu Ile Phe Gln Glu Thr
355 360 365
Ala Arg Phe Gln Pro Gly Val Leu Glu Ala Pro
370 375
17
648
PRT
Homo sapiens
17
Met Glu His Ile Gln Gly Ala Trp Lys Thr Ile Ser Asn Gly Phe Gly
1 5 10 15
Phe Lys Asp Ala Val Phe Asp Gly Ser Ser Cys Ile Ser Pro Thr Ile
20 25 30
Val Gln Gln Phe Gly Tyr Gln Arg Arg Ala Ser Asp Asp Gly Lys Leu
35 40 45
Thr Asp Pro Ser Lys Thr Ser Asn Thr Ile Arg Val Phe Leu Pro Asn
50 55 60
Lys Gln Arg Thr Val Val Asn Val Arg Asn Gly Met Ser Leu His Asp
65 70 75 80
Cys Leu Met Lys Ala Leu Lys Val Arg Gly Leu Gln Pro Glu Cys Cys
85 90 95
Ala Val Phe Arg Leu Leu His Glu His Lys Gly Lys Lys Ala Arg Leu
100 105 110
Asp Trp Asn Thr Asp Ala Ala Ser Leu Ile Gly Glu Glu Leu Gln Val
115 120 125
Asp Phe Leu Asp His Val Pro Leu Thr Thr His Asn Phe Ala Arg Lys
130 135 140
Thr Phe Leu Lys Leu Ala Phe Cys Asp Ile Cys Gln Lys Phe Leu Leu
145 150 155 160
Asn Gly Phe Arg Cys Gln Thr Cys Gly Tyr Lys Phe His Glu His Cys
165 170 175
Ser Thr Lys Val Pro Thr Met Cys Val Asp Trp Ser Asn Ile Arg Gln
180 185 190
Leu Leu Leu Phe Pro Asn Ser Thr Ile Gly Asp Ser Gly Val Pro Ala
195 200 205
Leu Pro Ser Leu Thr Met Arg Arg Met Arg Glu Ser Val Ser Arg Met
210 215 220
Pro Val Ser Ser Gln His Arg Tyr Ser Thr Pro His Ala Phe Thr Phe
225 230 235 240
Asn Thr Ser Ser Pro Ser Ser Glu Gly Ser Leu Ser Gln Arg Gln Arg
245 250 255
Ser Thr Ser Thr Pro Asn Val His Met Val Ser Thr Thr Leu Pro Val
260 265 270
Asp Ser Arg Met Ile Glu Asp Ala Ile Arg Ser His Ser Glu Ser Ala
275 280 285
Ser Pro Ser Ala Leu Ser Ser Ser Pro Asn Asn Leu Ser Pro Thr Gly
290 295 300
Trp Ser Gln Pro Lys Thr Pro Val Pro Ala Gln Arg Glu Arg Ala Pro
305 310 315 320
Val Ser Gly Thr Gln Glu Lys Asn Lys Ile Arg Pro Arg Gly Gln Arg
325 330 335
Asp Ser Ser Tyr Tyr Trp Glu Ile Glu Ala Ser Glu Val Met Leu Ser
340 345 350
Thr Arg Ile Gly Ser Gly Ser Phe Gly Thr Val Tyr Lys Gly Lys Trp
355 360 365
His Gly Asp Val Ala Val Lys Ile Leu Lys Val Val Asp Pro Thr Pro
370 375 380
Glu Gln Phe Gln Ala Phe Arg Asn Glu Val Ala Val Leu Arg Lys Thr
385 390 395 400
Arg His Val Asn Ile Leu Leu Phe Met Gly Tyr Met Thr Lys Asp Asn
405 410 415
Leu Ala Ile Val Thr Gln Trp Cys Glu Gly Ser Ser Leu Tyr Lys His
420 425 430
Leu His Val Gln Glu Thr Lys Phe Gln Met Phe Gln Leu Ile Asp Ile
435 440 445
Ala Arg Gln Thr Ala Gln Gly Met Asp Tyr Leu His Ala Lys Asn Ile
450 455 460
Ile His Arg Asp Met Lys Ser Asn Asn Ile Phe Leu His Glu Gly Leu
465 470 475 480
Thr Val Lys Ile Gly Asp Phe Gly Leu Ala Thr Val Lys Ser Arg Trp
485 490 495
Ser Gly Ser Gln Gln Val Glu Gln Pro Thr Gly Ser Val Leu Trp Met
500 505 510
Ala Pro Glu Val Ile Arg Met Gln Asp Asn Asn Pro Phe Ser Phe Gln
515 520 525
Ser Asp Val Tyr Ser Tyr Gly Ile Val Leu Tyr Glu Leu Met Thr Gly
530 535 540
Glu Leu Pro Tyr Ser His Ile Asn Asn Arg Asp Gln Ile Ile Phe Met
545 550 555 560
Val Gly Arg Gly Tyr Ala Ser Pro Asp Leu Ser Lys Leu Tyr Lys Asn
565 570 575
Cys Pro Lys Ala Met Lys Arg Leu Val Ala Asp Cys Val Lys Lys Val
580 585 590
Lys Glu Glu Arg Pro Leu Phe Pro Gln Ile Leu Ser Ser Ile Glu Leu
595 600 605
Leu Gln His Ser Leu Pro Lys Ile Asn Arg Ser Ala Ser Glu Pro Ser
610 615 620
Leu His Arg Ala Ala His Thr Glu Asp Ile Asn Ala Cys Thr Leu Thr
625 630 635 640
Thr Ser Pro Arg Leu Pro Val Phe
645
18
480
PRT
Homo sapiens
18
Met Ser Asp Val Ala Ile Val Lys Glu Gly Trp Leu His Lys Arg Gly
1 5 10 15
Glu Tyr Ile Lys Thr Trp Arg Pro Arg Tyr Phe Leu Leu Lys Asn Asp
20 25 30
Gly Thr Phe Ile Gly Tyr Lys Glu Arg Pro Gln Asp Val Asp Gln Arg
35 40 45
Glu Ala Pro Leu Asn Asn Phe Ser Val Ala Gln Cys Gln Leu Met Lys
50 55 60
Thr Glu Arg Pro Arg Pro Asn Thr Phe Ile Ile Arg Cys Leu Gln Trp
65 70 75 80
Thr Thr Val Ile Glu Arg Thr Phe His Val Glu Thr Pro Glu Glu Arg
85 90 95
Glu Glu Trp Thr Thr Ala Ile Gln Thr Val Ala Asp Gly Leu Lys Lys
100 105 110
Gln Glu Glu Glu Glu Met Asp Phe Arg Ser Gly Ser Pro Ser Asp Asn
115 120 125
Ser Gly Ala Glu Glu Met Glu Val Ser Leu Ala Lys Pro Lys His Arg
130 135 140
Val Thr Met Asn Glu Phe Glu Tyr Leu Lys Leu Leu Gly Lys Gly Thr
145 150 155 160
Phe Gly Lys Val Ile Leu Val Lys Glu Lys Ala Thr Gly Arg Tyr Tyr
165 170 175
Ala Met Lys Ile Leu Lys Lys Glu Val Ile Val Ala Lys Asp Glu Val
180 185 190
Ala His Thr Leu Thr Glu Asn Arg Val Leu Gln Asn Ser Arg His Pro
195 200 205
Phe Leu Thr Ala Leu Lys Tyr Ser Phe Gln Thr His Asp Arg Leu Cys
210 215 220
Phe Val Met Glu Tyr Ala Asn Gly Gly Glu Leu Phe Phe His Leu Ser
225 230 235 240
Arg Glu Arg Val Phe Ser Glu Asp Arg Ala Arg Phe Tyr Gly Ala Glu
245 250 255
Ile Val Ser Ala Leu Asp Tyr Leu His Ser Glu Lys Asn Val Val Tyr
260 265 270
Arg Asp Leu Lys Leu Glu Asn Leu Met Leu Asp Lys Asp Gly His Ile
275 280 285
Lys Ile Thr Asp Phe Gly Leu Cys Lys Glu Gly Ile Lys Asp Gly Ala
290 295 300
Thr Met Lys Thr Phe Cys Gly Thr Pro Glu Tyr Leu Ala Pro Glu Val
305 310 315 320
Leu Glu Asp Asn Asp Tyr Gly Arg Ala Val Asp Trp Trp Gly Leu Gly
325 330 335
Val Val Met Tyr Glu Met Met Cys Gly Arg Leu Pro Phe Tyr Asn Gln
340 345 350
Asp His Glu Lys Leu Phe Glu Leu Ile Leu Met Glu Glu Ile Arg Phe
355 360 365
Pro Arg Thr Leu Gly Pro Glu Ala Lys Ser Leu Leu Ser Gly Leu Leu
370 375 380
Lys Lys Asp Pro Lys Gln Arg Leu Gly Gly Gly Ser Glu Asp Ala Lys
385 390 395 400
Glu Ile Met Gln His Arg Phe Phe Ala Gly Ile Val Trp Gln His Val
405 410 415
Tyr Glu Lys Lys Leu Ser Pro Pro Phe Lys Pro Gln Val Thr Ser Glu
420 425 430
Thr Asp Thr Arg Tyr Phe Asp Glu Glu Phe Thr Ala Gln Met Ile Thr
435 440 445
Ile Thr Pro Pro Asp Gln Asp Asp Ser Met Glu Cys Val Asp Ser Glu
450 455 460
Arg Arg Pro His Phe Pro Gln Phe Ser Tyr Ser Ala Ser Ser Thr Ala
465 470 475 480
19
724
PRT
Homo sapiens
19
Met Ser Ala Glu Gly Tyr Gln Tyr Arg Ala Leu Tyr Asp Tyr Lys Lys
1 5 10 15
Glu Arg Glu Glu Asp Ile Asp Leu His Leu Gly Asp Ile Leu Thr Val
20 25 30
Asn Lys Gly Ser Leu Val Ala Leu Gly Phe Ser Asp Gly Gln Glu Ala
35 40 45
Arg Pro Glu Glu Ile Gly Trp Leu Asn Gly Tyr Asn Glu Thr Thr Gly
50 55 60
Glu Arg Gly Asp Phe Pro Gly Thr Tyr Val Glu Tyr Ile Gly Arg Lys
65 70 75 80
Lys Ile Ser Pro Pro Thr Pro Lys Pro Arg Pro Pro Arg Pro Leu Pro
85 90 95
Val Ala Pro Gly Ser Ser Lys Thr Glu Ala Asp Val Glu Gln Gln Ala
100 105 110
Leu Thr Leu Pro Asp Leu Ala Glu Gln Phe Ala Pro Pro Asp Ile Ala
115 120 125
Pro Pro Leu Leu Ile Lys Leu Val Glu Ala Ile Glu Lys Lys Gly Leu
130 135 140
Glu Cys Ser Thr Leu Tyr Arg Thr Gln Ser Ser Ser Asn Leu Ala Glu
145 150 155 160
Leu Arg Gln Leu Leu Asp Cys Asp Thr Pro Ser Val Asp Leu Glu Met
165 170 175
Ile Asp Val His Val Leu Ala Asp Ala Phe Lys Arg Tyr Leu Leu Asp
180 185 190
Leu Pro Asn Pro Val Ile Pro Ala Ala Val Tyr Ser Glu Met Ile Ser
195 200 205
Leu Ala Pro Glu Val Gln Ser Ser Glu Glu Tyr Ile Gln Leu Leu Lys
210 215 220
Lys Leu Ile Arg Ser Pro Ser Ile Pro His Gln Tyr Trp Leu Thr Leu
225 230 235 240
Gln Tyr Leu Leu Lys His Phe Phe Lys Leu Ser Gln Thr Ser Ser Lys
245 250 255
Asn Leu Leu Asn Ala Arg Val Leu Ser Glu Ile Phe Ser Pro Met Leu
260 265 270
Phe Arg Phe Ser Ala Ala Ser Ser Asp Asn Thr Glu Asn Leu Ile Lys
275 280 285
Val Ile Glu Ile Leu Ile Ser Thr Glu Trp Asn Glu Arg Gln Pro Ala
290 295 300
Pro Ala Leu Pro Pro Lys Pro Pro Lys Pro Thr Thr Val Ala Asn Asn
305 310 315 320
Gly Met Asn Asn Asn Met Ser Leu Gln Asn Ala Glu Trp Tyr Trp Gly
325 330 335
Asp Ile Ser Arg Glu Glu Val Asn Glu Lys Leu Arg Asp Thr Ala Asp
340 345 350
Gly Thr Phe Leu Val Arg Asp Ala Ser Thr Lys Met His Gly Asp Tyr
355 360 365
Thr Leu Thr Leu Arg Lys Gly Gly Asn Asn Lys Leu Ile Lys Ile Phe
370 375 380
His Arg Asp Gly Lys Tyr Gly Phe Ser Asp Pro Leu Thr Phe Ser Ser
385 390 395 400
Val Val Glu Leu Ile Asn His Tyr Arg Asn Glu Ser Leu Ala Gln Tyr
405 410 415
Asn Pro Lys Leu Asp Val Lys Leu Leu Tyr Pro Val Ser Lys Tyr Gln
420 425 430
Gln Asp Gln Val Val Lys Glu Asp Asn Ile Glu Ala Val Gly Lys Lys
435 440 445
Leu His Glu Tyr Asn Thr Gln Phe Gln Glu Lys Ser Arg Glu Tyr Asp
450 455 460
Arg Leu Tyr Glu Glu Tyr Thr Arg Thr Ser Gln Glu Ile Gln Met Lys
465 470 475 480
Arg Thr Ala Ile Glu Ala Phe Asn Glu Thr Ile Lys Ile Phe Glu Glu
485 490 495
Gln Cys Gln Thr Gln Glu Arg Tyr Ser Lys Glu Tyr Ile Glu Lys Phe
500 505 510
Lys Arg Glu Gly Asn Glu Lys Glu Ile Gln Arg Ile Met His Asn Tyr
515 520 525
Asp Lys Leu Lys Ser Arg Ile Ser Glu Ile Ile Asp Ser Arg Arg Arg
530 535 540
Leu Glu Glu Asp Leu Lys Lys Gln Ala Ala Glu Tyr Arg Glu Ile Asp
545 550 555 560
Lys Arg Met Asn Ser Ile Lys Pro Asp Leu Ile Gln Leu Arg Lys Thr
565 570 575
Arg Asp Gln Tyr Leu Met Trp Leu Thr Gln Lys Gly Val Arg Gln Lys
580 585 590
Lys Leu Asn Glu Trp Leu Gly Asn Glu Asn Thr Glu Asp Gln Tyr Ser
595 600 605
Leu Val Glu Asp Asp Glu Asp Leu Pro His His Asp Glu Lys Thr Trp
610 615 620
Asn Val Gly Ser Ser Asn Arg Asn Lys Ala Glu Asn Leu Leu Arg Gly
625 630 635 640
Lys Arg Asp Gly Thr Phe Leu Val Arg Glu Ser Ser Lys Gln Gly Cys
645 650 655
Tyr Ala Cys Ser Val Val Val Asp Gly Glu Val Lys His Cys Val Ile
660 665 670
Asn Lys Thr Ala Thr Gly Tyr Gly Phe Ala Glu Pro Tyr Asn Leu Tyr
675 680 685
Ser Ser Leu Lys Glu Leu Val Leu His Tyr Gln His Thr Ser Leu Val
690 695 700
Gln His Asn Asp Ser Leu Asn Val Thr Leu Ala Tyr Pro Val Tyr Ala
705 710 715 720
Gln Gln Arg Arg
20
3056
PRT
Homo sapiens
20
Met Ser Leu Val Leu Asn Asp Leu Leu Ile Cys Cys Arg Gln Leu Glu
1 5 10 15
His Asp Arg Ala Thr Glu Arg Lys Lys Glu Val Glu Lys Phe Lys Arg
20 25 30
Leu Ile Arg Asp Pro Glu Thr Ile Lys His Leu Asp Arg His Ser Asp
35 40 45
Ser Lys Gln Gly Lys Tyr Leu Asn Trp Asp Ala Val Phe Arg Phe Leu
50 55 60
Gln Lys Tyr Ile Gln Lys Glu Thr Glu Cys Leu Arg Ile Ala Lys Pro
65 70 75 80
Asn Val Ser Ala Ser Thr Gln Ala Ser Arg Gln Lys Lys Met Gln Glu
85 90 95
Ile Ser Ser Leu Val Lys Tyr Phe Ile Lys Cys Ala Asn Arg Arg Ala
100 105 110
Pro Arg Leu Lys Cys Gln Glu Leu Leu Asn Tyr Ile Met Asp Thr Val
115 120 125
Lys Asp Ser Ser Asn Gly Ala Ile Tyr Gly Ala Asp Cys Ser Asn Ile
130 135 140
Leu Leu Lys Asp Ile Leu Ser Val Arg Lys Tyr Trp Cys Glu Ile Ser
145 150 155 160
Gln Gln Gln Trp Leu Glu Leu Phe Ser Val Tyr Phe Arg Leu Tyr Leu
165 170 175
Lys Pro Ser Gln Asp Val His Arg Val Leu Val Ala Arg Ile Ile His
180 185 190
Ala Val Thr Lys Gly Cys Cys Ser Gln Thr Asp Gly Leu Asn Ser Lys
195 200 205
Phe Leu Asp Phe Phe Ser Lys Ala Ile Gln Cys Ala Arg Gln Glu Lys
210 215 220
Ser Ser Ser Gly Leu Asn His Ile Leu Ala Ala Leu Thr Ile Phe Leu
225 230 235 240
Lys Thr Leu Ala Val Asn Phe Arg Ile Arg Val Cys Glu Leu Gly Asp
245 250 255
Glu Ile Leu Pro Thr Leu Leu Tyr Ile Trp Thr Gln His Arg Leu Asn
260 265 270
Asp Ser Leu Lys Glu Val Ile Ile Glu Leu Phe Gln Leu Gln Ile Tyr
275 280 285
Ile His His Pro Lys Gly Ala Lys Thr Gln Glu Lys Gly Ala Tyr Glu
290 295 300
Ser Thr Lys Trp Arg Ser Ile Leu Tyr Asn Leu Tyr Asp Leu Leu Val
305 310 315 320
Asn Glu Ile Ser His Ile Gly Ser Arg Gly Lys Tyr Ser Ser Gly Phe
325 330 335
Arg Asn Ile Ala Val Lys Glu Asn Leu Ile Glu Leu Met Ala Asp Ile
340 345 350
Cys His Gln Val Phe Asn Glu Asp Thr Arg Ser Leu Glu Ile Ser Gln
355 360 365
Ser Tyr Thr Thr Thr Gln Arg Glu Ser Ser Asp Tyr Ser Val Pro Cys
370 375 380
Lys Arg Lys Lys Ile Glu Leu Gly Trp Glu Val Ile Lys Asp His Leu
385 390 395 400
Gln Lys Ser Gln Asn Asp Phe Asp Leu Val Pro Trp Leu Gln Ile Ala
405 410 415
Thr Gln Leu Ile Ser Lys Tyr Pro Ala Ser Leu Pro Asn Cys Glu Leu
420 425 430
Ser Pro Leu Leu Met Ile Leu Ser Gln Leu Leu Pro Gln Gln Arg His
435 440 445
Gly Glu Arg Thr Pro Tyr Val Leu Arg Cys Leu Thr Glu Val Ala Leu
450 455 460
Cys Gln Asp Lys Arg Ser Asn Leu Glu Ser Ser Gln Lys Ser Asp Leu
465 470 475 480
Leu Lys Leu Trp Asn Lys Ile Trp Cys Ile Thr Phe Arg Gly Ile Ser
485 490 495
Ser Glu Gln Ile Gln Ala Glu Asn Phe Gly Leu Leu Gly Ala Ile Ile
500 505 510
Gln Gly Ser Leu Val Glu Val Asp Arg Glu Phe Trp Lys Leu Phe Thr
515 520 525
Gly Ser Ala Cys Arg Pro Ser Cys Pro Ala Val Cys Cys Leu Thr Leu
530 535 540
Ala Leu Thr Thr Ser Ile Val Pro Gly Ala Val Lys Met Gly Ile Glu
545 550 555 560
Gln Asn Met Cys Glu Val Asn Arg Ser Phe Ser Leu Lys Glu Ser Ile
565 570 575
Met Lys Trp Leu Leu Phe Tyr Gln Leu Glu Gly Asp Leu Glu Asn Ser
580 585 590
Thr Glu Val Pro Pro Ile Leu His Ser Asn Phe Pro His Leu Val Leu
595 600 605
Glu Lys Ile Leu Val Ser Leu Thr Met Lys Asn Cys Lys Ala Ala Met
610 615 620
Asn Phe Phe Gln Ser Val Pro Glu Cys Glu His His Gln Lys Asp Lys
625 630 635 640
Glu Glu Leu Ser Phe Ser Glu Val Glu Glu Leu Phe Leu Gln Thr Thr
645 650 655
Phe Asp Lys Met Asp Phe Leu Thr Ile Val Arg Glu Cys Gly Ile Glu
660 665 670
Lys His Gln Ser Ser Ile Gly Phe Ser Val His Gln Asn Leu Lys Glu
675 680 685
Ser Leu Asp Arg Cys Leu Leu Gly Leu Ser Glu Gln Leu Leu Asn Asn
690 695 700
Tyr Ser Ser Glu Ile Thr Asn Ser Glu Thr Leu Val Arg Cys Ser Arg
705 710 715 720
Leu Leu Val Gly Val Leu Gly Cys Tyr Cys Tyr Met Gly Val Ile Ala
725 730 735
Glu Glu Glu Ala Tyr Lys Ser Glu Leu Phe Gln Lys Ala Asn Ser Leu
740 745 750
Met Gln Cys Ala Gly Glu Ser Ile Thr Leu Phe Lys Asn Lys Thr Asn
755 760 765
Glu Glu Phe Arg Ile Gly Ser Leu Arg Asn Met Met Gln Leu Cys Thr
770 775 780
Arg Cys Leu Ser Asn Cys Thr Lys Lys Ser Pro Asn Lys Ile Ala Ser
785 790 795 800
Gly Phe Phe Leu Arg Leu Leu Thr Ser Lys Leu Met Asn Asp Ile Ala
805 810 815
Asp Ile Cys Lys Ser Leu Ala Ser Phe Ile Lys Lys Pro Phe Asp Arg
820 825 830
Gly Glu Val Glu Ser Met Glu Asp Asp Thr Asn Gly Asn Leu Met Glu
835 840 845
Val Glu Asp Gln Ser Ser Met Asn Leu Phe Asn Asp Tyr Pro Asp Ser
850 855 860
Ser Val Ser Asp Ala Asn Glu Pro Gly Glu Ser Gln Ser Thr Ile Gly
865 870 875 880
Ala Ile Asn Pro Leu Ala Glu Glu Tyr Leu Ser Lys Gln Asp Leu Leu
885 890 895
Phe Leu Asp Met Leu Lys Phe Leu Cys Leu Cys Val Thr Thr Ala Gln
900 905 910
Thr Asn Thr Val Ser Phe Arg Ala Ala Asp Ile Arg Arg Lys Leu Leu
915 920 925
Met Leu Ile Asp Ser Ser Thr Leu Glu Pro Thr Lys Ser Leu His Leu
930 935 940
His Met Tyr Leu Met Leu Leu Lys Glu Leu Pro Gly Glu Glu Tyr Pro
945 950 955 960
Leu Pro Met Glu Asp Val Leu Glu Leu Leu Lys Pro Leu Ser Asn Val
965 970 975
Cys Ser Leu Tyr Arg Arg Asp Gln Asp Val Cys Lys Thr Ile Leu Asn
980 985 990
His Val Leu His Val Val Lys Asn Leu Gly Gln Ser Asn Met Asp Ser
995 1000 1005
Glu Asn Thr Arg Asp Ala Gln Gly Gln Phe Leu Thr Val Ile Gly Ala
1010 1015 1020
Phe Trp His Leu Thr Lys Glu Arg Lys Tyr Ile Phe Ser Val Arg Met
1025 1030 1035 1040
Ala Leu Val Asn Cys Leu Lys Thr Leu Leu Glu Ala Asp Pro Tyr Ser
1045 1050 1055
Lys Trp Ala Ile Leu Asn Val Met Gly Lys Asp Phe Pro Val Asn Glu
1060 1065 1070
Val Phe Thr Gln Phe Leu Ala Asp Asn His His Gln Val Arg Met Leu
1075 1080 1085
Ala Ala Glu Ser Ile Asn Arg Leu Phe Gln Asp Thr Lys Gly Asp Ser
1090 1095 1100
Ser Arg Leu Leu Lys Ala Leu Pro Leu Lys Leu Gln Gln Thr Ala Phe
1105 1110 1115 1120
Glu Asn Ala Tyr Leu Lys Ala Gln Glu Gly Met Arg Glu Met Ser His
1125 1130 1135
Ser Ala Glu Asn Pro Glu Thr Leu Asp Glu Ile Tyr Asn Arg Lys Ser
1140 1145 1150
Val Leu Leu Thr Leu Ile Ala Val Val Leu Ser Cys Ser Pro Ile Cys
1155 1160 1165
Glu Lys Gln Ala Leu Phe Ala Leu Cys Lys Ser Val Lys Glu Asn Gly
1170 1175 1180
Leu Glu Pro His Leu Val Lys Lys Val Leu Glu Lys Val Ser Glu Thr
1185 1190 1195 1200
Phe Gly Tyr Arg Arg Leu Glu Asp Phe Met Ala Ser His Leu Asp Tyr
1205 1210 1215
Leu Val Leu Glu Trp Leu Asn Leu Gln Asp Thr Glu Tyr Asn Leu Ser
1220 1225 1230
Ser Phe Pro Phe Ile Leu Leu Asn Tyr Thr Asn Ile Glu Asp Phe Tyr
1235 1240 1245
Arg Ser Cys Tyr Lys Val Leu Ile Pro His Leu Val Ile Arg Ser His
1250 1255 1260
Phe Asp Glu Val Lys Ser Ile Ala Asn Gln Ile Gln Glu Asp Trp Lys
1265 1270 1275 1280
Ser Leu Leu Thr Asp Cys Phe Pro Lys Ile Leu Val Asn Ile Leu Pro
1285 1290 1295
Tyr Phe Ala Tyr Glu Gly Thr Arg Asp Ser Gly Met Ala Gln Gln Arg
1300 1305 1310
Glu Thr Ala Thr Lys Val Tyr Asp Met Leu Lys Ser Glu Asn Leu Leu
1315 1320 1325
Gly Lys Gln Ile Asp His Leu Phe Ile Ser Asn Leu Pro Glu Ile Val
1330 1335 1340
Val Glu Leu Leu Met Thr Leu His Glu Pro Ala Asn Ser Ser Ala Ser
1345 1350 1355 1360
Gln Ser Thr Asp Leu Cys Asp Phe Ser Gly Asp Leu Asp Pro Ala Pro
1365 1370 1375
Asn Pro Pro His Phe Pro Ser His Val Ile Lys Ala Thr Phe Ala Tyr
1380 1385 1390
Ile Ser Asn Cys His Lys Thr Lys Leu Lys Ser Ile Leu Glu Ile Leu
1395 1400 1405
Ser Lys Ser Pro Asp Ser Tyr Gln Lys Ile Leu Leu Ala Ile Cys Glu
1410 1415 1420
Gln Ala Ala Glu Thr Asn Asn Val Tyr Lys Lys His Arg Ile Leu Lys
1425 1430 1435 1440
Ile Tyr His Leu Phe Val Ser Leu Leu Leu Lys Asp Ile Lys Ser Gly
1445 1450 1455
Leu Gly Gly Ala Trp Ala Phe Val Leu Arg Asp Val Ile Tyr Thr Leu
1460 1465 1470
Ile His Tyr Ile Asn Gln Arg Pro Ser Cys Ile Met Asp Val Ser Leu
1475 1480 1485
Arg Ser Phe Ser Leu Cys Cys Asp Leu Leu Ser Gln Val Cys Gln Thr
1490 1495 1500
Ala Val Thr Tyr Cys Lys Asp Ala Leu Glu Asn His Leu His Val Ile
1505 1510 1515 1520
Val Gly Thr Leu Ile Pro Leu Val Tyr Glu Gln Val Glu Val Gln Lys
1525 1530 1535
Gln Val Leu Asp Leu Leu Lys Tyr Leu Val Ile Asp Asn Lys Asp Asn
1540 1545 1550
Glu Asn Leu Tyr Ile Thr Ile Lys Leu Leu Asp Pro Phe Pro Asp His
1555 1560 1565
Val Val Phe Lys Asp Leu Arg Ile Thr Gln Gln Lys Ile Lys Tyr Ser
1570 1575 1580
Arg Gly Pro Phe Ser Leu Leu Glu Glu Ile Asn His Phe Leu Ser Val
1585 1590 1595 1600
Ser Val Tyr Asp Ala Leu Pro Leu Thr Arg Leu Glu Gly Leu Lys Asp
1605 1610 1615
Leu Arg Arg Gln Leu Glu Leu His Lys Asp Gln Met Val Asp Ile Met
1620 1625 1630
Arg Ala Ser Gln Asp Asn Pro Gln Asp Gly Ile Met Val Lys Leu Val
1635 1640 1645
Val Asn Leu Leu Gln Leu Ser Lys Met Ala Ile Asn His Thr Gly Glu
1650 1655 1660
Lys Glu Val Leu Glu Ala Val Gly Ser Cys Leu Gly Glu Val Gly Pro
1665 1670 1675 1680
Ile Asp Phe Ser Thr Ile Ala Ile Gln His Ser Lys Asp Ala Ser Tyr
1685 1690 1695
Thr Lys Ala Leu Lys Leu Phe Glu Asp Lys Glu Leu Gln Trp Thr Phe
1700 1705 1710
Ile Met Leu Thr Tyr Leu Asn Asn Thr Leu Val Glu Asp Cys Val Lys
1715 1720 1725
Val Arg Ser Ala Ala Val Thr Cys Leu Lys Asn Ile Leu Ala Thr Lys
1730 1735 1740
Thr Gly His Ser Phe Trp Glu Ile Tyr Lys Met Thr Thr Asp Pro Met
1745 1750 1755 1760
Leu Ala Tyr Leu Gln Pro Phe Arg Thr Ser Arg Lys Lys Phe Leu Glu
1765 1770 1775
Val Pro Arg Phe Asp Lys Glu Asn Pro Phe Glu Gly Leu Asp Asp Ile
1780 1785 1790
Asn Leu Trp Ile Pro Leu Ser Glu Asn His Asp Ile Trp Ile Lys Thr
1795 1800 1805
Leu Thr Cys Ala Phe Leu Asp Ser Gly Gly Thr Lys Cys Glu Ile Leu
1810 1815 1820
Gln Leu Leu Lys Pro Met Cys Glu Val Lys Thr Asp Phe Cys Gln Thr
1825 1830 1835 1840
Val Leu Pro Tyr Leu Ile His Asp Ile Leu Leu Gln Asp Thr Asn Glu
1845 1850 1855
Ser Trp Arg Asn Leu Leu Ser Thr His Val Gln Gly Phe Phe Thr Ser
1860 1865 1870
Cys Leu Arg His Phe Ser Gln Thr Ser Arg Ser Thr Thr Pro Ala Asn
1875 1880 1885
Leu Asp Ser Glu Ser Glu His Phe Phe Arg Cys Cys Leu Asp Lys Lys
1890 1895 1900
Ser Gln Arg Thr Met Leu Ala Val Val Asp Tyr Met Arg Arg Gln Lys
1905 1910 1915 1920
Arg Pro Ser Ser Gly Thr Ile Phe Asn Asp Ala Phe Trp Leu Asp Leu
1925 1930 1935
Asn Tyr Leu Glu Val Ala Lys Val Ala Gln Ser Cys Ala Ala His Phe
1940 1945 1950
Thr Ala Leu Leu Tyr Ala Glu Ile Tyr Ala Asp Lys Lys Ser Met Asp
1955 1960 1965
Asp Gln Glu Lys Arg Ser Leu Ala Phe Glu Glu Gly Ser Gln Ser Thr
1970 1975 1980
Thr Ile Ser Ser Leu Ser Glu Lys Ser Lys Glu Glu Thr Gly Ile Ser
1985 1990 1995 2000
Leu Gln Asp Leu Leu Leu Glu Ile Tyr Arg Ser Ile Gly Glu Pro Asp
2005 2010 2015
Ser Leu Tyr Gly Cys Gly Gly Gly Lys Met Leu Gln Pro Ile Thr Arg
2020 2025 2030
Leu Arg Thr Tyr Glu His Glu Ala Met Trp Gly Lys Ala Leu Val Thr
2035 2040 2045
Tyr Asp Leu Glu Thr Ala Ile Pro Ser Ser Thr Arg Gln Ala Gly Ile
2050 2055 2060
Ile Gln Ala Leu Gln Asn Leu Gly Leu Cys His Ile Leu Ser Val Tyr
2065 2070 2075 2080
Leu Lys Gly Leu Asp Tyr Glu Asn Lys Asp Trp Cys Pro Glu Leu Glu
2085 2090 2095
Glu Leu His Tyr Gln Ala Ala Trp Arg Asn Met Gln Trp Asp His Cys
2100 2105 2110
Thr Ser Val Ser Lys Glu Val Glu Gly Thr Ser Tyr His Glu Ser Leu
2115 2120 2125
Tyr Asn Ala Leu Gln Ser Leu Arg Asp Arg Glu Phe Ser Thr Phe Tyr
2130 2135 2140
Glu Ser Leu Lys Tyr Ala Arg Val Lys Glu Val Glu Glu Met Cys Lys
2145 2150 2155 2160
Arg Ser Leu Glu Ser Val Tyr Ser Leu Tyr Pro Thr Leu Ser Arg Leu
2165 2170 2175
Gln Ala Ile Gly Glu Leu Glu Ser Ile Gly Glu Leu Phe Ser Arg Ser
2180 2185 2190
Val Thr His Arg Gln Leu Ser Glu Val Tyr Ile Lys Trp Gln Lys His
2195 2200 2205
Ser Gln Leu Leu Lys Asp Ser Asp Phe Ser Phe Gln Glu Pro Ile Met
2210 2215 2220
Ala Leu Arg Thr Val Ile Leu Glu Ile Leu Met Glu Lys Glu Met Asp
2225 2230 2235 2240
Asn Ser Gln Arg Glu Cys Ile Lys Asp Ile Leu Thr Lys His Leu Val
2245 2250 2255
Glu Leu Ser Ile Leu Ala Arg Thr Phe Lys Asn Thr Gln Leu Pro Glu
2260 2265 2270
Arg Ala Ile Phe Gln Ile Lys Gln Tyr Asn Ser Val Ser Cys Gly Val
2275 2280 2285
Ser Glu Trp Gln Leu Glu Glu Ala Gln Val Phe Trp Ala Lys Lys Glu
2290 2295 2300
Gln Ser Leu Ala Leu Ser Ile Leu Lys Gln Met Ile Lys Lys Leu Asp
2305 2310 2315 2320
Ala Ser Cys Ala Ala Asn Asn Pro Ser Leu Lys Leu Thr Tyr Thr Glu
2325 2330 2335
Cys Leu Arg Val Cys Gly Asn Trp Leu Ala Glu Thr Cys Leu Glu Asn
2340 2345 2350
Pro Ala Val Ile Met Gln Thr Tyr Leu Glu Lys Ala Val Glu Val Ala
2355 2360 2365
Gly Asn Tyr Asp Gly Glu Ser Ser Asp Glu Leu Arg Asn Gly Lys Met
2370 2375 2380
Lys Ala Phe Leu Ser Leu Ala Arg Phe Ser Asp Thr Gln Tyr Gln Arg
2385 2390 2395 2400
Ile Glu Asn Tyr Met Lys Ser Ser Glu Phe Glu Asn Lys Gln Ala Leu
2405 2410 2415
Leu Lys Arg Ala Lys Glu Glu Val Gly Leu Leu Arg Glu His Lys Ile
2420 2425 2430
Gln Thr Asn Arg Tyr Thr Val Lys Val Gln Arg Glu Leu Glu Leu Asp
2435 2440 2445
Glu Leu Ala Leu Arg Ala Leu Lys Glu Asp Arg Lys Arg Phe Leu Cys
2450 2455 2460
Lys Ala Val Glu Asn Tyr Ile Asn Cys Leu Leu Ser Gly Glu Glu His
2465 2470 2475 2480
Asp Met Trp Val Phe Arg Leu Cys Ser Leu Trp Leu Glu Asn Ser Gly
2485 2490 2495
Val Ser Glu Val Asn Gly Met Met Lys Arg Asp Gly Met Lys Ile Pro
2500 2505 2510
Thr Tyr Lys Phe Leu Pro Leu Met Tyr Gln Leu Ala Ala Arg Met Gly
2515 2520 2525
Thr Lys Met Met Gly Gly Leu Gly Phe His Glu Val Leu Asn Asn Leu
2530 2535 2540
Ile Ser Arg Ile Ser Met Asp His Pro His His Thr Leu Phe Ile Ile
2545 2550 2555 2560
Leu Ala Leu Ala Asn Ala Asn Arg Asp Glu Phe Leu Thr Lys Pro Glu
2565 2570 2575
Val Ala Arg Arg Ser Arg Ile Thr Lys Asn Val Pro Lys Gln Ser Ser
2580 2585 2590
Gln Leu Asp Glu Asp Arg Thr Glu Ala Ala Asn Arg Ile Ile Cys Thr
2595 2600 2605
Ile Arg Ser Arg Arg Pro Gln Met Val Arg Ser Val Glu Ala Leu Cys
2610 2615 2620
Asp Ala Tyr Ile Ile Leu Ala Asn Leu Asp Ala Thr Gln Trp Lys Thr
2625 2630 2635 2640
Gln Arg Lys Gly Ile Asn Ile Pro Ala Asp Gln Pro Ile Thr Lys Leu
2645 2650 2655
Lys Asn Leu Glu Asp Val Val Val Pro Thr Met Glu Ile Lys Val Asp
2660 2665 2670
His Thr Gly Glu Tyr Gly Asn Leu Val Thr Ile Gln Ser Phe Lys Ala
2675 2680 2685
Glu Phe Arg Leu Ala Gly Gly Val Asn Leu Pro Lys Ile Ile Asp Cys
2690 2695 2700
Val Gly Ser Asp Gly Lys Glu Arg Arg Gln Leu Val Lys Gly Arg Asp
2705 2710 2715 2720
Asp Leu Arg Gln Asp Ala Val Met Gln Gln Val Phe Gln Met Cys Asn
2725 2730 2735
Thr Leu Leu Gln Arg Asn Thr Glu Thr Arg Lys Arg Lys Leu Thr Ile
2740 2745 2750
Cys Thr Tyr Lys Val Val Pro Leu Ser Gln Arg Ser Gly Val Leu Glu
2755 2760 2765
Trp Cys Thr Gly Thr Val Pro Ile Gly Glu Phe Leu Val Asn Asn Glu
2770 2775 2780
Asp Gly Ala His Lys Arg Tyr Arg Pro Asn Asp Phe Ser Ala Phe Gln
2785 2790 2795 2800
Cys Gln Lys Lys Met Met Glu Val Gln Lys Lys Ser Phe Glu Glu Lys
2805 2810 2815
Tyr Glu Val Phe Met Asp Val Cys Gln Asn Phe Gln Pro Val Phe Arg
2820 2825 2830
Tyr Phe Cys Met Glu Lys Phe Leu Asp Pro Ala Ile Trp Phe Glu Lys
2835 2840 2845
Arg Leu Ala Tyr Thr Arg Ser Val Ala Thr Ser Ser Ile Val Gly Tyr
2850 2855 2860
Ile Leu Gly Leu Gly Asp Arg His Val Gln Asn Ile Leu Ile Asn Glu
2865 2870 2875 2880
Gln Ser Ala Glu Leu Val His Ile Asp Leu Gly Val Ala Phe Glu Gln
2885 2890 2895
Gly Lys Ile Leu Pro Thr Pro Glu Thr Val Pro Phe Arg Leu Thr Arg
2900 2905 2910
Asp Ile Val Asp Gly Met Gly Ile Thr Gly Val Glu Gly Val Phe Arg
2915 2920 2925
Arg Cys Cys Glu Lys Thr Met Glu Val Met Arg Asn Ser Gln Glu Thr
2930 2935 2940
Leu Leu Thr Ile Val Glu Val Leu Leu Tyr Asp Pro Leu Phe Asp Trp
2945 2950 2955 2960
Thr Met Asn Pro Leu Lys Ala Leu Tyr Leu Gln Gln Arg Pro Glu Asp
2965 2970 2975
Glu Thr Glu Leu His Pro Thr Leu Asn Ala Asp Asp Gln Glu Cys Lys
2980 2985 2990
Arg Asn Leu Ser Asp Ile Asp Gln Ser Phe Asp Lys Val Ala Glu Arg
2995 3000 3005
Val Leu Met Arg Leu Gln Glu Lys Leu Lys Gly Val Glu Glu Gly Thr
3010 3015 3020
Val Leu Ser Val Gly Gly Gln Val Asn Leu Leu Ile Gln Gln Ala Ile
3025 3030 3035 3040
Asp Pro Lys Asn Leu Ser Arg Leu Phe Pro Gly Trp Lys Ala Trp Val
3045 3050 3055
21
450
PRT
Homo sapiens
21
Met Ser Ala Ile Gln Ala Ala Trp Pro Ser Gly Thr Glu Cys Ile Ala
1 5 10 15
Lys Tyr Asn Phe His Gly Thr Ala Glu Gln Asp Leu Pro Phe Cys Lys
20 25 30
Gly Asp Val Leu Thr Ile Val Ala Val Thr Lys Asp Pro Asn Trp Tyr
35 40 45
Lys Ala Lys Asn Lys Val Gly Arg Glu Gly Ile Ile Pro Ala Asn Tyr
50 55 60
Val Gln Lys Arg Glu Gly Val Lys Ala Gly Thr Lys Leu Ser Leu Met
65 70 75 80
Pro Trp Phe His Gly Lys Ile Thr Arg Glu Gln Ala Glu Arg Leu Leu
85 90 95
Tyr Pro Pro Glu Thr Gly Leu Phe Leu Val Arg Glu Ser Thr Asn Tyr
100 105 110
Pro Gly Asp Tyr Thr Leu Cys Val Ser Cys Asp Gly Lys Val Glu His
115 120 125
Tyr Arg Ile Met Tyr His Ala Ser Lys Leu Ser Ile Asp Glu Glu Val
130 135 140
Tyr Phe Glu Asn Leu Met Gln Leu Val Glu His Tyr Thr Ser Asp Ala
145 150 155 160
Asp Gly Leu Cys Thr Arg Leu Ile Lys Pro Lys Val Met Glu Gly Thr
165 170 175
Val Ala Ala Gln Asp Glu Phe Tyr Arg Ser Gly Trp Ala Leu Asn Met
180 185 190
Lys Glu Leu Lys Leu Leu Gln Thr Ile Gly Lys Gly Glu Phe Gly Asp
195 200 205
Val Met Leu Gly Asp Tyr Arg Gly Asn Lys Val Ala Val Lys Cys Ile
210 215 220
Lys Asn Asp Ala Thr Ala Gln Ala Phe Leu Ala Glu Ala Ser Val Met
225 230 235 240
Thr Gln Leu Arg His Ser Asn Leu Val Gln Leu Leu Gly Val Ile Val
245 250 255
Glu Glu Lys Gly Gly Leu Tyr Ile Val Thr Glu Tyr Met Ala Lys Gly
260 265 270
Ser Leu Val Asp Tyr Leu Arg Ser Arg Gly Arg Ser Val Leu Gly Gly
275 280 285
Asp Cys Leu Leu Lys Phe Ser Leu Asp Val Cys Glu Ala Met Glu Tyr
290 295 300
Leu Glu Gly Asn Asn Phe Val His Arg Asp Leu Ala Ala Arg Asn Val
305 310 315 320
Leu Val Ser Glu Asp Asn Val Ala Lys Val Ser Asp Phe Gly Leu Thr
325 330 335
Lys Glu Ala Ser Ser Thr Gln Asp Thr Gly Lys Leu Pro Val Lys Trp
340 345 350
Thr Ala Pro Glu Ala Leu Arg Glu Lys Lys Phe Ser Thr Lys Ser Asp
355 360 365
Val Trp Ser Phe Gly Ile Leu Leu Trp Glu Ile Tyr Ser Phe Gly Arg
370 375 380
Val Pro Tyr Pro Arg Ile Pro Leu Lys Asp Val Val Pro Arg Val Glu
385 390 395 400
Lys Gly Tyr Lys Met Asp Ala Pro Asp Gly Cys Pro Pro Ala Val Tyr
405 410 415
Glu Val Met Lys Asn Cys Trp His Leu Asp Ala Ala Met Arg Pro Ser
420 425 430
Phe Leu Gln Leu Arg Glu Gln Leu Glu His Ile Lys Thr His Glu Leu
435 440 445
His Leu
450
22
1142
PRT
Homo sapiens
22
Met Ala Phe Cys Ala Lys Met Arg Ser Ser Lys Lys Thr Glu Val Asn
1 5 10 15
Leu Glu Ala Pro Glu Pro Gly Val Glu Val Ile Phe Tyr Leu Ser Asp
20 25 30
Arg Glu Pro Leu Arg Leu Gly Ser Gly Glu Tyr Thr Ala Glu Glu Leu
35 40 45
Cys Ile Arg Ala Ala Gln Ala Cys Arg Ile Ser Pro Leu Cys His Asn
50 55 60
Leu Phe Ala Leu Tyr Asp Glu Asn Thr Lys Leu Trp Tyr Ala Pro Asn
65 70 75 80
Arg Thr Ile Thr Val Asp Asp Lys Met Ser Leu Arg Leu His Tyr Arg
85 90 95
Met Arg Phe Tyr Phe Thr Asn Trp His Gly Thr Asn Asp Asn Glu Gln
100 105 110
Ser Val Trp Arg His Ser Pro Lys Lys Gln Lys Asn Gly Tyr Glu Lys
115 120 125
Lys Lys Ile Pro Asp Ala Thr Pro Leu Leu Asp Ala Ser Ser Leu Glu
130 135 140
Tyr Leu Phe Ala Gln Gly Gln Tyr Asp Leu Val Lys Cys Leu Ala Pro
145 150 155 160
Ile Arg Asp Pro Lys Thr Glu Gln Asp Gly His Asp Ile Glu Asn Glu
165 170 175
Cys Leu Gly Met Ala Val Leu Ala Ile Ser His Tyr Ala Met Met Lys
180 185 190
Lys Met Gln Leu Pro Glu Leu Pro Lys Asp Ile Ser Tyr Lys Arg Tyr
195 200 205
Ile Pro Glu Thr Leu Asn Lys Ser Ile Arg Gln Arg Asn Leu Leu Thr
210 215 220
Arg Met Arg Ile Asn Asn Val Phe Lys Asp Phe Leu Lys Glu Phe Asn
225 230 235 240
Asn Lys Thr Ile Cys Asp Ser Ser Val Ser Thr His Asp Leu Lys Val
245 250 255
Lys Tyr Leu Ala Thr Leu Glu Thr Leu Thr Lys His Tyr Gly Ala Glu
260 265 270
Ile Phe Glu Thr Ser Met Leu Leu Ile Ser Ser Glu Asn Glu Met Asn
275 280 285
Trp Phe His Ser Asn Asp Gly Gly Asn Val Leu Tyr Tyr Glu Val Met
290 295 300
Val Thr Gly Asn Leu Gly Ile Gln Trp Arg His Lys Pro Asn Val Val
305 310 315 320
Ser Val Glu Lys Glu Lys Asn Lys Leu Lys Arg Lys Lys Leu Glu Asn
325 330 335
Lys Asp Lys Lys Asp Glu Glu Lys Asn Lys Ile Arg Glu Glu Trp Asn
340 345 350
Asn Phe Ser Phe Phe Pro Glu Ile Thr His Ile Val Ile Lys Glu Ser
355 360 365
Val Val Ser Ile Asn Lys Gln Asp Asn Lys Lys Met Glu Leu Lys Leu
370 375 380
Ser Ser His Glu Glu Ala Leu Ser Phe Val Ser Leu Val Asp Gly Tyr
385 390 395 400
Phe Arg Leu Thr Ala Asp Ala His His Tyr Leu Cys Thr Asp Val Ala
405 410 415
Pro Pro Leu Ile Val His Asn Ile Gln Asn Gly Cys His Gly Pro Ile
420 425 430
Cys Thr Glu Tyr Ala Ile Asn Lys Leu Arg Gln Glu Gly Ser Glu Glu
435 440 445
Gly Met Tyr Val Leu Arg Trp Ser Cys Thr Asp Phe Asp Asn Ile Leu
450 455 460
Met Thr Val Thr Cys Phe Glu Lys Ser Glu Gln Val Gln Gly Ala Gln
465 470 475 480
Lys Gln Phe Lys Asn Phe Gln Ile Glu Val Gln Lys Gly Arg Tyr Ser
485 490 495
Leu His Gly Ser Asp Arg Ser Phe Pro Ser Leu Gly Asp Leu Met Ser
500 505 510
His Leu Lys Lys Gln Ile Leu Arg Thr Asp Asn Ile Ser Phe Met Leu
515 520 525
Lys Arg Cys Cys Gln Pro Lys Pro Arg Glu Ile Ser Asn Leu Leu Val
530 535 540
Ala Thr Lys Lys Ala Gln Glu Trp Gln Pro Val Tyr Pro Met Ser Gln
545 550 555 560
Leu Ser Phe Asp Arg Ile Leu Lys Lys Asp Leu Val Gln Gly Glu His
565 570 575
Leu Gly Arg Gly Thr Arg Thr His Ile Tyr Ser Gly Thr Leu Met Asp
580 585 590
Tyr Lys Asp Asp Glu Gly Thr Ser Glu Glu Lys Lys Ile Lys Val Ile
595 600 605
Leu Lys Val Leu Asp Pro Ser His Arg Asp Ile Ser Leu Ala Phe Phe
610 615 620
Glu Ala Ala Ser Met Met Arg Gln Val Ser His Lys His Ile Val Tyr
625 630 635 640
Leu Tyr Gly Val Cys Val Arg Asp Val Glu Asn Ile Met Val Glu Glu
645 650 655
Phe Val Glu Gly Gly Pro Leu Asp Leu Phe Met His Arg Lys Ser Asp
660 665 670
Val Leu Thr Thr Pro Trp Lys Phe Lys Val Ala Lys Gln Leu Ala Ser
675 680 685
Ala Leu Ser Tyr Leu Glu Asp Lys Asp Leu Val His Gly Asn Val Cys
690 695 700
Thr Lys Asn Leu Leu Leu Ala Arg Glu Gly Ile Asp Ser Glu Cys Gly
705 710 715 720
Pro Phe Ile Lys Leu Ser Asp Pro Gly Ile Pro Ile Thr Val Leu Ser
725 730 735
Arg Gln Glu Cys Ile Glu Arg Ile Pro Trp Ile Ala Pro Glu Cys Val
740 745 750
Glu Asp Ser Lys Asn Leu Ser Val Ala Ala Asp Lys Trp Ser Phe Gly
755 760 765
Thr Thr Leu Trp Glu Ile Cys Tyr Asn Gly Glu Ile Pro Leu Lys Asp
770 775 780
Lys Thr Leu Ile Glu Lys Glu Arg Phe Tyr Glu Ser Arg Cys Arg Pro
785 790 795 800
Val Thr Pro Ser Cys Lys Glu Leu Ala Asp Leu Met Thr Arg Cys Met
805 810 815
Asn Tyr Asp Pro Asn Gln Arg Pro Phe Phe Arg Ala Ile Met Arg Asp
820 825 830
Ile Asn Lys Leu Glu Glu Gln Asn Pro Asp Ile Val Ser Arg Lys Lys
835 840 845
Asn Gln Pro Thr Glu Val Asp Pro Thr His Phe Glu Lys Arg Phe Leu
850 855 860
Lys Arg Ile Arg Asp Leu Gly Glu Gly His Phe Gly Lys Val Glu Leu
865 870 875 880
Cys Arg Tyr Asp Pro Glu Asp Asn Thr Gly Glu Gln Val Ala Val Lys
885 890 895
Ser Leu Lys Pro Glu Ser Gly Gly Asn His Ile Ala Asp Leu Lys Lys
900 905 910
Glu Ile Glu Ile Leu Arg Asn Leu Tyr His Glu Asn Ile Val Lys Tyr
915 920 925
Lys Gly Ile Cys Thr Glu Asp Gly Gly Asn Gly Ile Lys Leu Ile Met
930 935 940
Glu Phe Leu Pro Ser Gly Ser Leu Lys Glu Tyr Leu Pro Lys Asn Lys
945 950 955 960
Asn Lys Ile Asn Leu Lys Gln Gln Leu Lys Tyr Ala Val Gln Ile Cys
965 970 975
Lys Gly Met Asp Tyr Leu Gly Ser Arg Gln Tyr Val His Arg Asp Leu
980 985 990
Ala Ala Arg Asn Val Leu Val Glu Ser Glu His Gln Val Lys Ile Gly
995 1000 1005
Asp Phe Gly Leu Thr Lys Ala Ile Glu Thr Asp Lys Glu Tyr Tyr Thr
1010 1015 1020
Val Lys Asp Asp Arg Asp Ser Pro Val Phe Trp Tyr Ala Pro Glu Cys
1025 1030 1035 1040
Leu Met Gln Ser Lys Phe Tyr Ile Ala Ser Asp Val Trp Ser Phe Gly
1045 1050 1055
Val Thr Leu His Glu Leu Leu Thr Tyr Cys Asp Ser Asp Ser Ser Pro
1060 1065 1070
Met Ala Leu Phe Leu Lys Met Ile Gly Pro Thr His Gly Gln Met Thr
1075 1080 1085
Val Thr Arg Leu Val Asn Thr Leu Lys Glu Gly Lys Arg Leu Pro Cys
1090 1095 1100
Pro Pro Asn Cys Pro Asp Glu Val Tyr Gln Leu Met Arg Lys Cys Trp
1105 1110 1115 1120
Glu Phe Gln Pro Ser Asn Arg Thr Ser Phe Gln Asn Leu Ile Glu Gly
1125 1130 1135
Phe Glu Ala Leu Leu Lys
1140
23
1338
PRT
Homo sapiens
23
Met Val Ser Tyr Trp Asp Thr Gly Val Leu Leu Cys Ala Leu Leu Ser
1 5 10 15
Cys Leu Leu Leu Thr Gly Ser Ser Ser Gly Ser Lys Leu Lys Asp Pro
20 25 30
Glu Leu Ser Leu Lys Gly Thr Gln His Ile Met Gln Ala Gly Gln Thr
35 40 45
Leu His Leu Gln Cys Arg Gly Glu Ala Ala His Lys Trp Ser Leu Pro
50 55 60
Glu Met Val Ser Lys Glu Ser Glu Arg Leu Ser Ile Thr Lys Ser Ala
65 70 75 80
Cys Gly Arg Asn Gly Lys Gln Phe Cys Ser Thr Leu Thr Leu Asn Thr
85 90 95
Ala Gln Ala Asn His Thr Gly Phe Tyr Ser Cys Lys Tyr Leu Ala Val
100 105 110
Pro Thr Ser Lys Lys Lys Glu Thr Glu Ser Ala Ile Tyr Ile Phe Ile
115 120 125
Ser Asp Thr Gly Arg Pro Phe Val Glu Met Tyr Ser Glu Ile Pro Glu
130 135 140
Ile Ile His Met Thr Glu Gly Arg Glu Leu Val Ile Pro Cys Arg Val
145 150 155 160
Thr Ser Pro Asn Ile Thr Val Thr Leu Lys Lys Phe Pro Leu Asp Thr
165 170 175
Leu Ile Pro Asp Gly Lys Arg Ile Ile Trp Asp Ser Arg Lys Gly Phe
180 185 190
Ile Ile Ser Asn Ala Thr Tyr Lys Glu Ile Gly Leu Leu Thr Cys Glu
195 200 205
Ala Thr Val Asn Gly His Leu Tyr Lys Thr Asn Tyr Leu Thr His Arg
210 215 220
Gln Thr Asn Thr Ile Ile Asp Val Gln Ile Ser Thr Pro Arg Pro Val
225 230 235 240
Lys Leu Leu Arg Gly His Thr Leu Val Leu Asn Cys Thr Ala Thr Thr
245 250 255
Pro Leu Asn Thr Arg Val Gln Met Thr Trp Ser Tyr Pro Asp Glu Lys
260 265 270
Asn Lys Arg Ala Ser Val Arg Arg Arg Ile Asp Gln Ser Asn Ser His
275 280 285
Ala Asn Ile Phe Tyr Ser Val Leu Thr Ile Asp Lys Met Gln Asn Lys
290 295 300
Asp Lys Gly Leu Tyr Thr Cys Arg Val Arg Ser Gly Pro Ser Phe Lys
305 310 315 320
Ser Val Asn Thr Ser Val His Ile Tyr Asp Lys Ala Phe Ile Thr Val
325 330 335
Lys His Arg Lys Gln Gln Val Leu Glu Thr Val Ala Gly Lys Arg Ser
340 345 350
Tyr Arg Leu Ser Met Lys Val Lys Ala Phe Pro Ser Pro Glu Val Val
355 360 365
Trp Leu Lys Asp Gly Leu Pro Ala Thr Glu Lys Ser Ala Arg Tyr Leu
370 375 380
Thr Arg Gly Tyr Ser Leu Ile Ile Lys Asp Val Thr Glu Glu Asp Ala
385 390 395 400
Gly Asn Tyr Thr Ile Leu Leu Ser Ile Lys Gln Ser Asn Val Phe Lys
405 410 415
Asn Leu Thr Ala Thr Leu Ile Val Asn Val Lys Pro Gln Ile Tyr Glu
420 425 430
Lys Ala Val Ser Ser Phe Pro Asp Pro Ala Leu Tyr Pro Leu Gly Ser
435 440 445
Arg Gln Ile Leu Thr Cys Thr Ala Tyr Gly Ile Pro Gln Pro Thr Ile
450 455 460
Lys Trp Phe Trp His Pro Cys Asn His Asn His Ser Glu Ala Arg Cys
465 470 475 480
Asp Phe Cys Ser Asn Asn Glu Glu Ser Phe Ile Leu Asp Ala Asp Ser
485 490 495
Asn Met Gly Asn Arg Ile Glu Ser Ile Thr Gln Arg Met Ala Ile Ile
500 505 510
Glu Gly Lys Asn Lys Met Ala Ser Thr Leu Val Val Ala Asp Ser Arg
515 520 525
Ile Ser Gly Ile Tyr Ile Cys Ile Ala Ser Asn Lys Val Gly Thr Val
530 535 540
Gly Arg Asn Ile Ser Phe Tyr Ile Thr Asp Val Pro Asn Gly Phe His
545 550 555 560
Val Asn Leu Glu Lys Met Pro Thr Glu Gly Glu Asp Leu Lys Leu Ser
565 570 575
Cys Thr Val Asn Lys Phe Leu Tyr Arg Asp Val Thr Trp Ile Leu Leu
580 585 590
Arg Thr Val Asn Asn Arg Thr Met His Tyr Ser Ile Ser Lys Gln Lys
595 600 605
Met Ala Ile Thr Lys Glu His Ser Ile Thr Leu Asn Leu Thr Ile Met
610 615 620
Asn Val Ser Leu Gln Asp Ser Gly Thr Tyr Ala Cys Arg Ala Arg Asn
625 630 635 640
Val Tyr Thr Gly Glu Glu Ile Leu Gln Lys Lys Glu Ile Thr Ile Arg
645 650 655
Asp Gln Glu Ala Pro Tyr Leu Leu Arg Asn Leu Ser Asp His Thr Val
660 665 670
Ala Ile Ser Ser Ser Thr Thr Leu Asp Cys His Ala Asn Gly Val Pro
675 680 685
Glu Pro Gln Ile Thr Trp Phe Lys Asn Asn His Lys Ile Gln Gln Glu
690 695 700
Pro Gly Ile Ile Leu Gly Pro Gly Ser Ser Thr Leu Phe Ile Glu Arg
705 710 715 720
Val Thr Glu Glu Asp Glu Gly Val Tyr His Cys Lys Ala Thr Asn Gln
725 730 735
Lys Gly Ser Val Glu Ser Ser Ala Tyr Leu Thr Val Gln Gly Thr Ser
740 745 750
Asp Lys Ser Asn Leu Glu Leu Ile Thr Leu Thr Cys Thr Cys Val Ala
755 760 765
Ala Thr Leu Phe Trp Leu Leu Leu Thr Leu Leu Ile Arg Lys Met Lys
770 775 780
Arg Ser Ser Ser Glu Ile Lys Thr Asp Tyr Leu Ser Ile Ile Met Asp
785 790 795 800
Pro Asp Glu Val Pro Leu Asp Glu Gln Cys Glu Arg Leu Pro Tyr Asp
805 810 815
Ala Ser Lys Trp Glu Phe Ala Arg Glu Arg Leu Lys Leu Gly Lys Ser
820 825 830
Leu Gly Arg Gly Ala Phe Gly Lys Val Val Gln Ala Ser Ala Phe Gly
835 840 845
Ile Lys Lys Ser Pro Thr Cys Arg Thr Val Ala Val Lys Met Leu Lys
850 855 860
Glu Gly Ala Thr Ala Ser Glu Tyr Lys Ala Leu Met Thr Glu Leu Lys
865 870 875 880
Ile Leu Thr His Ile Gly His His Leu Asn Val Val Asn Leu Leu Gly
885 890 895
Ala Cys Thr Lys Gln Gly Gly Pro Leu Met Val Ile Val Glu Tyr Cys
900 905 910
Lys Tyr Gly Asn Leu Ser Asn Tyr Leu Lys Ser Lys Arg Asp Leu Phe
915 920 925
Phe Leu Asn Lys Asp Ala Ala Leu His Met Glu Pro Lys Lys Glu Lys
930 935 940
Met Glu Pro Gly Leu Glu Gln Gly Lys Lys Pro Arg Leu Asp Ser Val
945 950 955 960
Thr Ser Ser Glu Ser Phe Ala Ser Ser Gly Phe Gln Glu Asp Lys Ser
965 970 975
Leu Ser Asp Val Glu Glu Glu Glu Asp Ser Asp Gly Phe Tyr Lys Glu
980 985 990
Pro Ile Thr Met Glu Asp Leu Ile Ser Tyr Ser Phe Gln Val Ala Arg
995 1000 1005
Gly Met Glu Phe Leu Ser Ser Arg Lys Cys Ile His Arg Asp Leu Ala
1010 1015 1020
Ala Arg Asn Ile Leu Leu Ser Glu Asn Asn Val Val Lys Ile Cys Asp
1025 1030 1035 1040
Phe Gly Leu Ala Arg Asp Ile Tyr Lys Asn Pro Asp Tyr Val Arg Lys
1045 1050 1055
Gly Asp Thr Arg Leu Pro Leu Lys Trp Met Ala Pro Glu Ser Ile Phe
1060 1065 1070
Asp Lys Ile Tyr Ser Thr Lys Ser Asp Val Trp Ser Tyr Gly Val Leu
1075 1080 1085
Leu Trp Glu Ile Phe Ser Leu Gly Gly Ser Pro Tyr Pro Gly Val Gln
1090 1095 1100
Met Asp Glu Asp Phe Cys Ser Arg Leu Arg Glu Gly Met Arg Met Arg
1105 1110 1115 1120
Ala Pro Glu Tyr Ser Thr Pro Glu Ile Tyr Gln Ile Met Leu Asp Cys
1125 1130 1135
Trp His Arg Asp Pro Lys Glu Arg Pro Arg Phe Ala Glu Leu Val Glu
1140 1145 1150
Lys Leu Gly Asp Leu Leu Gln Ala Asn Val Gln Gln Asp Gly Lys Asp
1155 1160 1165
Tyr Ile Pro Ile Asn Ala Ile Leu Thr Gly Asn Ser Gly Phe Thr Tyr
1170 1175 1180
Ser Thr Pro Ala Phe Ser Glu Asp Phe Phe Lys Glu Ser Ile Ser Ala
1185 1190 1195 1200
Pro Lys Phe Asn Ser Gly Ser Ser Asp Asp Val Arg Tyr Val Asn Ala
1205 1210 1215
Phe Lys Phe Met Ser Leu Glu Arg Ile Lys Thr Phe Glu Glu Leu Leu
1220 1225 1230
Pro Asn Ala Thr Ser Met Phe Asp Asp Tyr Gln Gly Asp Ser Ser Thr
1235 1240 1245
Leu Leu Ala Ser Pro Met Leu Lys Arg Phe Thr Trp Thr Asp Ser Lys
1250 1255 1260
Pro Lys Ala Ser Leu Lys Ile Asp Leu Arg Val Thr Ser Lys Ser Lys
1265 1270 1275 1280
Glu Ser Gly Leu Ser Asp Val Ser Arg Pro Ser Phe Cys His Ser Ser
1285 1290 1295
Cys Gly His Val Ser Glu Gly Lys Arg Arg Phe Thr Tyr Asp His Ala
1300 1305 1310
Glu Leu Glu Arg Lys Ile Ala Cys Cys Ser Pro Pro Pro Asp Tyr Asn
1315 1320 1325
Ser Val Val Leu Tyr Ser Thr Pro Pro Ile
1330 1335
24
309
PRT
Homo sapiens
24
Met Asp Glu Lys Val Phe Thr Lys Glu Leu Asp Gln Trp Ile Glu Gln
1 5 10 15
Leu Asn Glu Cys Lys Gln Leu Ser Glu Ser Gln Val Lys Ser Leu Cys
20 25 30
Glu Lys Ala Lys Glu Ile Leu Thr Lys Glu Ser Asn Val Gln Glu Val
35 40 45
Arg Cys Pro Val Thr Val Cys Gly Asp Val His Gly Gln Phe His Asp
50 55 60
Leu Met Glu Leu Phe Arg Ile Gly Gly Lys Ser Pro Asp Thr Asn Tyr
65 70 75 80
Leu Phe Met Gly Asp Tyr Val Asp Arg Gly Tyr Tyr Ser Val Glu Thr
85 90 95
Val Thr Leu Leu Val Ala Leu Lys Val Arg Tyr Arg Glu Arg Ile Thr
100 105 110
Ile Leu Arg Gly Asn His Glu Ser Arg Gln Ile Thr Gln Val Tyr Gly
115 120 125
Phe Tyr Asp Glu Cys Leu Arg Lys Tyr Gly Asn Ala Asn Val Trp Lys
130 135 140
Tyr Phe Thr Asp Leu Phe Asp Tyr Leu Pro Leu Thr Ala Leu Val Asp
145 150 155 160
Gly Gln Ile Phe Cys Leu His Gly Gly Leu Ser Pro Ser Ile Asp Thr
165 170 175
Leu Asp His Ile Arg Ala Leu Asp Arg Leu Gln Glu Val Pro His Glu
180 185 190
Gly Pro Met Cys Asp Leu Leu Trp Ser Asp Pro Asp Asp Arg Gly Gly
195 200 205
Trp Gly Ile Ser Pro Arg Gly Ala Gly Tyr Thr Phe Gly Gln Asp Ile
210 215 220
Ser Glu Thr Phe Asn His Ala Asn Gly Leu Thr Leu Val Ser Arg Ala
225 230 235 240
His Gln Leu Val Met Glu Gly Tyr Asn Trp Cys His Asp Arg Asn Val
245 250 255
Val Thr Ile Phe Ser Ala Pro Asn Tyr Cys Tyr Arg Cys Gly Asn Gln
260 265 270
Ala Ala Ile Met Glu Leu Asp Asp Thr Leu Lys Tyr Ser Phe Leu Gln
275 280 285
Phe Asp Pro Ala Pro Arg Arg Gly Glu Pro His Val Thr Arg Arg Thr
290 295 300
Pro Asp Tyr Phe Leu
305
25
394
PRT
Homo sapiens
25
Met Val Thr Met Glu Glu Leu Arg Glu Met Asp Cys Ser Val Leu Lys
1 5 10 15
Arg Leu Met Asn Arg Asp Glu Asn Gly Gly Gly Ala Gly Gly Ser Gly
20 25 30
Ser His Gly Thr Leu Gly Leu Pro Ser Gly Gly Lys Cys Leu Leu Leu
35 40 45
Asp Cys Arg Pro Phe Leu Ala His Ser Ala Gly Tyr Ile Leu Gly Ser
50 55 60
Val Asn Val Arg Cys Asn Thr Ile Val Arg Arg Arg Ala Lys Gly Ser
65 70 75 80
Val Ser Leu Glu Gln Ile Leu Pro Ala Glu Glu Glu Val Arg Ala Arg
85 90 95
Leu Arg Ser Gly Leu Tyr Ser Ala Val Ile Val Tyr Asp Glu Gly Ser
100 105 110
Pro Arg Ala Glu Ser Leu Arg Glu Asp Ser Thr Val Ser Leu Val Val
115 120 125
Gln Ala Leu Arg Arg Asn Ala Glu Arg Thr Asp Ile Cys Leu Leu Lys
130 135 140
Gly Gly Tyr Glu Arg Phe Ser Ser Glu Tyr Pro Glu Phe Cys Ser Lys
145 150 155 160
Thr Lys Ala Leu Ala Ala Ile Pro Pro Pro Val Pro Pro Ser Ala Thr
165 170 175
Glu Pro Leu Asp Leu Gly Cys Ser Ser Cys Gly Thr Pro Leu His Asp
180 185 190
Gln Gly Gly Pro Val Glu Ile Leu Pro Phe Leu Tyr Leu Gly Ser Ala
195 200 205
Tyr His Ala Ala Arg Arg Asp Met Leu Asp Ala Leu Gly Ile Thr Ala
210 215 220
Leu Leu Asn Val Ser Ser Asp Cys Pro Asn His Phe Glu Gly His Tyr
225 230 235 240
Gln Tyr Lys Cys Ile Pro Val Glu Asp Asn His Lys Ala Asp Ile Ser
245 250 255
Ser Trp Phe Met Glu Ala Ile Glu Tyr Ile Asp Ala Val Lys Asp Cys
260 265 270
Arg Gly Arg Val Leu Val His Cys Gln Ala Gly Ile Ser Arg Ser Ala
275 280 285
Thr Ile Cys Leu Ala Tyr Leu Met Met Lys Lys Arg Val Arg Leu Glu
290 295 300
Glu Ala Phe Glu Phe Val Lys Gln Arg Arg Ser Ile Ile Ser Pro Asn
305 310 315 320
Phe Ser Phe Met Gly Gln Leu Leu Gln Phe Glu Ser Gln Val Leu Ala
325 330 335
Thr Ser Cys Ala Ala Glu Ala Ala Ser Pro Ser Gly Pro Leu Arg Glu
340 345 350
Arg Gly Lys Thr Pro Ala Thr Pro Thr Ser Gln Phe Val Phe Ser Phe
355 360 365
Pro Val Ser Val Gly Val His Ser Ala Pro Ser Ser Leu Pro Tyr Leu
370 375 380
His Ser Pro Ile Thr Thr Ser Pro Ser Cys
385 390
26
185
PRT
Homo sapiens
26
Met Ser Gly Ser Phe Glu Leu Ser Val Gln Asp Leu Asn Asp Leu Leu
1 5 10 15
Ser Asp Gly Ser Gly Cys Tyr Ser Leu Pro Ser Gln Pro Cys Asn Glu
20 25 30
Val Thr Pro Arg Ile Tyr Val Gly Asn Ala Ser Val Ala Gln Asp Ile
35 40 45
Pro Lys Leu Gln Lys Leu Gly Ile Thr His Val Leu Asn Ala Ala Glu
50 55 60
Gly Arg Ser Phe Met His Val Asn Thr Asn Ala Asn Phe Tyr Lys Asp
65 70 75 80
Ser Gly Ile Thr Tyr Leu Gly Ile Lys Ala Asn Asp Thr Gln Glu Phe
85 90 95
Asn Leu Ser Ala Tyr Phe Glu Arg Ala Ala Asp Phe Ile Asp Gln Ala
100 105 110
Leu Ala Gln Lys Asn Gly Arg Val Leu Val His Cys Arg Glu Gly Tyr
115 120 125
Ser Arg Ser Pro Thr Leu Val Ile Ala Tyr Leu Met Met Arg Gln Lys
130 135 140
Met Asp Val Lys Ser Ala Leu Ser Ile Val Arg Gln Asn Arg Glu Ile
145 150 155 160
Gly Pro Asn Asp Gly Phe Leu Ala Gln Leu Cys Gln Leu Asn Asp Arg
165 170 175
Leu Ala Lys Glu Gly Lys Leu Lys Pro
180 185
27
657
PRT
Homo sapiens
27
Met Arg Arg Ala Val Cys Phe Pro Ala Leu Cys Leu Leu Leu Asn Leu
1 5 10 15
His Ala Ala Gly Cys Phe Ser Gly Asn Asn Asp His Phe Leu Ala Ile
20 25 30
Asn Gln Lys Lys Ser Gly Lys Pro Val Phe Ile Tyr Lys His Ser Gln
35 40 45
Asp Ile Glu Lys Ser Leu Asp Ile Ala Pro Gln Lys Ile Tyr Arg His
50 55 60
Ser Tyr His Ser Ser Ser Glu Ala Gln Val Ser Lys Arg His Gln Ile
65 70 75 80
Val Asn Ser Ala Phe Pro Arg Pro Ala Tyr Asp Pro Ser Leu Asn Leu
85 90 95
Leu Ala Met Asp Gly Gln Asp Leu Glu Val Glu Asn Leu Pro Ile Pro
100 105 110
Ala Ala Asn Val Ile Val Val Thr Leu Gln Met Asp Val Asn Lys Leu
115 120 125
Asn Ile Thr Leu Leu Arg Ile Phe Arg Gln Gly Val Ala Ala Ala Leu
130 135 140
Gly Leu Leu Pro Gln Gln Val His Ile Asn Arg Leu Ile Gly Lys Lys
145 150 155 160
Asn Ser Ile Glu Leu Phe Val Ser Pro Ile Asn Arg Lys Thr Gly Ile
165 170 175
Ser Asp Ala Leu Pro Ser Glu Glu Val Leu Arg Ser Leu Asn Ile Asn
180 185 190
Val Leu His Gln Ser Leu Ser Gln Phe Gly Ile Thr Glu Val Ser Pro
195 200 205
Glu Lys Asn Val Leu Gln Gly Gln His Glu Ala Asp Lys Ile Trp Ser
210 215 220
Lys Glu Gly Phe Tyr Ala Val Val Ile Phe Leu Ser Ile Phe Val Ile
225 230 235 240
Ile Val Thr Cys Leu Met Ile Leu Tyr Arg Leu Lys Glu Arg Phe Gln
245 250 255
Leu Ser Leu Arg Gln Asp Lys Glu Lys Asn Gln Glu Ile His Leu Ser
260 265 270
Pro Ile Thr Leu Gln Pro Ala Leu Ser Glu Ala Lys Thr Val His Ser
275 280 285
Met Val Gln Pro Glu Gln Ala Pro Lys Val Leu Asn Val Val Val Asp
290 295 300
Pro Gln Gly Arg Gly Ala Pro Glu Ile Arg Ala Thr Thr Ala Thr Ser
305 310 315 320
Val Cys Pro Ser Pro Phe Lys Met Lys Pro Ile Gly Leu Gln Glu Arg
325 330 335
Arg Gly Ser Asn Val Ser Leu Thr Leu Asp Met Ser Ser Leu Gly Asn
340 345 350
Ile Glu Pro Phe Val Ser Ile Pro Thr Pro Arg Glu Lys Val Ala Met
355 360 365
Glu Tyr Leu Gln Ser Ala Ser Arg Ile Leu Thr Arg Ser Gln Leu Arg
370 375 380
Asp Val Val Ala Ser Ser His Leu Leu Gln Ser Glu Phe Met Glu Ile
385 390 395 400
Pro Met Asn Phe Val Asp Pro Lys Glu Ile Asp Ile Pro Arg His Gly
405 410 415
Thr Lys Asn Arg Tyr Lys Thr Ile Leu Pro Asn Pro Leu Ser Arg Val
420 425 430
Cys Leu Arg Pro Lys Asn Val Thr Asp Ser Leu Ser Thr Tyr Ile Asn
435 440 445
Ala Asn Tyr Ile Arg Gly Tyr Ser Gly Lys Glu Lys Ala Phe Ile Ala
450 455 460
Thr Gln Gly Pro Met Ile Asn Thr Val Asp Asp Phe Trp Gln Met Val
465 470 475 480
Trp Gln Glu Asp Ser Pro Val Ile Val Met Ile Thr Lys Leu Lys Glu
485 490 495
Lys Asn Glu Lys Cys Val Leu Tyr Trp Pro Glu Lys Arg Gly Ile Tyr
500 505 510
Gly Lys Val Glu Val Leu Val Ile Ser Val Asn Glu Cys Asp Asn Tyr
515 520 525
Thr Ile Arg Asn Leu Val Leu Lys Gln Gly Ser His Thr Gln His Val
530 535 540
Lys His Tyr Trp Tyr Thr Ser Trp Pro Asp His Lys Thr Pro Asp Ser
545 550 555 560
Ala Gln Pro Leu Leu Gln Leu Met Leu Asp Val Glu Glu Asp Arg Leu
565 570 575
Ala Ser Gln Gly Arg Gly Pro Val Val Val His Cys Ser Ala Gly Ile
580 585 590
Gly Arg Thr Gly Cys Phe Ile Ala Thr Ser Ile Gly Cys Gln Gln Leu
595 600 605
Lys Glu Glu Gly Val Val Asp Ala Leu Ser Ile Val Cys Gln Leu Arg
610 615 620
Met Asp Arg Gly Gly Met Val Gln Thr Ser Glu Gln Tyr Glu Phe Val
625 630 635 640
His His Ala Leu Cys Leu Tyr Glu Ser Arg Leu Ser Ala Glu Thr Val
645 650 655
Gln
28
537
PRT
Homo sapiens
28
Glu Arg Leu Leu Gly Arg Pro Gln Pro Ile Val Met Glu Ala Leu Asp
1 5 10 15
Glu Ala Glu Gly Leu Gln Asp Ser Gln Arg Glu Met Pro Pro Pro Pro
20 25 30
Pro Pro Ser Pro Pro Ser Asp Pro Ala Gln Lys Pro Pro Pro Arg Gly
35 40 45
Ala Gly Ser His Ser Leu Thr Val Arg Ser Ser Leu Cys Leu Phe Ala
50 55 60
Ala Ser Gln Phe Leu Leu Ala Cys Gly Val Leu Trp Phe Ser Gly Tyr
65 70 75 80
Gly His Met Trp Ser Gln Asn Ala Thr Asn Leu Val Ser Ser Leu Leu
85 90 95
Thr Leu Leu Lys Gln Leu Glu Pro Thr Ser Trp Leu Asp Ser Gly Thr
100 105 110
Trp Gly Val Pro Gly Leu Leu Leu Val Phe Leu Ser Val Gly Leu Val
115 120 125
Leu Val Thr Thr Leu Val Trp His Leu Leu Arg Thr Pro Pro Glu Pro
130 135 140
Pro Thr Pro Leu Pro Pro Glu Asp Arg Arg Gln Ser Val Ser Arg Gln
145 150 155 160
Pro Ser Phe Thr Tyr Ser Glu Trp Met Glu Glu Lys Ile Glu Asp Asp
165 170 175
Phe Leu Asp Leu Asp Pro Val Pro Glu Thr Pro Val Phe Asp Cys Val
180 185 190
Met Asp Ile Lys Pro Glu Ala Asp Pro Thr Ser Leu Thr Val Lys Ser
195 200 205
Met Gly Leu Gln Glu Arg Arg Gly Ser Asn Val Ser Leu Thr Leu Asp
210 215 220
Met Cys Thr Pro Gly Cys Asn Glu Glu Gly Phe Gly Tyr Leu Met Ser
225 230 235 240
Pro Arg Glu Glu Ser Ala Arg Glu Tyr Leu Leu Ser Ala Ser Arg Val
245 250 255
Leu Gln Ala Glu Glu Leu His Glu Lys Ala Leu Asp Pro Phe Leu Leu
260 265 270
Gln Ala Glu Phe Phe Glu Ile Pro Met Asn Phe Val Val Pro Lys Glu
275 280 285
Tyr Asp Ile Pro Gly Arg Cys Arg Lys Asn Arg Tyr Lys Thr Ile Leu
290 295 300
Pro Asn Pro His Ser Arg Val Cys Leu Thr Ser Pro Asp Pro Asp Asp
305 310 315 320
Pro Leu Ser Ser Tyr Ile Asn Ala Asn Tyr Ile Arg Gly Tyr Gly Gly
325 330 335
Glu Glu Lys Val Tyr Ile Ala Thr Gln Gly Pro Ile Val Ser Thr Val
340 345 350
Ala Asp Phe Trp Arg Met Val Trp Gln Glu His Thr Pro Ile Ile Val
355 360 365
Met Ile Thr Asn Ile Glu Glu Met Asn Glu Lys Cys Thr Glu Tyr Trp
370 375 380
Pro Glu Glu Gln Val Ala Tyr Asp Gly Val Glu Ile Thr Val Gln Lys
385 390 395 400
Val Ile His Thr Glu Asp Tyr Arg Leu Arg Leu Ile Ser Leu Lys Ser
405 410 415
Gly Thr Glu Glu Arg Gly Leu Lys His Tyr Trp Phe Thr Ser Trp Pro
420 425 430
Asp Gln Lys Thr Pro Asp Arg Ala Pro Pro Leu Leu His Leu Val Arg
435 440 445
Glu Val Glu Glu Ala Ala Gln Gln Glu Gly Pro His Cys Ala Pro Ile
450 455 460
Ile Val His Cys Ser Ala Gly Ile Gly Arg Thr Gly Cys Phe Ile Ala
465 470 475 480
Thr Ser Ile Cys Cys Gln Gln Leu Arg Gln Glu Gly Val Val Asp Ile
485 490 495
Leu Lys Thr Thr Cys Gln Leu Arg Gln Asp Arg Gly Gly Met Ile Gln
500 505 510
His Cys Glu Gln Tyr Gln Phe Val His His Val Met Ser Leu Tyr Glu
515 520 525
Lys Gln Leu Ser His Gln Ser Pro Glu
530 535
29
403
PRT
Homo sapiens
29
Met Thr Ala Ile Ile Lys Glu Ile Val Ser Arg Asn Lys Arg Arg Tyr
1 5 10 15
Gln Glu Asp Gly Phe Asp Leu Asp Leu Thr Tyr Ile Tyr Pro Asn Ile
20 25 30
Ile Ala Met Gly Phe Pro Ala Glu Arg Leu Glu Gly Val Tyr Arg Asn
35 40 45
Asn Ile Asp Asp Val Val Arg Phe Leu Asp Ser Lys His Lys Asn His
50 55 60
Tyr Lys Ile Tyr Asn Leu Cys Ala Glu Arg His Tyr Asp Thr Ala Lys
65 70 75 80
Phe Asn Cys Arg Val Ala Gln Tyr Pro Phe Glu Asp His Asn Pro Pro
85 90 95
Gln Leu Glu Leu Ile Lys Pro Phe Cys Glu Asp Leu Asp Gln Trp Leu
100 105 110
Ser Glu Asp Asp Asn His Val Ala Ala Ile His Cys Lys Ala Gly Lys
115 120 125
Gly Arg Thr Gly Val Met Ile Cys Ala Tyr Leu Leu His Arg Gly Lys
130 135 140
Phe Leu Lys Ala Gln Glu Ala Leu Asp Phe Tyr Gly Glu Val Arg Thr
145 150 155 160
Arg Asp Lys Lys Gly Val Thr Ile Pro Ser Gln Arg Arg Tyr Val Tyr
165 170 175
Tyr Tyr Ser Tyr Leu Leu Lys Asn His Leu Asp Tyr Arg Pro Val Ala
180 185 190
Leu Leu Phe His Lys Met Met Phe Glu Thr Ile Pro Met Phe Ser Gly
195 200 205
Gly Thr Cys Asn Pro Gln Phe Val Val Cys Gln Leu Lys Val Lys Ile
210 215 220
Tyr Ser Ser Asn Ser Gly Pro Thr Arg Arg Glu Asp Lys Phe Met Tyr
225 230 235 240
Phe Glu Phe Pro Gln Pro Leu Pro Val Cys Gly Asp Ile Lys Val Glu
245 250 255
Phe Phe His Lys Gln Asn Lys Met Leu Lys Lys Asp Lys Met Phe His
260 265 270
Phe Trp Val Asn Thr Phe Phe Ile Pro Gly Pro Glu Glu Thr Ser Glu
275 280 285
Lys Val Glu Asn Gly Ser Leu Cys Asp Gln Glu Ile Asp Ser Ile Cys
290 295 300
Ser Ile Glu Arg Ala Asp Asn Asp Lys Glu Tyr Leu Val Leu Thr Leu
305 310 315 320
Thr Lys Asn Asp Leu Asp Lys Ala Asn Lys Asp Lys Ala Asn Arg Tyr
325 330 335
Phe Ser Pro Asn Phe Lys Val Lys Leu Tyr Phe Thr Lys Thr Val Glu
340 345 350
Glu Pro Ser Asn Pro Glu Ala Ser Ser Ser Thr Ser Val Thr Pro Asp
355 360 365
Val Ser Asp Asn Glu Pro Asp His Tyr Arg Tyr Ser Asp Thr Thr Asp
370 375 380
Ser Asp Pro Glu Asn Glu Pro Phe Asp Glu Asp Gln His Thr Gln Ile
385 390 395 400
Thr Lys Val
30
447
PRT
Homo sapiens
30
Met Arg Ser Ser Thr Leu Gln Asp Pro Arg Arg Arg Asp Pro Gln Asp
1 5 10 15
Asp Val Tyr Val Asp Ile Thr Asp Arg Leu Arg Phe Ala Ile Leu Tyr
20 25 30
Ser Arg Pro Lys Ser Ala Ser Asn Val His Tyr Phe Ser Ile Asp Asn
35 40 45
Glu Leu Glu Tyr Glu Asn Phe Ser Glu Asp Phe Gly Pro Leu Asn Leu
50 55 60
Ala Met Val Tyr Arg Tyr Cys Cys Lys Ile Asn Lys Lys Leu Lys Ser
65 70 75 80
Ile Thr Met Leu Arg Lys Lys Ile Val His Phe Thr Gly Ser Asp Gln
85 90 95
Arg Lys Gln Ala Asn Ala Ala Phe Leu Val Gly Cys Tyr Met Val Ile
100 105 110
Tyr Leu Gly Arg Thr Pro Glu Ala Ala Tyr Arg Ile Leu Ile Phe Gly
115 120 125
Asp Thr Pro Tyr Ile Pro Phe Arg Asp Ala Ala Tyr Gly Ser Cys Asn
130 135 140
Phe Tyr Ile Thr Leu Leu Asp Cys Phe His Ala Val Lys Lys Ala Met
145 150 155 160
Gln Tyr Gly Phe Leu Asn Phe Asn Ser Phe Asn Leu Asp Glu Tyr Glu
165 170 175
His Tyr Glu Lys Ala Glu Asn Gly Asp Leu Asn Trp Ile Ile Pro Asp
180 185 190
Arg Phe Ile Ala Phe Cys Gly Pro His Ser Arg Ala Arg Leu Glu Ser
195 200 205
Gly Tyr His Gln His Ser Pro Glu Thr Tyr Ile Gln Tyr Phe Lys Asn
210 215 220
His Asn Val Thr Thr Ile Ile Arg Leu Asn Lys Arg Met Tyr Asp Ala
225 230 235 240
Lys Arg Phe Thr Asp Ala Gly Phe Asp His His Asp Leu Phe Phe Ala
245 250 255
Asp Gly Ser Thr Pro Thr Asp Ala Ile Val Lys Arg Phe Leu Asp Ile
260 265 270
Cys Glu Asn Ala Glu Gly Ala Ile Ala Val His Cys Lys Ala Gly Leu
275 280 285
Gly Arg Thr Gly Thr Leu Ile Ala Cys Tyr Ile Met Lys His Tyr Arg
290 295 300
Met Thr Ala Ala Glu Thr Ile Ala Trp Val Arg Ile Cys Arg Pro Gly
305 310 315 320
Leu Val Ile Gly Pro Gln Gln Gln Phe Leu Val Met Lys Gln Thr Ser
325 330 335
Leu Trp Leu Glu Gly Asp Tyr Phe Arg Gln Arg Leu Lys Gly Gln Glu
340 345 350
Asn Gly Gln His Arg Ala Ala Phe Ser Lys Leu Leu Ser Gly Val Asp
355 360 365
Asp Ile Ser Ile Asn Gly Val Glu Asn Gln Asp Gln Gln Glu Pro Lys
370 375 380
Pro Tyr Ser Asp Asp Asp Glu Ile Asn Gly Val Thr Gln Gly Asp Arg
385 390 395 400
Ser Arg Ala Leu Lys Arg Arg Arg Gln Ser Lys Thr Asn Asp Ile Leu
405 410 415
Leu Pro Ser Pro Leu Ala Val Leu Thr Phe Thr Leu Cys Ser Val Val
420 425 430
Ile Trp Trp Ile Val Cys Asp Tyr Ile Leu Pro Ile Leu Leu Phe
435 440 445
31
340
PRT
Homo sapiens
31
Met Leu Glu Ala Pro Gly Pro Ser Asp Gly Cys Glu Leu Ser Asn Pro
1 5 10 15
Ser Ala Ser Arg Val Ser Cys Ala Gly Gln Met Leu Glu Val Gln Pro
20 25 30
Gly Leu Tyr Phe Gly Gly Ala Ala Ala Val Ala Glu Pro Asp His Leu
35 40 45
Arg Glu Ala Gly Ile Thr Ala Val Leu Thr Val Asp Ser Glu Glu Pro
50 55 60
Ser Phe Lys Ala Gly Pro Gly Val Glu Asp Leu Trp Arg Leu Phe Val
65 70 75 80
Pro Ala Leu Asp Lys Pro Glu Thr Asp Leu Leu Ser His Leu Asp Arg
85 90 95
Cys Val Ala Phe Ile Gly Gln Ala Arg Ala Glu Gly Arg Ala Val Leu
100 105 110
Val His Cys His Ala Gly Val Ser Arg Ser Val Ala Ile Ile Thr Ala
115 120 125
Phe Leu Met Lys Thr Asp Gln Leu Pro Phe Glu Lys Ala Tyr Glu Lys
130 135 140
Leu Gln Ile Leu Lys Pro Glu Ala Lys Met Asn Glu Gly Phe Glu Trp
145 150 155 160
Gln Leu Lys Leu Tyr Gln Ala Met Gly Tyr Glu Val Asp Thr Ser Ser
165 170 175
Ala Ile Tyr Lys Gln Tyr Arg Leu Gln Lys Val Thr Glu Lys Tyr Pro
180 185 190
Glu Leu Gln Asn Leu Pro Gln Glu Leu Phe Ala Val Asp Pro Thr Thr
195 200 205
Val Ser Gln Gly Leu Lys Asp Glu Val Leu Tyr Lys Cys Arg Lys Cys
210 215 220
Arg Arg Ser Leu Phe Arg Ser Ser Ser Ile Leu Asp His Arg Glu Gly
225 230 235 240
Ser Gly Pro Ile Ala Phe Ala His Lys Arg Met Thr Pro Ser Ser Met
245 250 255
Leu Thr Thr Gly Arg Gln Ala Gln Cys Thr Ser Tyr Phe Ile Glu Pro
260 265 270
Val Gln Trp Met Glu Ser Ala Leu Leu Gly Val Met Asp Gly Gln Leu
275 280 285
Leu Cys Pro Lys Cys Ser Ala Lys Leu Gly Ser Phe Asn Trp Tyr Gly
290 295 300
Glu Gln Cys Ser Cys Gly Arg Trp Ile Thr Pro Ala Phe Gln Ile His
305 310 315 320
Lys Asn Arg Val Asp Glu Met Lys Ile Leu Pro Val Leu Gly Ser Gln
325 330 335
Thr Gly Lys Ile
340
32
150
PRT
Homo sapiens
32
Met Gly Val Gln Pro Pro Asn Phe Ser Trp Val Leu Pro Gly Arg Leu
1 5 10 15
Ala Gly Leu Ala Leu Pro Arg Leu Pro Ala His Tyr Gln Phe Leu Leu
20 25 30
Asp Leu Gly Val Arg His Leu Val Ser Leu Thr Glu Arg Gly Pro Pro
35 40 45
His Ser Asp Ser Cys Pro Gly Leu Thr Leu His Arg Leu Arg Ile Pro
50 55 60
Asp Phe Cys Pro Pro Ala Pro Asp Gln Ile Asp Arg Phe Val Gln Ile
65 70 75 80
Val Asp Glu Ala Asn Ala Arg Gly Glu Ala Val Gly Val His Cys Ala
85 90 95
Leu Gly Phe Gly Arg Thr Gly Thr Met Leu Ala Cys Tyr Leu Val Lys
100 105 110
Glu Arg Gly Leu Ala Ala Gly Asp Ala Ile Ala Glu Ile Arg Arg Leu
115 120 125
Arg Pro Gly Pro Ile Glu Thr Tyr Glu Gln Glu Lys Ala Val Phe Gln
130 135 140
Phe Tyr Gln Arg Thr Lys
145 150
33
322
PRT
Homo sapiens
33
Gly Leu Met Leu Arg Arg Leu Arg Lys Gly Asn Leu Pro Ile Arg Ser
1 5 10 15
Ile Ile Pro Asn His Ala Asp Lys Glu Arg Phe Ala Thr Arg Cys Lys
20 25 30
Ala Ala Thr Val Leu Leu Tyr Asp Glu Ala Thr Ala Glu Trp Gln Pro
35 40 45
Glu Pro Gly Ala Pro Ala Ser Val Leu Gly Leu Leu Leu Gln Lys Leu
50 55 60
Arg Asp Asp Gly Cys Gln Ala Tyr Tyr Leu Gln Gly Gly Phe Asn Lys
65 70 75 80
Phe Gln Thr Glu Tyr Ser Glu His Cys Glu Thr Asn Val Asp Ser Ser
85 90 95
Ser Ser Pro Ser Ser Ser Pro Pro Thr Ser Val Leu Gly Leu Gly Gly
100 105 110
Leu Arg Ile Ser Ser Asp Cys Ser Asp Gly Glu Ser Asp Arg Glu Leu
115 120 125
Pro Ser Ser Ala Thr Glu Ser Asp Gly Ser Pro Val Pro Ser Ser Gln
130 135 140
Pro Ala Phe Pro Val Gln Ile Leu Pro Tyr Leu Tyr Leu Gly Cys Ala
145 150 155 160
Lys Asp Ser Thr Asn Leu Asp Val Leu Gly Lys Tyr Gly Ile Lys Tyr
165 170 175
Ile Leu Asn Val Thr Pro Asn Leu Pro Asn Ala Phe Glu His Gly Gly
180 185 190
Glu Phe Thr Tyr Lys Gln Ile Pro Ile Ser Asp His Trp Ser Gln Asn
195 200 205
Leu Ser Gln Phe Phe Pro Glu Ala Ile Ser Phe Ile Asp Glu Ala Arg
210 215 220
Ser Lys Lys Cys Gly Val Leu Val His Cys Leu Ala Gly Ile Ser Arg
225 230 235 240
Ser Val Thr Val Thr Val Ala Tyr Leu Met Gln Lys Met Asn Leu Ser
245 250 255
Leu Asn Asp Ala Tyr Asp Phe Val Lys Arg Lys Lys Ser Asn Ile Ser
260 265 270
Pro Asn Phe Asn Phe Met Gly Gln Leu Leu Asp Phe Glu Arg Thr Leu
275 280 285
Gly Leu Ser Ser Pro Cys Asp Asn His Ala Ser Ser Glu Gln Leu Tyr
290 295 300
Phe Ser Thr Pro Thr Asn His Asn Leu Phe Pro Leu Asn Thr Leu Glu
305 310 315 320
Ser Thr
34
521
PRT
Homo sapiens
34
Met Ser Glu Pro Lys Ala Ile Asp Pro Lys Leu Ser Thr Thr Asp Arg
1 5 10 15
Val Val Lys Ala Val Pro Phe Pro Pro Ser His Arg Leu Thr Ala Lys
20 25 30
Glu Val Phe Asp Asn Asp Gly Lys Pro Arg Val Asp Ile Leu Lys Ala
35 40 45
His Leu Met Lys Glu Gly Arg Leu Glu Glu Ser Val Ala Leu Arg Ile
50 55 60
Ile Thr Glu Gly Ala Ser Ile Leu Arg Gln Glu Lys Asn Leu Leu Asp
65 70 75 80
Ile Asp Ala Pro Val Thr Val Cys Gly Asp Ile His Gly Gln Phe Phe
85 90 95
Asp Leu Met Lys Leu Phe Glu Val Gly Gly Ser Pro Ala Asn Thr Arg
100 105 110
Tyr Leu Phe Leu Gly Asp Tyr Val Asp Arg Gly Tyr Phe Ser Ile Glu
115 120 125
Cys Val Leu Tyr Leu Trp Ala Leu Lys Ile Leu Tyr Pro Lys Thr Leu
130 135 140
Phe Leu Leu Arg Gly Asn His Glu Cys Arg His Leu Thr Glu Tyr Phe
145 150 155 160
Thr Phe Lys Gln Glu Cys Lys Ile Lys Tyr Ser Glu Arg Val Tyr Asp
165 170 175
Ala Cys Met Asp Ala Phe Asp Cys Leu Pro Leu Ala Ala Leu Met Asn
180 185 190
Gln Gln Phe Leu Cys Val His Gly Gly Leu Ser Pro Glu Ile Asn Thr
195 200 205
Leu Asp Asp Ile Arg Lys Leu Asp Arg Phe Lys Glu Pro Pro Ala Tyr
210 215 220
Gly Pro Met Cys Asp Ile Leu Trp Ser Asp Pro Leu Glu Asp Phe Gly
225 230 235 240
Asn Glu Lys Thr Gln Glu His Phe Thr His Asn Thr Val Arg Gly Cys
245 250 255
Ser Tyr Phe Tyr Ser Tyr Pro Ala Val Cys Glu Phe Leu Gln His Asn
260 265 270
Asn Leu Leu Ser Ile Leu Arg Ala His Glu Ala Gln Asp Ala Gly Tyr
275 280 285
Arg Met Tyr Arg Lys Ser Gln Thr Thr Gly Phe Pro Ser Leu Ile Thr
290 295 300
Ile Phe Ser Ala Pro Asn Tyr Leu Asp Val Tyr Asn Asn Lys Ala Ala
305 310 315 320
Val Leu Lys Tyr Glu Asn Asn Val Met Asn Ile Arg Gln Phe Asn Cys
325 330 335
Ser Pro His Pro Tyr Trp Leu Pro Asn Phe Met Asp Val Phe Thr Trp
340 345 350
Ser Leu Pro Phe Val Gly Glu Lys Val Thr Glu Met Leu Val Asn Val
355 360 365
Leu Asn Ile Cys Ser Asp Asp Glu Leu Gly Ser Glu Glu Asp Gly Phe
370 375 380
Asp Gly Ala Thr Ala Ala Ala Arg Lys Glu Val Ile Arg Asn Lys Ile
385 390 395 400
Arg Ala Ile Gly Lys Met Ala Arg Val Phe Ser Val Leu Arg Glu Glu
405 410 415
Ser Glu Ser Val Leu Thr Leu Lys Gly Leu Thr Pro Thr Gly Met Leu
420 425 430
Pro Ser Gly Val Leu Ser Gly Gly Lys Gln Thr Leu Gln Ser Ala Thr
435 440 445
Val Glu Ala Ile Glu Ala Asp Glu Ala Ile Lys Gly Phe Ser Pro Gln
450 455 460
His Lys Ile Thr Ser Phe Glu Glu Ala Lys Gly Leu Asp Arg Ile Asn
465 470 475 480
Glu Arg Met Pro Pro Arg Arg Asp Ala Met Pro Ser Asp Ala Asn Leu
485 490 495
Asn Ser Ile Asn Lys Ala Leu Thr Ser Glu Thr Asn Gly Thr Asp Ser
500 505 510
Asn Gly Ser Asn Ser Ser Asn Ile Gln
515 520
35
1267
PRT
Homo sapiens
35
Asp Leu Ser Arg Ser His Cys His Val Tyr Leu Ala His Leu Glu Asn
1 5 10 15
Ser Phe Gly Pro Ser Gly Ala Arg Glu Gly Ser Leu Ser Ser Gln Asp
20 25 30
Ser Arg Thr Glu Ser Ala Ser Leu Ser Gln Ser Gln Val Asn Gly Phe
35 40 45
Phe Ala Ser His Leu Gly Asp Gln Thr Trp Gln Glu Ser Gln His Gly
50 55 60
Ser Pro Ser Pro Ser Val Ile Ser Lys Ala Thr Glu Lys Glu Thr Phe
65 70 75 80
Thr Asp Ser Asn Gln Ser Lys Thr Lys Lys Pro Gly Ile Ser Asp Val
85 90 95
Thr Asp Tyr Ser Asp Arg Gly Asp Ser Asp Met Asp Glu Ala Thr Tyr
100 105 110
Ser Ser Ser Gln Asp His Gln Thr Pro Lys Gln Glu Ser Ser Ser Ser
115 120 125
Val Asn Thr Ser Asn Lys Met Asn Phe Lys Thr Phe Pro Ser Ser Pro
130 135 140
Pro Arg Ser Gly Asp Ile Phe Glu Val Glu Leu Ala Lys Asn Asp Asn
145 150 155 160
Ser Leu Gly Ile Ser Val Thr Gly Gly Val Asn Thr Ser Val Arg His
165 170 175
Gly Gly Ile Tyr Val Lys Ala Val Ile Pro Gln Gly Ala Ala Glu Ser
180 185 190
Asp Gly Arg Ile His Lys Gly Asp Arg Val Leu Ala Val Asn Gly Val
195 200 205
Ser Leu Glu Gly Ala Thr His Lys Gln Ala Val Glu Thr Leu Arg Asn
210 215 220
Thr Gly Gln Val Val His Leu Leu Leu Glu Lys Gly Gln Ser Pro Thr
225 230 235 240
Ser Lys Glu His Val Pro Val Thr Pro Gln Cys Thr Leu Ser Asp Gln
245 250 255
Asn Ala Gln Gly Gln Gly Pro Glu Lys Val Lys Lys Thr Thr Gln Val
260 265 270
Lys Asp Tyr Ser Phe Val Thr Glu Glu Asn Thr Phe Glu Val Lys Leu
275 280 285
Phe Lys Asn Ser Ser Gly Leu Gly Phe Ser Phe Ser Arg Glu Asp Asn
290 295 300
Leu Ile Pro Glu Gln Ile Asn Ala Ser Ile Val Arg Val Lys Lys Leu
305 310 315 320
Phe Pro Gly Gln Pro Ala Ala Glu Ser Gly Lys Ile Asp Val Gly Asp
325 330 335
Val Ile Leu Lys Val Asn Gly Ala Ser Leu Lys Gly Leu Ser Gln Gln
340 345 350
Glu Val Ile Ser Ala Leu Arg Gly Thr Ala Pro Glu Val Phe Leu Leu
355 360 365
Leu Cys Arg Pro Pro Pro Gly Val Leu Pro Glu Ile Asp Thr Ala Leu
370 375 380
Leu Thr Pro Leu Gln Ser Pro Ala Gln Val Leu Pro Asn Ser Ser Lys
385 390 395 400
Asp Ser Ser Gln Pro Ser Cys Val Glu Gln Ser Thr Ser Ser Asp Glu
405 410 415
Asn Glu Met Ser Asp Lys Ser Lys Lys Gln Cys Lys Ser Pro Ser Arg
420 425 430
Lys Asp Ser Tyr Ser Asp Ser Ser Gly Ser Gly Glu Asp Asp Leu Val
435 440 445
Thr Ala Pro Ala Asn Ile Ser Asn Ser Thr Trp Ser Ser Ala Leu His
450 455 460
Gln Thr Leu Ser Asn Met Val Ser Gln Ala Gln Ser His His Glu Ala
465 470 475 480
Pro Arg Val Lys Lys Ile Pro Phe Val Pro Cys Phe Thr Ile Leu Arg
485 490 495
Lys Arg Pro Asn Lys Pro Glu Phe Glu Asp Ser Asn Pro Ser Pro Leu
500 505 510
Pro Pro Asp Met Ala Pro Gly Gln Ser Tyr Gln Pro Gln Ser Glu Ser
515 520 525
Ala Ser Ser Ser Ser Met Asp Lys Tyr His Ile His His Ile Ser Glu
530 535 540
Pro Thr Arg Gln Glu Asn Trp Thr Pro Leu Lys Asn Asp Leu Glu Asn
545 550 555 560
His Leu Glu Asp Phe Glu Leu Glu Val Glu Leu Leu Ile Thr Leu Ile
565 570 575
Lys Ser Glu Lys Gly Ser Leu Gly Phe Thr Val Thr Lys Gly Asn Gln
580 585 590
Arg Ile Gly Cys Tyr Val His Asp Val Ile Gln Asp Pro Ala Lys Ser
595 600 605
Asp Gly Arg Leu Lys Pro Gly Asp Arg Leu Ile Lys Val Asn Asp Thr
610 615 620
Asp Val Thr Asn Met Thr His Thr Asp Ala Val Asn Leu Leu Arg Gly
625 630 635 640
Ser Lys Thr Val Arg Leu Val Ile Gly Arg Val Leu Glu Leu Pro Arg
645 650 655
Ile Pro Met Leu Pro His Leu Leu Pro Asp Ile Thr Leu Thr Cys Asn
660 665 670
Lys Glu Glu Leu Gly Phe Ser Leu Cys Gly Gly His Asp Ser Leu Tyr
675 680 685
Gln Val Val Tyr Ile Ser Asp Ile Asn Pro Arg Ser Val Ala Ala Ile
690 695 700
Glu Gly Asn Leu Gln Leu Leu Asp Val Ile His Tyr Val Asn Gly Val
705 710 715 720
Ser Thr Gln Gly Met Thr Leu Glu Glu Val Asn Arg Ala Leu Asp Met
725 730 735
Ser Leu Pro Ser Leu Val Leu Lys Ala Thr Arg Asn Asp Leu Pro Val
740 745 750
Val Pro Ser Ser Lys Arg Ser Ala Val Ser Ala Pro Lys Ser Thr Lys
755 760 765
Gly Asn Gly Ser Tyr Ser Val Gly Ser Cys Ser Gln Pro Ala Leu Thr
770 775 780
Pro Asn Asp Ser Phe Ser Thr Val Ala Gly Glu Glu Ile Asn Glu Ile
785 790 795 800
Ser Tyr Pro Lys Gly Lys Cys Ser Thr Tyr Gln Ile Lys Gly Ser Pro
805 810 815
Asn Leu Thr Leu Pro Lys Glu Ser Tyr Ile Gln Glu Asp Asp Ile Tyr
820 825 830
Asp Asp Ser Gln Glu Ala Glu Val Ile Gln Ser Leu Leu Asp Val Val
835 840 845
Asp Glu Glu Ser Gln Asn Leu Leu Asn Glu Asn Asn Ala Ala Gly Tyr
850 855 860
Ser Cys Gly Pro Gly Thr Leu Lys Met Asn Gly Lys Leu Ser Glu Glu
865 870 875 880
Arg Thr Glu Asp Thr Asp Cys Asp Gly Ser Pro Leu Pro Glu Tyr Phe
885 890 895
Thr Glu Ala Thr Lys Met Asn Gly Cys Glu Glu Tyr Cys Glu Glu Lys
900 905 910
Val Lys Ser Glu Ser Leu Ile Gln Lys Pro Gln Glu Lys Lys Thr Asp
915 920 925
Asp Asp Glu Ile Thr Trp Gly Asn Asp Glu Leu Pro Ile Glu Arg Thr
930 935 940
Asn His Glu Asp Ser Asp Lys Asp His Ser Phe Leu Thr Asn Asp Glu
945 950 955 960
Leu Ala Val Leu Pro Val Val Lys Val Leu Pro Ser Gly Lys Tyr Thr
965 970 975
Gly Ala Asn Leu Lys Ser Val Ile Arg Val Leu Arg Val Ala Arg Ser
980 985 990
Gly Ile Pro Ser Lys Glu Leu Glu Asn Leu Gln Glu Leu Lys Pro Leu
995 1000 1005
Asp Gln Cys Leu Ile Gly Gln Thr Lys Glu Asn Arg Arg Lys Asn Arg
1010 1015 1020
Tyr Lys Asn Ile Leu Pro Tyr Asp Ala Thr Arg Val Pro Leu Gly Asp
1025 1030 1035 1040
Glu Gly Gly Tyr Ile Asn Ala Ser Phe Ile Lys Ile Pro Val Gly Lys
1045 1050 1055
Glu Glu Phe Val Tyr Ile Ala Cys Gln Gly Pro Leu Pro Thr Thr Val
1060 1065 1070
Gly Asp Phe Trp Gln Met Ile Trp Glu Gln Lys Ser Thr Val Ile Ala
1075 1080 1085
Met Met Thr Gln Glu Val Glu Gly Glu Lys Ile Lys Cys Gln Arg Tyr
1090 1095 1100
Trp Pro Asn Ile Leu Gly Lys Thr Thr Met Val Ser Asn Arg Leu Arg
1105 1110 1115 1120
Leu Ala Leu Val Arg Met Gln Gln Leu Lys Gly Phe Val Val Arg Ala
1125 1130 1135
Met Thr Leu Glu Asp Ile Gln Thr Arg Glu Val Arg His Ile Ser His
1140 1145 1150
Leu Asn Phe Thr Ala Trp Pro Asp His Asp Thr Pro Ser Gln Pro Asp
1155 1160 1165
Asp Leu Leu Thr Phe Ile Ser Tyr Met Arg His Ile His Arg Ser Gly
1170 1175 1180
Pro Ile Ile Thr His Cys Ser Ala Gly Ile Gly Arg Ser Gly Thr Leu
1185 1190 1195 1200
Ile Cys Ile Asp Val Val Leu Gly Leu Ile Ser Gln Asp Leu Asp Phe
1205 1210 1215
Asp Ile Ser Asp Leu Val Arg Cys Met Arg Leu Gln Arg His Gly Met
1220 1225 1230
Val Gln Thr Glu Asp Gln Tyr Ile Phe Cys Tyr Gln Val Ile Leu Tyr
1235 1240 1245
Val Leu Thr Arg Leu Gln Ala Glu Glu Glu Gln Lys Gln Gln Pro Gln
1250 1255 1260
Leu Leu Lys
1265
36
551
PRT
Homo sapiens
36
Met Asn Glu Ser Pro Asp Pro Thr Asp Leu Ala Gly Val Ile Ile Glu
1 5 10 15
Leu Gly Pro Asn Asp Ser Pro Gln Thr Ser Glu Phe Lys Gly Ala Thr
20 25 30
Glu Glu Ala Pro Ala Lys Glu Ser Pro His Thr Ser Glu Phe Lys Gly
35 40 45
Ala Ala Arg Val Ser Pro Ile Ser Glu Ser Val Leu Ala Arg Leu Ser
50 55 60
Lys Phe Glu Val Glu Asp Ala Glu Asn Val Ala Ser Tyr Asp Ser Lys
65 70 75 80
Ile Lys Lys Ile Val His Ser Ile Val Ser Ser Phe Ala Phe Gly Leu
85 90 95
Phe Gly Val Phe Leu Val Leu Leu Asp Val Thr Leu Ile Leu Ala Asp
100 105 110
Leu Ile Phe Thr Asp Ser Lys Leu Tyr Ile Pro Leu Glu Tyr Arg Ser
115 120 125
Ile Ser Leu Ala Ile Ala Leu Phe Phe Leu Met Asp Val Leu Leu Arg
130 135 140
Val Phe Val Glu Arg Arg Gln Gln Tyr Phe Ser Asp Leu Phe Asn Ile
145 150 155 160
Leu Asp Thr Ala Ile Ile Val Ile Leu Leu Leu Val Asp Val Val Tyr
165 170 175
Ile Phe Phe Asp Ile Lys Leu Leu Arg Asn Ile Pro Arg Trp Thr His
180 185 190
Leu Leu Arg Leu Leu Arg Leu Ile Ile Leu Leu Arg Ile Phe His Leu
195 200 205
Phe His Gln Lys Arg Gln Leu Glu Lys Leu Ile Arg Arg Arg Val Ser
210 215 220
Glu Asn Lys Arg Arg Tyr Thr Arg Asp Gly Phe Asp Leu Asp Leu Thr
225 230 235 240
Tyr Val Thr Glu Arg Ile Ile Ala Met Ser Phe Pro Ser Ser Gly Arg
245 250 255
Gln Ser Phe Tyr Arg Asn Pro Ile Lys Glu Val Val Arg Phe Leu Asp
260 265 270
Lys Lys His Arg Asn His Tyr Arg Val Tyr Asn Leu Cys Ser Glu Arg
275 280 285
Ala Tyr Asp Pro Lys His Phe His Asn Arg Val Val Arg Ile Met Ile
290 295 300
Asp Asp His Asn Val Pro Thr Leu His Gln Met Val Val Phe Thr Lys
305 310 315 320
Glu Val Asn Glu Trp Met Ala Gln Asp Leu Glu Asn Ile Val Ala Ile
325 330 335
His Cys Lys Gly Gly Thr Asp Arg Thr Gly Thr Met Val Cys Ala Phe
340 345 350
Leu Ile Ala Ser Glu Ile Cys Ser Thr Ala Lys Glu Ser Leu Tyr Tyr
355 360 365
Phe Gly Glu Arg Arg Thr Asp Lys Thr His Ser Glu Lys Phe Gln Gly
370 375 380
Val Glu Thr Pro Ser Gln Lys Arg Tyr Val Ala Tyr Phe Ala Gln Val
385 390 395 400
Lys His Leu Tyr Asn Trp Asn Leu Pro Pro Arg Arg Ile Leu Phe Ile
405 410 415
Lys His Phe Ile Ile Tyr Ser Ile Pro Arg Tyr Val Arg Asp Leu Lys
420 425 430
Ile Gln Ile Glu Met Glu Lys Lys Val Val Phe Ser Thr Ile Ser Leu
435 440 445
Gly Lys Cys Ser Val Leu Asp Asn Ile Thr Thr Asp Lys Ile Leu Ile
450 455 460
Asp Val Phe Asp Gly Pro Pro Leu Tyr Asp Asp Val Lys Val Gln Phe
465 470 475 480
Phe Tyr Ser Asn Leu Pro Thr Tyr Tyr Asp Asn Cys Ser Phe Tyr Phe
485 490 495
Trp Leu His Thr Ser Phe Ile Glu Asn Asn Arg Leu Tyr Leu Pro Lys
500 505 510
Asn Glu Leu Asp Asn Leu His Lys Gln Lys Ala Arg Arg Ile Tyr Pro
515 520 525
Ser Asp Phe Ala Val Glu Ile Leu Phe Gly Glu Lys Met Thr Ser Ser
530 535 540
Asp Val Val Ala Gly Ser Asp
545 550
37
323
PRT
Homo sapiens
37
Met Ala Asp Leu Asp Lys Leu Asn Ile Asp Ser Ile Ile Gln Arg Leu
1 5 10 15
Leu Glu Val Arg Gly Ser Lys Pro Gly Lys Asn Val Gln Leu Gln Glu
20 25 30
Asn Glu Ile Arg Gly Leu Cys Leu Lys Ser Arg Glu Ile Phe Leu Ser
35 40 45
Gln Pro Ile Leu Leu Glu Leu Glu Ala Pro Leu Lys Ile Cys Gly Asp
50 55 60
Ile His Gly Gln Tyr Tyr Asp Leu Leu Arg Leu Phe Glu Tyr Gly Gly
65 70 75 80
Phe Pro Pro Glu Ser Asn Tyr Leu Phe Leu Gly Asp Tyr Val Asp Arg
85 90 95
Gly Lys Gln Ser Leu Glu Thr Ile Cys Leu Leu Leu Ala Tyr Lys Ile
100 105 110
Lys Tyr Pro Glu Asn Phe Phe Leu Leu Arg Gly Asn His Glu Cys Ala
115 120 125
Ser Ile Asn Arg Ile Tyr Gly Phe Tyr Asp Glu Cys Lys Arg Arg Tyr
130 135 140
Asn Ile Lys Leu Trp Lys Thr Phe Thr Asp Cys Phe Asn Cys Leu Pro
145 150 155 160
Ile Ala Ala Ile Val Asp Glu Lys Ile Phe Cys Cys His Gly Gly Leu
165 170 175
Ser Pro Asp Leu Gln Ser Met Glu Gln Ile Arg Arg Ile Met Arg Pro
180 185 190
Thr Asp Val Pro Asp Gln Gly Leu Leu Cys Asp Leu Leu Trp Ser Asp
195 200 205
Pro Asp Lys Asp Val Leu Gly Trp Gly Glu Asn Asp Arg Gly Val Ser
210 215 220
Phe Thr Phe Gly Ala Glu Val Val Ala Lys Phe Leu His Lys His Asp
225 230 235 240
Leu Asp Leu Ile Cys Arg Ala His Gln Val Val Glu Asp Gly Tyr Glu
245 250 255
Phe Phe Ala Lys Arg Gln Leu Val Thr Leu Phe Ser Ala Pro Asn Tyr
260 265 270
Cys Gly Glu Phe Asp Asn Ala Gly Ala Met Met Ser Val Asp Glu Thr
275 280 285
Leu Met Cys Ser Phe Gln Ile Leu Lys Pro Ala Glu Lys Lys Lys Pro
290 295 300
Asn Ala Thr Arg Pro Val Thr Pro Pro Arg Gly Met Ile Thr Lys Gln
305 310 315 320
Ala Lys Lys
38
319
PRT
Homo sapiens
38
Asp Lys Leu Asn Ile Asp Ser Ile Ile Gln Arg Leu Leu Glu Val Arg
1 5 10 15
Gly Ser Lys Pro Gly Lys Asn Val Gln Leu Gln Glu Asn Glu Ile Arg
20 25 30
Gly Leu Cys Leu Lys Ser Arg Glu Ile Phe Leu Ser Gln Pro Ile Leu
35 40 45
Leu Glu Leu Glu Ala Pro Leu Lys Ile Cys Gly Asp Ile His Gly Gln
50 55 60
Tyr Tyr Asp Leu Leu Arg Leu Phe Glu Tyr Gly Gly Phe Pro Pro Glu
65 70 75 80
Ser Asn Tyr Leu Phe Leu Gly Asp Tyr Val Asp Arg Gly Lys Gln Ser
85 90 95
Leu Glu Thr Ile Cys Leu Leu Leu Ala Tyr Lys Ile Lys Tyr Pro Glu
100 105 110
Asn Phe Phe Leu Leu Arg Gly Asn His Glu Cys Ala Ser Ile Asn Arg
115 120 125
Ile Tyr Gly Phe Tyr Asp Glu Cys Lys Arg Arg Tyr Asn Ile Lys Leu
130 135 140
Trp Lys Thr Phe Thr Asp Cys Phe Asn Cys Leu Pro Ile Ala Ala Ile
145 150 155 160
Val Asp Glu Lys Ile Phe Cys Cys His Gly Gly Leu Ser Pro Asp Leu
165 170 175
Gln Ser Met Glu Gln Ile Arg Arg Ile Met Arg Pro Thr Asp Val Pro
180 185 190
Asp Gln Gly Leu Leu Cys Asp Leu Leu Trp Ser Asp Pro Asp Lys Asp
195 200 205
Val Leu Gly Trp Gly Glu Asn Asp Arg Gly Val Ser Phe Thr Phe Gly
210 215 220
Ala Glu Val Val Ala Lys Phe Leu His Lys His Asp Leu Asp Leu Ile
225 230 235 240
Cys Arg Ala His Gln Val Val Glu Asp Gly Tyr Glu Phe Phe Ala Lys
245 250 255
Arg Gln Leu Val Thr Leu Phe Ser Ala Pro Asn Tyr Cys Gly Glu Phe
260 265 270
Asp Asn Ala Gly Ala Met Met Ser Val Asp Glu Thr Leu Met Cys Ser
275 280 285
Phe Gln Ile Leu Lys Pro Ala Glu Lys Lys Lys Pro Asn Ala Thr Arg
290 295 300
Pro Val Thr Pro Pro Arg Gly Met Ile Thr Lys Gln Ala Lys Lys
305 310 315
39
309
PRT
Homo sapiens
39
Met Asp Glu Lys Val Phe Thr Lys Glu Leu Asp Gln Trp Ile Glu Gln
1 5 10 15
Leu Asn Glu Cys Lys Gln Leu Ser Glu Ser Gln Val Lys Ser Leu Cys
20 25 30
Glu Lys Ala Lys Glu Ile Leu Thr Lys Glu Ser Asn Val Gln Glu Val
35 40 45
Arg Cys Pro Val Thr Val Cys Gly Asp Val His Gly Gln Phe His Asp
50 55 60
Leu Met Glu Leu Phe Arg Ile Gly Gly Lys Ser Pro Asp Thr Asn Tyr
65 70 75 80
Leu Phe Met Gly Asp Tyr Val Asp Arg Gly Tyr Tyr Ser Val Glu Thr
85 90 95
Val Thr Leu Leu Val Ala Leu Lys Val Arg Tyr Arg Glu Arg Ile Thr
100 105 110
Ile Leu Arg Gly Asn His Glu Ser Arg Gln Ile Thr Gln Val Tyr Gly
115 120 125
Phe Tyr Asp Glu Cys Leu Arg Lys Tyr Gly Asn Ala Asn Val Trp Lys
130 135 140
Tyr Phe Thr Asp Leu Phe Asp Tyr Leu Pro Leu Thr Ala Leu Val Asp
145 150 155 160
Gly Gln Ile Phe Cys Leu His Gly Gly Leu Ser Pro Ser Ile Asp Thr
165 170 175
Leu Asp His Ile Arg Ala Leu Asp Arg Leu Gln Glu Val Pro His Glu
180 185 190
Gly Pro Met Cys Asp Leu Leu Trp Ser Asp Pro Asp Asp Arg Gly Gly
195 200 205
Trp Gly Ile Ser Pro Arg Gly Ala Gly Tyr Thr Phe Gly Gln Asp Ile
210 215 220
Ser Glu Thr Phe Asn His Ala Asn Gly Leu Thr Leu Val Ser Arg Ala
225 230 235 240
His Gln Leu Val Met Glu Gly Tyr Asn Trp Cys His Asp Arg Asn Val
245 250 255
Val Thr Ile Phe Ser Ala Pro Asn Tyr Cys Tyr Arg Cys Gly Asn Gln
260 265 270
Ala Ala Ile Met Glu Leu Asp Asp Thr Leu Lys Tyr Ser Phe Leu Gln
275 280 285
Phe Asp Pro Ala Pro Arg Arg Gly Glu Pro His Val Thr Arg Arg Thr
290 295 300
Pro Asp Tyr Phe Leu
305
40
20
DNA
Artificial Sequence
Artificially Synthesized Primer Sequence
40
tacggaagtg ttacttctgc 20
41
20
DNA
Artificial Sequence
Artificially Synthesized Primer Sequence
41
tgtgggaggt tttttctcta 20
42
17
DNA
Artificial Sequence
Artificially Synthesized Primer Sequence
42
gttttcccag tcacgac 17
43
17
DNA
Artificial Sequence
Artificially Synthesized Primer Sequence
43
caggaaacag ctatgac 17 | Selection of clones having the kinase and/or phosphatase-like structure from clones which had been isolated and the structures thereof had been determined in the Helix Research Institute (helix clones; Japanese Patent Application No. 2000-183767) was conducted. Two novel genes were provided by carrying out homology search for all the helix clones by using the amino acid sequences of known kinases and phosphatases as queries. The genes are expected to be involved in intracellular signal transduction. The physiological functions of the inventive genes can be tested by using reporter gene assay systems capable of detecting signal transduction. The proteins of the present invention are useful as target molecules in drug discovery and in the development of new pharmaceuticals. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to a fluoropolyether compound having an aromatic group and hydroxyl groups, a lubricant containing the compound and a magnetic disk having the lubricant applied thereto.
BACKGROUND ART
[0002] With the increased recording density of magnetic disks, the distance between a magnetic disk serving as a recording medium and a head for recording and reproducing information has become almost nil as they approach coming into contact with each other. The magnetic disk surface is provided with a carbon protective, film and a lubricant film to diminish abrasion caused by contact with the head or sliding of the head thereon, and to prevent contamination of the disk surface. The carbon protective film is typically formed by sputtering or CVD. The disk surface is protected by two films, i.e., the carbon protective film and the lubricant film provided thereover. In particular, the lubricant layer provided on the top must have various properties, such as long-term stability, chemical resistance, friction properties, and heat resistance.
[0003] Conventionally used lubricants for magnetic disks are fluoropolyethers having functional groups, such as hydroxyl and amino, at their molecular terminals. However, fluoropolyether-based lubricants have low durability against Lewis acids. When the lubricants come into contact with the magnetic head, their backbone is cleaved by alumina (Al 2 O 3 ; contained in a magnetic head component, whereby the lubricants become lower molecules, ultimately dissipating from the magnetic disk surface. Thus, the film formed by such lubricants cannot be maintained in a system where the magnetic head comes into contact with the magnetic disk or slides on the magnetic disk,
[0004] A recent rapid increase in the information recording density of magnetic disks requires a reduction in magnetic spacing between the magnetic head and the recording layer of the magnetic disk. It is thus becoming important to further reduce the thickness of the lubricant layer present between the magnetic head and the recording layer of the magnetic disk.
[0005] In response to this need, fluoropolyether-based lubricants have been proposed which have functional groups at their molecular terminals and in the middle of the molecular chains (e.g., Patent Documents 1 to 4). Patent Document 1 teaches that the use of a lubricant having hydroxyl both in the molecular chain and at the molecular terminals reduces the thickness of one molecule even when the lubricant is highly polymerized. Patent Document 2 teaches that the use of a lubricant having hydroxyl at the molecular terminals and in the center of the molecular chain, optionally with an aromatic ring in the center of the molecular chain, reduces the thickness of a lubricant layer while enabling high film coverage. Patent Document 3 teaches that the use of a compound having an aromatic ring at the molecular terminals and in the center of the molecular chain can improve the heat resistance. Patent Document 4 teaches that the use of a lubricant having hydroxyl at the molecular terminals and a benzene ring in the center of the molecular chain reduces the thickness of one molecule to thereby reduce the spacing between the head and the disk, thus enabling durability against sliding.
[0006] However, neither of Patent Documents 1 to 4 discloses a lubricant that can reduce the thickness of one molecule to thereby reduce the spacing between the magnetic head and the magnetic disk, while being resistant to decomposition by alumina when coming into contact with the magnetic head.
CITATION LIST
Patent Documents
Patent Document 1: JP2006-070173A
[0007] Patent Document 2: International Publication No. WO2008/038799
Patent Document 3: US2010/0197669A
Patent Document 4: Japanese Patent No. 5327855
SUMMARY OF INVENTION
Technical Problem
[0008] An object of the present invention is to provide a compound that is resistant to decomposition even when coming into contact with a magnetic head while enabling a reduced spacing between the magnetic head and the magnetic disk, and to provide a lubricant comprising the compound, and a magnetic disk comprising the compound.
Solution to Problem
[0009] The present inventor conducted extensive research, and found that the above-described object is achieved by the use of a compound having a benzene ring disubstituted or trisubstituted with a specific fluoropolyether chain having a functional group, such as hydroxyl, in the molecular terminal. The inventor then completed the present invention.
[0010] The present invention relates to the following compound, lubricant, and magnetic disk.
[0000] 1. A compound represented by formula (1):
[0000] C 6 H 6-i —[O—(CH 2 ) n —O—CH 2 —R—CH 2 —X] i (1)
[0000] wherein n is an integer of 2 to 6; i is an integer of 2 or 3; X is a group represented by —OH, —O—(CH 2 ) m —OH, —OCH 2 CH(OH)CH 2 OH, —OCH 2 CH(OH)CH 2 O—C 6 H 5 , or —OCH 2 CH(OH)CH 2 O—C 6 H 4 —OCH 2 ; m is an integer of 1 to 6; R is —(CF 2 ) p O(CF 2 O) x (CF 2 CF 2 O) y (CF 2 CF 2 CF 2 O) z (CF 2 CF 2 CF 2 CF 2 O) w (CF 2 ) p ; x and y are each a real number of 0 to 30; z is a real number of 0 to 30; w is a real number of 0 to 20; and p is an integer of 1 to 3.
2. A lubricant comprising the compound represented by formula (1).
3. A magnetic disk comprising′, in sequence, a substrate, a recording layer, and a protective layer, the magnetic disk further comprising a lubricant layer formed on the protective layer, the lubricant layer comprising the compound represented by formula (1).
Advantageous Effects of Invention
[0011] A fluoropolyether compound having an aromatic group and hydroxyl groups according to the present invention is a compound that can simultaneously achieve two objects, a reduction in thickness of one molecule and resistance to decomposition. A magnetic disk comprising a lubricant containing the compound according to the present invention enables reduced spacing between a magnetic head and a magnetic disk, and exhibits excellent durability when the head comes into contact with or slidably moves on the disk.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a cross-sectional diagram showing the configuration of a magnetic disk according to the present invention.
DESCRIPTION OF EMBODIMENTS
[0013] The fluoropolyether represented by formula (1) according to the present invention is a fluoropolyether compound having an aromatic group and hydroxyl groups.
[0014] The compound represented by formula (1) according to the present invention can be obtained, for example, by reacting (a) a straight-chain fluoropolyether having a hydroxyl group at one terminal and an ester group, a siloxy group, or an alkoxy group at the other terminal with (b) benzene having 2 or 3 halogenated alkoxy groups. Specifically, the compound can be synthesized by the following process.
[0015] The first step is to synthesize (a) the straight-chain fluoropolyether having a hydroxyl group at one terminal and an ester group, a siloxy group, or an alkoxy group at the other terminal.
[0016] (c) A straight-chain fluoropolyether having a hydroxyl group at each terminal is reacted with (d) a compound that is reactive with a hydroxyl group to thereby produce an ester group, a siloxy group, or an alkoxy group. The reaction temperature is typically 10 to 60° C., and preferably 20 to 40° C. The reaction time is typically 2 to 20 hours, and preferably 10 to 15 hours. The compound (d) is added preferably in an amount of 0.5 to 1.5 equivalents based on the amount of the fluoropolyether (c). For this reaction, a reaction accelerator may be used. Thereafter, the reaction mixture is purified by, for example, column chromatography, to thereby obtain the straight-chain fluoropolyether having a hydroxyl group at one terminal and an ester group, a siloxy group, or an alkoxy group at the other terminal. The reaction may be carried out in a solvent. Examples of solvents include dimethylformaldehyde, 1,4-dioxane, dimethyl sulfoxide, and dimethylacetamide. Examples of reaction accelerators include imidazole, pyridine, and sodium hydroxide.
[0017] Examples of (c) fluoropolyethers having a hydroxyl group at each terminal include compounds represented by HOCH 2 CF 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 CF 2 O) w CF 2 CF 2 CF 2 CH 2 OH (c-1), compounds represented by HOCH 2 CF 2 O(CF 2 O) x (CF 2 CF 2 O) y CF 2 CH 2 OH (c-2) and compounds represented by HOCH 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 O) z CF 2 CF 2 CH 2 OH (c-3) These fluoropolyethers have a number average molecular weight of typically 300 to 2,000, preferably 400 to 1,500, and more preferably 500 to 800. As used herein, the term “number average molecular weight” refers to a value of 19 F-NMR measured with JNM-ECX400 (JEOL Ltd.). In NMR measurement, the samples themselves were measured without being diluted with a solvent. The standard chemical shift that was used is a known peak, which is a portion of the backbone structure of a fluoropolyether.
[0018] w is typically a real number of 0 to 20, preferably 0 to 10, and more preferably 0 to 5. x is typically a real number of 0 to 30, preferably 1 to 20, and more preferably 5 to 10. y is typically a real number of 0 to 30, preferably 1 to 20, and more preferably 5 to 10. z is typically a real number of 0 to 20, preferably 1 to 15, and more preferably 3 to 10. In Compound (c-1), p is 3; in Compound (c-2), p is 1; and in Compound (c-3), p is 2.
[0019] The fluoropolyether (c) is a compound having a molecular weight distribution. The molecular weight distribution (PD), which is represented by weight average molecular weight/number average molecular weight, is typically 1.0 to 1.5, preferably 1.0 to 1.3, and more preferably 1.0 to 1.1. The molecular weight distribution is a characteristic value obtained by using HPLC-8220GPC (Tosoh Corporation), a column (PLgel Mixed E; Polymer Laboratories Ltd.), an HCFC-based alternative CFC as an eluent, and a non-functional fluoropolyether serving as a reference material.
[0020] Examples of compounds that are reactive with a hydroxyl group to thereby produce an ester group, a siloxy group, or an alkoxy group include acid anhydrides, silyl halides, and alkyl halides.
[0021] Examples of acid anhydrides include maleic anhydride, succinic anhydride, phthalic anhydride, and compounds represented by R a OR b wherein R a and R b are the same or different, and R a and R b are each CH 3 CO, PhCO, CR 3 SO 2 , PhSO 2 , CF 3 CH 2 CO, or CH 3 C 6 H 4 SO 2 wherein Ph is phenyl. Specific examples of the compounds represented by R a OR b include trifluoromethylacetic anhydride, benzoic anhydride, p-toluenesulfonic anhydride, trifluoromethanesulfonic anhydride, acetic anhydride, acetic benzoic anhydride, methanesulfonic anhydride, and benzenesulfonic anhydride.
[0022] Examples of silyl halides include (R c ) 3 SiY, R d (R e ) 2 SiY, and R d R e R g SiY wherein R c is C 1-4 alkyl or Ph; R d is C 1-18 alkyl, C 1-4 alkoxy, Ph, PhCH 2 , pentafluorophenyl, cyanopropyl, or vinyl; R e is C 1-2 alkyl or Ph; P g is C 1-4 alkyl substituted with phenyl; and Y is a halogen, such as chlorine, bromine, and iodine. Specific examples include trimethylsilyl chloride, triethylsilyl chloride, triisopropylsilyl chloride, t-butyldimethylsilyl chloride, butyldiphenylsilyl chloride, (3-cyanopropyl)dimethylchlorosilane, benzylchlorodimethylsilane, butyldimethylchlorosilane, chloro(decyl)dimethylsilane, chloro(dodecyl)dimethylsilane, chlorodimethyl(3-phenylpropyl)silane, chlorodimethylphenylsilane, chlorodimethylpropylsilane, chlorodimethylvinylsilane, diethylisopropylsilyl chloride, dimethyl-n-octylchlorosilane, dimethylethylsilyl chloride, dimethylisopropylchlorosilane, dimethyloctadecylchlorosilane, diphenylmethylchlorosilane, methyloctadecyl(3-phenylpropyl)chlorosilane, pentafluorophenyl dimethylchlorosilane, t-butoxydiphenylchlorosilane, t-butyldiphenylchlorosilane, and triphenylchlorosilane.
[0023] Examples of alkyl halides include compounds represented by AY wherein A is C 1-5 alkyl, and Y is a halogen, such as chlorine, bromine, and iodine. Specific examples include chloromethane, bromomethane, iodomethane, chloroethane, bromoethane, iodoethane, 1-bromopropane, 2-bromopropane, 1-iodopropane, 2-iodopropane, 1-bromo-2-methylpropane, 1-bromobutane, 2-bromo-2-methylpropane, 2-bromobutane, 1-iodo-2-methylpropane, 1-iodobutane, 2-iodo-2-methylpropane, 2-iodobutane, 1-iodo-2-methylbutane, 1-iodo-3-methylbutane, 1-bromo-3-methylbutane, 1-bromopentane, 2-bromo-2-methylbutane, and 3-bromopentane.
[0024] For example, when HOCH 2 CF 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 CF 2 O) w CF 2 CF 2 CF 2 CH 2 OH and acetic anhydride are used, respectively, as Compound (c) and Compound (d), the reaction between these compounds generates CH 3 COOCH 2 CF 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 CF 2 O) w CF 2 CF 2 CF 2 CH 2 OH, CH 3 COOH, and CH 3 COOH. The former is Compound (a). The use of trimethylsilyl chloride as Compound (d) generates (CH 3 ) 3 SiOCH 2 CF 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 CF 2 O) w CF 2 CF 2 CF 2 CH 2 OH.
[0025] The second step is to synthesize the compound according to the present invention.
[0026] The fluoropolyether (a) obtained in the first step is reacted with benzene having 2 or 3 halogenated alkoxy groups (b) represented by formula (2)
[0000] C 6 H 6-i —[O—(CH 2 ) n —Y] i (2)
[0000] wherein n is an integer of 2 to 6; i is an integer of 2 or 3; and Y is a halogen, such as chlorine, bromine, and iodine, in the presence of a catalyst or an alkali metal.
[0027] In formula (2), n is preferably an integer of 2 to 4. Specific examples of compounds represented by formula (2) wherein i is 3 include 1,3,5-tri(bromopropoxy)benzene, 1,2,3-tri(bromopropoxy)benzene, 1,2,4-tri(bromopropoxy)benzene, 1,3,5-tri(bromoethoxy)benzene, 1,2,3-tri(bromoethoxy)benzene, and 1,2,4-tri(bromoethoxy)benzene. Specific examples of compounds represented by formula (2) wherein i is 2 include o-di(bromopropoxy)benzene, m-di(bromopropoxy)benzene, p-di(bromopropoxy)benzene, o-di(bromoethoxy)benzene, m-di(bromoethoxy)benzene, and p-di(bromoethoxy)benzene.
[0028] The reaction temperature is typically 50 to 100° C., and preferably 70 to 90° C. The reaction time is typically 20 to 100 hours, and preferably 50 to 80 hours. Compound (b) is preferably added in an amount of 0.2 to 1.0 equivalents based on the amount of Compound (a). The catalyst is preferably added in an amount of 0.05 to 0.1 equivalents based on the amount of Compound (a), and the alkali metal is preferably added in an amount of 1.0 to 2.0 equivalents based on the amount of Compound (a). Examples of catalysts for use include alkali compounds, such as sodium t-butoxide, potassium t-butoxide, and sodium, hydride. Examples of alkali metals for use include sodium and potassium. The reaction may be carried out in a solvent. Examples of solvents for use include t-butanol, toluene, and xylene. Thereafter, the reaction mixture is, for example, washed with water and dehydrated. Subsequently, the protecting group (an ester group, a siloxy group, or an alkoxy group) remaining at one terminal of the fluoropolyether is eliminated by hydrolysis or the like, thereby giving Compound (1) according to the present invention wherein X is —OH. For elimination of the protecting group, a deprotection promoter, such as tetrabutylammonium fluoride, potassium fluoride, and sodium fluoride, may be used.
[0029] Compound (1) according to the present invention wherein X is —O(CH 2 ) m OH, —OCH 2 CH(OH)CH 2 OH, —OCH 2 CH(OH)CH 2 O—C 6 H 5 , or —OCH 2 CH(OH)CH 2 O—C 6 H 4 —CCH 3 can be produced from the compound wherein X is —OH obtained in the above-step in accordance with the following procedure, for example.
[0030] A reaction of the compound wherein X is —OH with a haloalcohol represented by Y(CH 2 ) m OH wherein Y is a halogen, such as chlorine, bromine, and iodine, and m is an integer of 1 to 6 in the presence of an alkali metal generates Compound (11) according to the present invention wherein X is —O(CH 2 ) m OH. m is preferably 1 to 4, and more preferably 2 to 4. Examples of alkali metals for use include sodium and potassium.
[0031] Compound (1) of the present invention wherein X is —CCH 2 CH(OH)CH 2 OH is obtained by reacting the compound wherein X is —OH with glycidol in the presence of a catalyst.
[0032] Compound (1) of the present invention wherein X is —OCH 2 CH(OH)CH 2 O—C 6 H 5 is obtained by reacting the compound wherein X is —OH with glycidyl phenyl ether in the presence of a catalyst.
[0033] Compound (1) of the present invention wherein X is —OCH 2 CH(OH)CH 2 O—C 6 H 4 —OCH 3 is obtained by reacting the compound wherein X is —OH with glycidyl 4-methoxy phenyl ether in the presence of a catalyst.
[0034] The reaction temperature for these reactions is typically 50 to 100° C., and preferably 70 to 90° C. The reaction time is typically 20 to 100 hours, and preferably 50 to 80 hours. The reactions may be carried out in a solvent. The alkali compound is preferably added in an amount of 1.0 to 2.0 equivalents based on the amount of the hydroxyl group of Compound (1) according to the present invention wherein X is —OH. The catalyst is preferably added in an amount of 0.05 to 0.1 equivalents based on the amount of the hydroxyl group of Compound (1) according to the present invention wherein X is —OH. Y(CH 2 ) m OH, glycidol, glycidyl phenyl ether, or glycidyl 4-methoxy phenyl ether is preferably added in an amount of 1.0 to 2.0 equivalents based on the amount of the hydroxyl group or Compound (1) according to the present invention wherein. X is —OH. Thereafter, the reaction mixture is, for example, washed with water and dehydrated, and purified by silica gel column chromatography to thereby obtain the target compound as a fraction.
[0035] When applying the compound of the present invention onto the surface of a magnetic disk, it is preferable to dilute the compound with a solvent before applying the compound. Examples of solvents include PF-5060, PF-5080, HFE-7100 and HFE-7200 (all manufactured by 3M) and Vertrel-XF (DuPont). The diluted compound has a concentration of 1 wt % or less, and preferably 0.001 to 0.1 wt %.
[0036] While the compound of the present invention is usable singly, the compound can also be used as mixed in a desired ratio with another material, such as Fomblin Zdol, Ztetraol, Zdol TX, AM (all manufactured by Solvay Solexis), Denmum (Daikin Industries, Ltd.), and Krytox (DuPont).
[0037] The compound of the present invention can be used as a lubricant for reducing the spacing between a magnetic disk and a head inside a magnetic disk apparatus and improving the durability against sliding. A feature of the compound of the present invention is that the hydroxyl groups at the molecular terminals can interact with the polar sites present in the carbon protective film, and the aromatic group in the molecular chain can interact with unsaturated carbon bonds present in the carbon protective film. Accordingly, the compound is usable for not only magnetic disks, but also magnetic heads, photomagnetic recording devices, and magnetic tapes, all three of which have a carbon protective film, a surface protective film, for organic materials, such as plastics, and a surface protective film for inorganic materials, such as Si 3 N 4 , SiC, and SiO 2 .
[0038] FIG. 1 is a cross-sectional diagram showing a magnetic disk according to the present invention. The magnetic disk of the present invention comprises at least one recording layer 2 formed on a substrate 1 , a protective layer 3 formed on the at least one recording layer 2 , and a lubricant layer 4 comprising the compound of the present invention formed on the protective layer 3 as the outermost layer. Examples of substrates include aluminium alloys, ceramics such as glass, and polycarbonate.
[0039] Examples of constituent materials for a magnetic layer, which is the recording layer of the magnetic disk, include primarily elements capable of forming a ferromagnet, such as iron, cobalt, and nickel; alloys containing chromium, platinum, tantalum, or the like in addition to such elements; and oxides thereof. The layer of these materials is formed by a technique such as plating and sputtering. Examples of materials for the protective layer include SiC and SiO 2 . The layer of these materials is formed by sputtering or CVD.
[0040] Lubricant layers presently available have a thickness of 30 Å or less. Thus, when a lubricant having a viscosity of about 100 mPa·s or more at 20° C. is applied as it is, the resulting film could have an excessively large thickness. Therefore, a lubricant dissolved in a solvent is used in coating. If the compound of the present invention is dissolved in a solvent, it is easier to desirably control the film thickness in either case where the compound of the present invention is used as a lubricant singly, or used as mixed with other lubricants. However, the concentration varies depending on the coating technique and conditions, the mixing ratio, and the like. The film thickness formed by the lubricant of the present invention is preferably 5 to 15 Å.
[0041] To facilitate the adsorption of the lubricant to the underlayer, a heat treatment and/or an ultraviolet treatment can be carried out. The heat treatment is typically carried out at a temperature of 60 to 150° C., and preferably at 80 to 150° C. The ultraviolet treatment is preferably carried out using ultraviolet rays having a dominant wavelength of 185 nm or 254 nm.
[0042] The magnetic disk of the present invention can be used in a magnetic disk apparatus comprising: a magnetic disk drive that accommodates the disk and comprises a magnetic head for recording, reproducing and erasing information and a motor for rotating the disk; and a control system for controlling the drive.
[0043] The magnetic disk according to the present invention and a magnetic disk apparatus comprising the magnetic disk can be used, for example, in external memories for electronic computers and word processors. The disk and apparatus can also be used in various devices, such as navigation systems, games, cellular phones, and PHS; internal or external recoding devices for building security, power plant administration systems, and power plant control systems; and the like.
EXAMPLES
[0044] The following Examples will describe the present invention in detail. However, the present invention is not limited to the Examples. Note that 19 F-NMR was measured without a solvent, and using as the standard chemical shift a known peak that is a portion of the backbone structure of a fluoropolyether, and 1 H-NMR was measured without a solvent and using D 2 O as the standard substance.
Example 1
Synthesis of C 6 H 3 —[O—(CH 3 ) 3 —O—CH 2 —R—CH 2 —OH] 3 (Compound 1) wherein R is —CF 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 CF 2 O) w CF 2 CF 2 CF 2 —
[0045] In an argon atmosphere, 50 g of dimethylformaldehyde, 100 g of a fluoropolyether represented by HOCH 2 CF 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 CF 2 O) w CH 2 CF 2 CF 2 CH 2 OH (w=1.5, number average molecular weight: 700, molecular weight distribution: 1.15), 25 g of triisopropylsilyl chloride, and 11 g of imidazole were mixed whale stirring at 30° C. for 12 hours. Subsequently, the mixture was washed with water, dehydrated, and purified by silica gel column chromatography, thereby giving 56 g of Compound (a1) having one hydroxyl group at one terminal and a triisopropylsilyl group at the other terminal, 56 g of Compound (a1) was dissolved in 28 g of t-butanol, and 7 g of a compound represented by formula (b1):
[0000]
[0000] and 3 g of sodium hydride were added thereto, followed by stirring at 70° C. for 4 days.
[0046] The mixture was then washed with water, and mixed with 52 ml, of a solution of 1M tetrabutylammonium fluoride in tetrahydrofuran, followed by purification by column chromatography, thereby giving 20 g of Compound 1.
[0047] Compound 1 was a colorless transparent liquid, and had a density of 1.68 g/cm 3 at 20° C. Compound 1 was identified by NMR as shown below.
[0048] 19 F-NMR (solvent: none, standard substance: OCF 2 C F 2 C F 2 CF 2 O in the obtained product, which was taken as −125.8 ppm)
[0000] δ=−83.5 ppm
[30F, —OC F 2 CF 2 CF 2 C F 2 O—, —OC F 2 CF 2 CF 2 CH 2 OH, (—OC F 2 CF 2 CF 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ],
δ=−120.3 ppm
[6F, (—OCF 2 CF 2 C F 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ], [6F, —OCF 2 CF 2 C F 2 CH 2 OH],
δ=−123.1 ppm
[6F, —OCF 2 CF 2 C F 2 CH 2 OH],
δ=−125.8 ppm
[18F, — 0 CF 2 C F 2 C F 2 CF 2 O—],
δ=−127.4 ppm
[12F, —OCF 2 C F 2 CF 2 CH 2 OH, (—OCF 2 C F 2 CF 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ],
w=1.5
[0049] 1 H-NMR (solvent: none, standard substance: D 2 O)
[0000] δ=1.9 ppm
[6H, (—OCF 2 CF 2 CF 2 CH 2 OCH 2 C H 2 CH 2 O) 3 —C 6 H 3 ],
δ=3.2 to 3.8 ppm
[27H, H OC H 2 CF 2 CF 2 CF 2 O—, (—OCF 2 CF 2 CF 2 C H 2 OC H 2 CH 2 C H 2 O) 3 —C 6 H 3 ],
δ=6.1 ppm
[3H, (—OCF 2 CF 2 CF 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ]
Example 2
Synthesis of C 6 H 3 —[O—(CH 2 ) 3 —O—CH 2 —R—CH 2 —OH] 3 (Compound 2) wherein R is —CF 2 O(CF 2 O) x (CF 2 CF 2 O) y CF 2 —
[0050] In an argon atmosphere, 100 g of dimethylformaldehyde, 200 g of a fluoropolyether represented by HOCH 2 CF 2 O(CF 2 O) x (CF 2 CF 2 O) y CF 2 CH 2 OH (x=6, y=6, number average molecular weight: 1,300, molecular weight distribution: 1.20), 25 g of triisopropylsilyl chloride, and 9 g of imidazole were mixed while stirring at 30° C. for 12 hours. Subsequently, the mixture was washed with water, dehydrated, and purified by silica gel column chromatography, thereby giving 100 g of Compound (a2) having one hydroxyl group at one terminal and a triisopropylsilyl group at the other terminal. 82 g of Compound (a2) was dissolved in 74 g of t-butanol, and 7 g of a compound represented by the above-mentioned formula (b1) and 3 g of sodium hydride were added thereto, followed by stirring at 70° C. for 4 days. The mixture was then washed with water, and mixed with 52 mL of a solution of 1M tetrabutylammonium fluoride in tetrahydrofuran, followed by purification by column chromatography, thereby giving 27 g of Compound 2.
[0051] Compound 2 was a colorless transparent liquid, and had a density of 1.76 g/cm 3 at 20° C. Compound 2 was identified by NMR as shown below.
[0052] 19 F-NMR (solvent: none, standard substance: OC F 2 O in the obtained product, which was taken as −53.7 ppm)
[0000] δ=−52.1 ppm, −53.7 ppm, −55.4 ppm
[32F, —OC F 2 O—],
[0053] δ=−78.0 ppm, −80.0 ppm
[6F, (−OC F 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ],
δ=−81.0, −83.0 ppm
[6F, —C F 2 CH 2 OH],
δ=−89.1 ppm, −90.7 ppm
[67F, —OC F 2 C F 2 O—]
x=5.4
y=5.6
[0054] 1 H-NMR (solvent: none, standard substance: D 2 O)
[0000] δ=1.9 ppm
[6H, (—OCF 2 CH 2 OCH 2 C H 2 CH 2 O) 3 —C 6 H 3 ],
δ=3.0 to 4.0 ppm
[27H, H OC H 2 CF 2 O—, (—OCF 2 C H 2 OC H 2 CH 2 C H 2 O) 3 —C 6 H 3 ],
δ=6.1 ppm
[3H, (—OCF 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ]
Example 3
Synthesis of C 6 H 3 —[O—(CH 2 ) 3 —O—CH 2 —R—CH 2 —OH] 3 (Compound 3) wherein R is —CF 2 CF 2 O(CF 2 CF 2 CF 2 O) z CF 2 CF 2 —
[0055] In an argon atmosphere, 175 g of dimethylformaldehyde, 350 g of a fluoropolyether represented by HOCH 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 O) z CF 2 CF 2 CH 2 OH (z=7, number average molecular weight: 1,480, molecular weight distribution: 1.20), 45 g of triisopropylsilyl chloride, and 18 g of imidazole were mixed while stirring at 30° C. for 12 hours. Subsequently, the mixture was washed with water, dehydrated, and purified by silica gel column chromatography, thereby giving 200 g of Compound (a3) having one hydroxyl group at one terminal and a triisopropylsilyl group at the other terminal. 140 g of Compound (a3) was dissolved in 140 g of t-butanol, and 12 g of a compound represented by the above-mentioned formula (b1) and 4 g of sodium hydride were added thereto, followed by stirring at 70° C. for 4 days. The mixture was then washed with water, and mixed with 100 mL of a solution of 1M tetrabutylammonium fluoride in tetrahydrofuran, followed by purification by column chromatography, thereby giving 30 g of Compound 3.
[0056] Compound 3 was a colorless transparent liquid, and had a density of 1.77 g/cm 3 at 20° C. Compound 3 was identified by NMR as shown below.
[0057] 19 F-NMR (solvent: none, standard substance: OCF 2 C F 2 CF 2 O in the obtained product, which was taken as −129.7 ppm)
[0000] δ=−83.7 ppm
[88F, —OC F 2 C F 2 CF 2 O—]
δ=−86.4 ppm
[12F, —OC F 2 CF 2 CH 2 OH, (—OC F 2 CF 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ]
δ=−124.3 ppm
[6F, (—OCF 2 C F 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ],
δ=−127.5 ppm
[6F, —OCF 2 C F 2 CH 2 OH],
δ=−129.7 ppm
[44F, —OCF 2 C F 2 CF 2 O—]
z=7.3
[0058] 1 H-NMR (solvent: none, standard substance: D 2 O)
[0000] δ=1.9 ppm
[6H, (—OCF 2 CF 2 CH 2 OCH 2 C H 2 CH 2 O) 3 —C 6 H 3 ],
δ=2.8 to 4.2 ppm
[27H, H OC H 2 CF 2 CF 2 O—, (—OCF 2 CF 2 C H 2 OC H 2 CH 2 C H 2 O) 3 —C 6 H 3 ]
δ=6.1 ppm
[3H, (—OCF 2 CF 2 CH 2 OCH 2 CH 2 CH 2 O) 3 —C 6 H 3 ]
Example 4
Synthesis of C 6 H 4 —[O—(CH 2 ) 2 —O—CH 2 —R—CH 2 —OH] 2 (Compound 4) wherein R is —CF 2 CF 2 O(CF 2 CF 2 CF 2 O) z CF 2 CF 2 —
[0059] In an argon atmosphere, 175 g of dimethylformaldehyde, 350 g of a fluoropolyether represented by HOCH 2 CF 2 CF 2 O(CF 2 CF 2 CF 2 O) z CF 2 CF 2 CH 2 OH (z=7, number average molecular weight: 1,480, molecular weight distribution: 1.20), 45 g of triisopropylsilyl chloride, and 18 g of imidazole were mixed while stirring at 30° C. for 12 hours. Subsequently, the mixture was washed with water, dehydrated, and purified by silica gel column chromatography, thereby giving 200 g of Compound (a3) having one hydroxyl group at one terminal and a triisopropylsilyl group at the other terminal. 140 g of Compound (a3) was dissolved in 140 g of t-butanol, and 10 g of a compound represented by formula (b2):
[0000]
[0000] and 3 g of sodium hydride were added thereto, followed by stirring at 70° C. for 4 days.
[0060] The mixture was then washed with water, and mixed with 52 mL of a solution of 1M tetrabutylammonium fluoride in tetrahydrofuran, followed by purification by column chromatography, thereby giving 32 g of Compound 4.
[0061] Compound 4 was a colorless transparent liquid, and had a density of 1.71 g/cm 3 at 20° C. Compound 4 was identified by NMR as shown below.
[0062] 19 F-NMR (solvent: none, standard substance: OCF 2 C F 2 CF 2 O in the obtained product, which was taken as −129.7 ppm)
[0000] δ=−83.7 ppm
[57F, —OC F 2 CF 2 C F 2 O—]
δ=−86.4 ppm
[8F, —OC F 2 CF 2 CH 2 OH, (—OC F 2 CF 2 CH 2 OCH 2 CH 2 O) 2 —C 6 H 4 ]
δ=−124.3 ppm
[4F, (—OCF 2 C F 2 CH 2 OCH 2 CH 2 O) 2 —C 6 H 4 ]
δ=−127.5 ppm
[4F, —OCF 2 C F 2 CH 2 OH]
δ=−129.7 ppm
[28F, —OCF 2 C F 2 CF 2 O—]
z=7.1
[0063] 1 H-NMR (solvent: none, standard substance: D 2 O)
[0000] δ=3.2 to 3.8 ppm
[18H, H OC H 2 CF 2 CF 2 O—, (—OCF 2 CF 2 C H 2 OC H 2 C H 2 O) 2 —C 6 H 4 ],
δ=6.8 ppm
[4H, (—OCF 2 CF 2 CH 2 OCH 2 CH 2 O) 2 —C 6 H 4 ]
Example 5
Synthesis of C 6 H 4 —[O—(CH 2 ) 2 —O—CH 2 —R—CH 2 —OCH 2 CH(OH)CH 2 OH] 2 (Compound 5) wherein R is —CF 2 CF 2 O(CF 2 CF 2 CF 2 O) z CF 2 CF 2 —
[0064] 30 g of Compound 4 obtained in Example 4 was dissolved in 15 g of t-butanol, and 1.5 g of glycidol and 0.2 g of potassium t-butoxide were added thereto, followed by stirring at 70° C. for 80 hours. Subsequently, the mixture was washed with water, and purified by column chromatography, thereby giving 13 g of Compound 5.
[0065] Compound 5 was a colorless transparent liquid, and had a density of 1.69 g/cm 4 at 20° C. Compound 5 was identified by NMR as shown below.
[0066] 19 F-NMR (solvent: none, standard substance: OCF 2 C F 2 CF 2 O in the obtained product, which was taken as −129.7 ppm)
[0000] δ=−83.7 ppm
[55F, —OC F 2 CF 2 C F 2 O—]
δ=−86.4 ppm
[8F, —OC F 2 CF 2 CH 2 OCH 2 CH(OH)CH 2 OH, (—OC F 2 CF 2 CH 2 OCH 2 CH 2 O) 2 —C 6 H 4 ]
δ=−124.3 ppm
[8F, —OCF 2 C F 2 CH 2 OCH 2 CH(OH)CH 2 OH, (—OCF 2 C F 2 CH 2 OCH 2 CH 2 O) 2 —C 6 H 4 ]
δ=−129.7 ppm
[28F, —OCF 2 C F 2 CF 2 O—]
z=6.9
[0067] 1 H-NMR (solvent: none, standard substance: D 2 O)
[0000] δ=3.2 to 3.8 ppm
[26H, H OC H 2 C H (O H )C H 2 CF 2 CF 2 O—, (—OCF 2 CF 2 C H 2 OC H 2 C H 2 O) 2 —C 6 H 4 ],
δ=6.8 ppm
[4H, (—OCF 2 CF 2 CH 2 OCH 2 CH 2 O) 2 —C 6 H 4 ]
[0068] For comparison, Compound 6 synthesized in accordance with Example 2 of Patent Document 4 was used.
Compound 6
[0069] (HO—CH 2 —R 2 —CH 2 O—CH 2 ) 3 —R 1 wherein R 1 is a group represented by the following formula (a):
[0000]
[0000] and R 2 is —CF 2 CF 2 O(CF 2 CF 2 CF 2 O) z CF 2 CF 2 —.
Test Example 1
Evaluation of Compound in Decomposition Resistance to Aluminium Oxide
[0070] 20 wt % of Al 2 O 3 was added to each lubricant (Compounds 1 to 6), and the mixtures were strongly shaken, followed by further mixing by ultrasound, thereby preparing samples for evaluation of decomposition resistance. Evaluation of the decomposition resistance was conducted by measuring the weight decrease of the lubricants heated at 250° C. for 100 minutes using a thermal analyzer (TG/TDA). The measurement was conducted in a nitrogen atmosphere by using 20 mg of each sample. Table 1 shows the results.
[0000]
TABLE 1
Decrease in Weight (%)
Compound 1
<1
Compound 2
23
Compound 3
5
Compound 4
2
Compound 5
5
Compound 6
75
Test Example 2
Evaluation of Retention Properties of Lubricant on High-Speed-Rotating Disk
[0071] The lubricants (Compounds 1, 2, 5, and 6) were individually dissolved in Vertrel-XF (DuPont). These solutions contained respective lubricants in a concentration of 0.05 wt %. Magnetic disks having a diameter of 2.5 inches were individually immersed in respective solutions for 1 minute, and retrieved at a rate of 2 mm/s. Each disk was then irradiated with light having a wavelength of 185 nm for 20 seconds by using a low-pressure mercury lamp, and the average film thickness of the compound on each magnetic disk was measured with FT-IR. This film thickness is referred to as hÅ. Subsequently, the disks on which the lubricants were applied at 5,400 rpm, a temperature of 30 to 40° C., and a humidity of 80 to 90 RH % were spun at high speed for 4 weeks. Thereafter, the average film thickness of the compound remaining on each magnetic disk was measured with FT-IR. This film thickness is referred to as cÅ. To indicate the degree of adsorption of the lubricants to the magnetic disks under high-speed rotating conditions, a lubricant retention rate was determined from the following equation.
[0000] Lubricant Retention Rate (%)=100× c/h
[0000]
TABLE 2
Initial
Week
Week
0
1
2
4
Compound 1
100.0
100.0
100.0
100.0
Compound 2
100.0
91.2
93.0
92.7
Compound 5
100.0
97.0
96.6
97.0
Compound 6
100.0
86.7
81.8
74.8
Test Example 3
Measurement of Monomolecular Film Thickness
[0072] As described in Journal of Tribology (October 2004, Vol. 126, Page 751), the monomolecular film thickness (the thickness of one molecule) of a lubricant applied on a magnetic disk can be confirmed when the diffusive behavior of the lubricant on the disk is observed with an ellipsometer. The thickness of the terrace portion of the lubricant film is determined as the monomolecular film thickness.
[0073] Specifically, Compounds 1, 2, 3, 5, and 6 were individually dissolved in Vertrel-XF (DuPont). These solutions, respectively, contained Compounds 1, 2, 3, 5, and 6 in a concentration of 0.1 wt %. A portion (about ¼) of a magnetic disk having a diameter of 2.5 inches was immersed in each of the solutions, and retrieved at a rate of 4 mm/s, thereby preparing disks each having a portion coated with Compounds 1, 2, 3, 5, or 6, and an uncoated portion. The average film thickness of the coated portions was 32 Å.
[0074] After being prepared, these disks were placed on an ellipsometer and measured for change in the film thickness in the vicinity of the boundary of the coated portion and uncoated portion at a predetermined time interval at 50° C., whereby the monomolecular film thickness of each lubricant was determined as the film thickness of the formed terrace portion. Table 3 shows the results.
[0000]
TABLE 3
Sample
Film Thickness (Å)
Compound 1
10
Compound 2
11
Compound 3
11
Compound 5
11
Compound 6
13
[0075] The results indicate that the fluoropolyether compound having an aromatic group and hydroxyl groups according to the present invention is superior to Compound 6 having a benzene ring to which 3 fluoropolyether chains are bonded via CH 2 in terms of alumina decomposition resistance and lubricant retention properties, and has a smaller monomolecular film thickness than Compound 6.
DESCRIPTION OF REFERENCE NUMERALS
[0000]
1 Substrate
2 Recording Layer
3 Protective Layer
4 Lubricant Layer | An object of the present invention is to provide a compound that is resistant to decomposition even when coming into contact with a magnetic head, while enabling a reduced spacing between the magnetic head and a magnetic disk, and to provide a lubricant comprising the compound, and a magnetic disk comprising the compound. The present invention relates to a compound represented by formula (1), a lubricant comprising the compound, and a magnetic disk comprising the compound:
C 6 H 6-i —[O—(CH 2 ) n —O—CH 2 —R—CH 2 —X] i (1)
wherein n is an integer of 2 to 6; i is an integer of 2 or 3; X is a group represented by —OH, —O—(CH 2 ) m —OH, —OCH 2 CH(OH)CH 2 OH, —OCH 2 CH(OH)CH 2 O—C 6 H 5 , or —OCH 2 CH(OH)CH 2 O—C 6 H 4 —OCH 3 ; m is an integer of 1 to 6; R is —(CF 2 ) p O(CF 2 O) x (CF 2 CF 2 O) y (CF 2 CF 2 CF 2 O) z (CF 2 CF 2 CF 2 CF 2 O) w (CF 2 ) p —; x and y are each a real number of 0 to 30; z is a real number of 0 to 30; w is a real number of 0 to 20; and p is an integer of 1 to 3. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of copending application Ser. No. 08/124,740, filed on Sep. 21, 1993, and issued on Oct. 10, 1995 as U.S. Pat. No. 5,456,093, which is a continuation-in-part of Ser. No. 07/895,975, filed Jun. 9, 1992, and issued on Nov. 9, 1993 as U.S. Pat. No. 5,260,243, which is a continuation-in-part of Ser. No. 07/386,319, filed Jul. 28, 1989, and issued on Jun. 9, 1992 as U.S. Pat. No. 5,120,694 and the above herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates in general to adsorbent composites and more particularly to methods for coating the inside surface of a tube with a layer of solid adsorbent to form an adsorbent-lined tube, to a process for sorption cooling utilizing the adsorbent-lined tube and to an apparatus useful for sorption cooling.
BACKGROUND OF THE INVENTION
There are a variety of solid adsorbents which have been useful in adsorption and catalysis including commonly known materials such as activated carbons, activated clays, silica gel, activated alumina, and crystalline molecular sieves. Of these adsorbents, crystalline molecular sieves such as silicoalumino phosphates, aluminophosphates and aluminosilicate zeolites have been particularly useful because of their uniformpore size.
In many instances it is desirable to have the solid adsorbent deposited on a substrate as a coating instead of being contained in particulate form as pellets, beads, or other particles. There are several reasons why solid adsorbent coatings have been used including for example, to improve the catalytic or adsorption properties of the solid adsorbent by improving the surface area to weight ratio, to reduce the mount of solid adsorbent required, to protect the underlying substrate material from a harmful environment, to achieve a particular strength or form, and, to perform the particular adsorptive or catalytic function over the entire coated surface of the substrate.
Despite the diversity of coating methods and end uses known to exist, new methods are sought which can be used to coat the inside surfaces of tubes with solid adsorbents without the use of adsorbent formation reactions, frits and enamels, paints, varnishes and the like, in order to provide adsorbent-substrate composites that have physical and performance properties suitable for sorption cooling use.
Some thermodynamic processes for cooling and heating by adsorption of a refrigerating fluid on a solid adsorbent use zeolite, and other sorption materials such as activated carbon and silica gel. In these processes, the thermal energy from adsorbing zeolite in one place is used to heat desorbing zeolite located in another place. U.S. Pat. No. 4,138,850 relates to a system for such solar heat utilization employing a solid zeolite adsorbent mixed with a binder, pressed, and sintered into divider panels and hermetically sealed in containers. U.S. Pat. No. 4,637,218 relates to systems for a heat pump using zeolite as an adsorbent wherein the zeolite is prepared by slicing natural zeolite rock with a carbide saw, or by pressing slightly-wetted, powdered zeolite into bricks. The bricks used in U.S. Pat. No. 4,637,218 are preferably not more than 10 mm in thickness.
U.S. Pat. No. 4,548,046 relates to an apparatus for cooling or heating by adsorption of a refrigerating fluid on a solid adsorbent. The operations employ a plurality of tubes provided with parallel radial fins filled or covered with solid adsorbent such as Zeolite 13X located on the outside of the tubes.
The thermodynamic aspects of developing a zeolite-water adsorption refrigeration unit are well known. An article entitled, "Thermodynamic Analysis of a Solar Zeolite Refrigeration System," by S. Chang and J. A. Roux, which appeared in the Journal of Solar Energy Engineering, August 1985, Volume 107, pages 189-194 provides a discussion of the main parameters, including adsorber properties.
In adsorber/generator based cooling systems the most significant parameter is the overall heat transfer coefficient between the adsorbent bed and the cooling or heating gases per unit weight of adsorbent in the system. This parameter has been related in the literature to the cooling power per kilogram of adsorbent. The higher the cooling power, the more efficient the adsorber/generator system. Current systems are limited by requiring a high adsorbent regenerator temperature or a long cycle time to achieve relatively low cooling power values.
In a paper titled, "Application of Adsorption Cooling System to Automobiles,"by Moloyuki Suzuki, presented at the Solid Sorption Refrigeration Symposium --Paris, France, Nov. 18-20, 1992. Suzuki disclosed the results of a study to particularly point out the technological limits associated with the application of adsorption cooling systems to passenger car air conditioning. Suzuki's model considered an adsorbent bed wherein the adsorption step corresponds to the cooling step where water evaporation takes place at a water container, and wherein regeneration step corresponding to a generation step where the adsorbent bed is heated by exhaust gases to desorb the water. These steps are repeated in series requiting at least two units to achieve continuous cooling. Suzuki suggests the use of "quick cycles with a high overall heat transfer coefficient will result in acceptable designs. Currently, overall heat transfer coefficients in the ranges of 25 to 50 are reported in a paper title, "Reaction Beds for Dry Sorption Machines," by M. Groll and presented at the above mentioned Solid Sorption Refrigeration Symposium. Suzuki predicts a threshold value of 100 kW/m 3 K (about 150 W/m 2 ) for overall heat transfer k, m coefficient as a target for the future work, and further points out the need for systems with mechanical strength for use in automobiles, but does not suggest how this value which is greater than 3 times the ability of the current art can be achieved.
Prior methods of using zeolite adsorbents in devices for cooling or heating by adsorption of a refrigerating fluid on a solid adsorbent have been inefficient and difficult to prepare. Those methods of preparation included cutting natural rock into thin bricks and mounting these bricks on to heat exchange surfaces or casting powdered zeolites and mixtures thereof with clays into panels or slabs for direct contact with fluids. Methods are sought to improve the operating efficiency of these devices, and to improve the way in which the solid zeolite adsorbent is employed in these devices.
OBJECTS OF THE INVENTION
It is the object of this instant invention to provide an improved method of coating the inside of tubes.
It is a further object of the instant invention to provide an improved sorption cooling apparatus for use in waste heat recovery and air conditioning systems.
It is a further objective of the instant invention to provide an adsorbent/refrigerant system which provides a high overall efficiency within the limits of typical waste heat recovery and air conditioning cycles.
It is a still further object of the instant invention to provide a sorption cooling cycle with an improved overall thermal efficiency.
SUMMARY OF THE INVENTION
The present invention provides adsorbent composites wherein solid adsorbents are bonded to the inside surfaces of tube substrates such as aluminum metal, copper metal, aluminized steel, copperclad steel, steel, or aluminized ceramic. These composites can form linings that have improved adsorption properties over pelleted or beaded adsorbent particles as well as excellent physical and thermal cycling properties.
The present invention provides a method of lining of the inside surface of a tube with a layer of solid adsorbent selected from the group consisting of crystalline molecular sieves, activated alumina and mixtures thereof which includes the steps of heating the surface in an oxygen containing atmosphere, preferably containing at least about 1 mol % oxygen and more preferably consisting of air, to a temperature sufficient to enable bonding of the solid adsorbent to the surface and preferably oxidation of the surface, wherein the temperature is at least about 300° C., preferably between about 300° C. and 650° C. contacting the heated surface with a slurry comprising the solid adsorbent and a binder selected from the group consisting of kaolin, silica, and mixtures thereof in a suspending liquid to form a slurry-coated surface, drying the surface for a period of time ranging from about 0.25 to about 1 hour at a temperature of at least 100° C., and heating the surface to a temperature ranging from about 500° C. to about 650° C. to form an adsorbent coating on the surface. In a preferred aspect the adsorbent coated surface is heated to a temperature and for a period of time sufficient to cause hardening thereof, wherein the temperature is preferably between about 500° C. and 650° C., and the time is at least 0.25 hours and preferably about 1 hour.
The method comprising the steps of heating the surface, contacting with slurry, and drying the surface is repeated until the adsorbent layer has a uniform thickness ranging between about 0.6 to 3 mm, and preferably has a uniform thickness of from about 1.0 to 1.2 mm, before the final heating step. The composites may be used as an adsorbent layer applied to the interior surface of tubes used in devices for cooling and heating by adsorption of a refrigerant on a solid adsorbent. The crystalline molecular sieves comprise a zeolite selected from the group consisting of zeolite A, zeolite X, zeolite Y, zeolite L, chabazite, silicalite and mixtures thereof. A particular formulation was discovered which provides both strength of bonding and a more efficient method of preparing a uniform adsorbent lining for tubes. In employing adsorbent-lined tubes in sorption cooling cycles, it was discovered that zeolite Y, and more particularly zeolite Y-85, low cerium rare earth exchanged Y-84 and rare earth exchanged LZ-210 in combination with a refrigerant provided very high overall thermal efficiendes. With the above combination of the improved bonding method to provide a uniform lining of adsorbent on the inside surface of a tube; an adsorbent selected from the group consisting of zeolite Y-85, low cerium mixed rare earth exchanged Y-84, rare earth exchanged LZ-210 and mixtures thereof; and the sorbent cooling apparatus of the present invention, a significant improvement in the overall thermal efficiency with an overall heat transfer coefficient of about 175 W/m 2 /K in a sorption cooling cycle was achieved.
In another embodiment of the invention a zeolite-lined heat exchanger tube having a first end and a second end opposite and an inside space lined with a zeolite layer is prepared in accordance with this invention. The inside space of the tube is evacuated to a pressure of at least 1 micron of mercury while the tube is heated to a temperature of at least 350° C. The tube is maintained at these conditions for a period from about 2 hours to about 4 hours and sufficient to provide a uniform and low level of residual moisture in the zeolite layer. The zeolite layer is then brought into equilibrium with a refrigerant vapor at a level of up to about one-half the saturation value of the zeolite layer. The first end and the second end are sealed.
In a further embodiment of the invention, a desiccant cooling apparatus comprises a housing having a first fluid inlet and first fluid outlet and a second fluid inlet and fluid outlet. A plurality of zeolite-lined exchanger tubes extend substantially longitudinally within the housing. The tubes have a first end and a second end opposite and have an interior surface which is lined with a zeolite composition. The zeolite composition is bonded directly to the interior surface of the tubes and defines an internal tube space containing a refrigerant. The tubes are aligned in a parallel relationship with each other, spaced to permit transverse fluid flow and sealed at said first end. A header plate is disposed at each of the tubes. The header plates have a plurality of holes for inserting the ends of the tubes and are disposed in sealing contact with the tubes. At least one insulating baffle is disposed at a point between the ends of the tubes. The insulating baffle has a plurality of holes for inserting the tubes therethrough and is aligned generally transverse to the tubes. The insulating frame is disposed in a sealing contact with the tubes and said housing thereby defining a first zone and a second zone within said housing. The first zone is between the first end and the insulating baffle and is in fluid communication with the first fluid inlet and first fluid outlet for the flow of a first fluid therethrough. The second zone is between the insulating baffle and the second end. The second zone is in fluid communication with the second fluid inlet and the second fluid outlet for the flow of a second fluid therethrough. An end cap is disposed in sealing contact to the header plate at the second end of the tubes, thus defining a third zone in fluid communication with the interior tube space and a valve disposed on the end cap in fluid communication with the third zone.
In a still further embodiment a process for sorption cooling is provided to refrigerate a feedstream from an initial temperature to a lower temperature and comprises a series of sequential steps. A first fluid at a first temperature is passed to a first zone of a desiccant cooling apparatus containing at least one zeolite-lined tube. Each tube has a first tube portion in the first zone and a second tube portion in a second zone of the desiccant cooling apparatus. The zeolite-lined tube has a uniform lining comprising zeolite and an inner tube space containing a refrigerant. A portion of the refrigerant is desorb ed from the first tube portion to produce a vaporized refrigerant stream therein. The vaporized refrigerant stream is passed to the second tube portion. Simultaneously, a second fluid at a second temperature is passed to the second zone of the desiccant cooling apparatus to condense and reabsorb the vaporized refrigerant stream within the second tube portion. The above steps are terminated. The second fluid at the second temperature is passed to the first zone to heat the second fluid to a third temperature. Simultaneously, the feedstream at the initial temperature is passed to the second zone and the feedstream is withdrawn at the lower temperature. The passing of the second fluid and the feedstream are terminated and all of the above steps are repeated to provide a sorption cooling cycle. At least one other desiccant cooling apparatus is operated according to the sorption cooling cycle and offset by at least one-half of the sorption cooling cycle to provide continuous cooling of the feedstream. An adsorber/generator cooling system based on the present invention achieves an overall heat transfer coefficient of about 175 W/m 2 /K, a value which is 15 percent greater than predicted as desirable for use in automotive air conditioners.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a diagrammatic illustration of a sorption cooling apparatus of the present invention for conditioning liquid streams, the housing being partially broken away to show FIG. 1B, a detail of the partition between a first and a second zone and FIG. 1C, a detail of FIG. 1B showing cross-section of a zeolite-lined tube.
FIG. 2A is a diagrammatic illustration of a sorption cooling apparatus of the present invention for conditioning vapor streams, the housing being partially broken away to show FIG. 2B, a detail of the zeolite-lined tube and the partition.
FIG. 3 is a graph of the ability of the sorbent, a low cerium rare earth exchanged zeolite Y-84 to adsorb water at various temperatures and known as an adsorption isotherm.
FIG. 4 is a graph similar to FIG. 3 for a zeolite Y-85 adsorbent.
FIG. 5 is a graph similar to FIG. 3 showing the water isotherm for a rare earth exchange zeolite IZ-210 adsorbent.
FIG. 6 is a schematic diagram of the sorption cooling apparatus of Example V.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides adsorbent-substrate composites and methods for preparing the composites by coating an inside surface of a tube with a layer of solid adsorbent, preferably molecular sieve, and more preferably zeolite. Other aspects of the present invention relate to process for utilizing the adsorbent coatings.
The substrates used in the present invention provide structural support for the solid adsorbent layer as well as provide a suitable bonding medium for the solid adsorbent and binder. The substrate may be, for example, copper, aluminum metal, steel, glass, aluminized ceramic and other similar materials. It is not necessary for the substrate to be chemically treated or washed with solvent in order to practice the present invention, however the substrate should be relatively free from large amounts of foreign matter which may adversely affect bonding, such as dirt or grease.
Virtually any synthetic or naturally occurring solid adsorbent capable of maintaining its physical integrity during the coating process is suitable for use according to the present invention. The selection of the particular solid adsorbent will depend on factors such as its effective pore diameter and the particular end use intended. The term "effective pore diameter" is conventional in the art and is used herein to functionally define the pore size in terms of the size of molecules that can enter the pores rather than actual dimensions which are often difficult to determine as the pores are often irregularly shaped, i.e., noncircular. D. W. Breck, in Zeolite Molecular Sieves, John Wiley and Sons, New York, 1974, at pages 633 to 641, provides a discussion of effective pore diameter which is hereby incorporated by reference.
Although there are a variety of solid adsorbents which are suitable for use according to the present invention including but not limited to activated carbons, activated clays, silica gel, activated alumina and crystalline molecular sieves, molecular sieves are preferred for adsorption and catalysis because of their uniform pore size, i.e., effective pore diameter. These molecular sieves include, for example, the various forms of silicoaluminophosphates, and aluminophosphates disclosed in U.S. Pat. Nos. 4,440,871, 4,310,440, and 4,567,027, hereby incorporated by reference, as well as zeolitic molecular sieves.
Zeolitic molecular sieves in the calcined form may be represented by the general formula:
Me.sub.2/n O:Al.sub.2 O.sub.3 :xSiO.sub.2 :yH.sub.2 O
where Me is a cation, n is the valence of the cation, x has a value from about 2 to infinity and y has a value of from about 2 to 10.
Typical well known zeolites which may be used include, chabazite, also referred to as Zeolite D, clinoptilolite, erionite, faujasite, also referred to as Zeolite X and Zeolite Y, ferricrite, mordenite, Zeolite A, and Zeolite P. Detailed descriptions of the above-identified zeolites, as well as others, may be found in D. W. Breck, Zeolite Molecular Sieves, John Wiley and Sons, New York, 1974, hereby incorporated by reference. Other zeolites suitable for use according to the present invention are those having a high silica content, i.e. those having silica to alumina ratios greater than 10 and typically greater than 100. One such high silica zeolite is silicalite, as the term used herein includes both the silicapolymorph disclosed in U.S. Pat. No. 4,061,724 and also the F-silicalite disclosed in U.S. Pat. No. 4,104,294, hereby incorporated by reference.
Zeolites which are preferred for use in the present invention are those zeolites which permit the desorption of water at moderate to low temperatures and have a relatively low heat capacity. Such preferred zeolites may be selected from the group consisting of X and Y zeolites, and more particularly are selected from the group consisting of zeolite Y-85, low cerium exchanged zeolite Y-84 and rare earth exchanged IZ-210. Zeolite Y-85 is a stream stabilized modified zeolite Y the preparation of which is disclosed in U.S. Pat. No. 5,208,197 in column 7, line 16 to column 8 line 40 and is herein incorporated by reference. The low cerium exchanged zeolite Y-84 is prepared in a manner similar to the preparation of Y-85, except that the second ammonium ion exchange is carried out in the conventional manner at a pH well above 4.0 and the resulting zeolite is subjected to a rare earth exchange by contacting the zeolite with an aqueous solution of rare earth salt in the known manner. A mixed rare earth chloride salt can be added to an aqueous slurry of the ammonium exchanged zeolite to yield a zeolite product having a rare earth content generally in the range of 3.5 to 12.0 weight percent rare earth as RE 2 O 3 . The product is then water washed and calcined in dry air at a temperature of from about 55° C. to about 850° C., preferably 600° C. to about 750° C. for a period of time to reduce the unit cell dimension to less than 24.6 Angstrom and more particularly in the range of 24.4 to 24.6 Angstroms. The final low cerium exchanged zeolite Y-84 has a cerium content less than about 0.2 weight percent. Zeolite LZ-210 is defined in a U.S. Pat. No. 4,503,023 in column 12, lines 5-68. The rare earth exchanged zeolite LZ-210 may be prepared by subjecting the LZ-210 to a conventional rare earth exchange step followed by the dry air calcination step described above. U.S. Pat. No. 4,503,023 is hereby incorporated by reference.
For purposes of the present invention it is required that the solid adsorbent be agglomerated with a binder in order to ensure that the coating will have suitable physical properties. Although there are a variety of synthetic and naturally occurring binder materials available such as metal oxides, clays, silicas, aluminas, silica-aluminas, silica-zirconias, silica-thorias, silica-berylias, silica-titanias, silica-alumina- thorias, silica-aluminazirconias, mixtures of these and the like, clay type binders are preferred. Examples of clays which may be employed to agglomerate the zeolites without substantially altering the adsorptive properties of the zeolite are attapulgite, kaolin, volclay, sepiolite, halloysite, polygorskite, kaolinitc, bentonitc, montmorillonite, illite and chlorite. A kaolin binder in combination with silica is particularly preferred for practicing the present invention. The addition of a small amount of silica to the binder surprisingly permitted the bonding of the solid adsorbent to high conductivity materials such as copper and steel, as well as aluminized surfaces. The preferred amount of silica in the binder ranges from about 5 to 40 wt. % and more particularly ranges from about 20 to about 30 wt. % of the binder. It is to be understood that certain solid adsorbents, such as activated alma, can function adequately as both the adsorbent and the binder. Hence, in such a case, it is not necessary to utilize an additional binder. However, it may nonetheless be advantageous to use an additional binder, such as clay, for economic reasons, etc.
According to the present invention the substrate is coated with the solid adsorbent by contacting the surface of the substrate, after heating the surface as hereinafter described, with a slurry comprising the solid adsorbent and binder. The solid particles used in the slurry including both the solid adsorbent and binder material may be of any size to functionally suitable in the present invention. However, the solid adsorbent and binder are desirably present as small particles, preferably having a particle size of from about 1 to 500 microns more preferably from about 1 to 50 microns.
If necessary, the solid particles may be subjected to mechanical size reduction, e.g., grinding, crushing, milling and the like, in order to obtain the desired particle size. However, it is preferred that the solid particles be more smooth, and more preferably also more spherical, relative to solid particles of similar composition obtained by mechanical size reduction. Such particle smoothness and sphericity tends to improve evenness of the mating and may also allow increased solids loading in the slurry, if desired. One particularly useful processing step to achieve such smoothness and sphericity is to employ spray drying as part of the said particle manufacturing process to form the solid particles or precursors of the solid particles. An additional advantage of employing such spray drying is that the conditions of such step can be controlled so that the product solid particles are of a desired particle size or size range. The use of spray drying in such solid particle manufacturing is conventional and well known, and therefore need not be discussed in detail here. It is to be understood that the solid adsorbent and binder may be agglomerated and subjected to size reduction prior to forming the slurry, if desired.
The solid adsorbent and binder may be mixed in the slurry in a variety of proportions, whether as segregated or agglomerated particles, although it-is generally desirable to use only as much binder as is required to give sufficient strength to the coated surface. It is preferred that the adsorbent portion comprises about 60 to 95 wt. % of the total weight of solids, i.e., adsorbent and binder, in the slurry and that the remaining 5 to 40 wt. % comprises binder. In addition to the adsorbent and binder, the slurry may contain a dispersing agent or surfactant to aid in suspending the particles or vary the viscosity of the slurry. Suitable surfactants include for example, Dispex, a salt of a polymedc carboxylic acid available from Allied Colloids, Suffolk, Va., and TSPP, a tetrasodium pyrophosphate available from Monsanto, St. Louis, Mo. When a surfactant or dispersing agent is used, it is preferred that its concentration be in the range of about 0.5 to 5.0 wt. % of the solids content of the slurry.
While it can be appreciated that the solid adsorbent and binder can be suspended in a dry slurry, i.e., fluidized bed, it is desirable in accordance with the present invention that the slurry contain a suspending liquid. The suspending liquid should be one which is not likely to chemically react, e.g., by itself or with the substrate or other components in the slurry. More preferably, the suspending liquid should be substantially non-reactive and should not interfere with the internal pores of the solid adsorbent. Water is a preferred suspending liquid for use according to the present invention. The proportion of suspending liquid can be varied to adjust the viscosity of the slurry and hence, the thickness of the coating. The determination of the appropriate proportions to achieve the desired coating thickness can be made experimentally by measuring the thickness resulting from a given slurry and then either increasing the solids proportion, i.e. higher viscosity, to obtain a thicker coating, or decreasing the solids proportion, i.e., lower viscosity, to obtain a thinner coating. One way to determine the thickness of the coating is to calculate the area density coverage, i.e., the weight of solid adsorbent per unit area, and then divide by the density of the solid adsorbent. It is generally preferred that the solid materials comprise about 10 to 40 wt. %, and preferably about 20 to 40 wt. % of the total weight of the slurry, and more preferably about 25 to about 35 wt. % of the slurry with the balance preferably consisting essentially of the suspending liquid and any surfactants or dispersing agents.
In order to ensure sufficient bonding of the solid adsorbent to the substrate, it is necessary to heat the surface of the substrate in an oxygen containing atmosphere, preferably containing at least about 1 mol% oxygen and more preferably consisting of air, to a temperature of at least 300° C., preferably between about 300°-650° C. This heating preferably causes the surface of the substrate to become oxidized. While not wishing to be bound to any particular theory, it is suspected that the oxidation is at least partially responsible for achieving sufficient bonding.
The heated surface is then contacted with the slurry, preferably by dipping the surface into the slurry or by spraying the slurry onto the surface, to form a slurry-coated surface. In the case of coating the inside surface of a tube, it was found that heating the tube, stoppering one end of the tube, filling the tube with slurry and draining the tube after a period of time ranging from about 0.25 to 2 min., and preferably from about 0.5 to 1 min. provided an efficient method of uniformly coating the surface. If, after the initial contacting, it is desired to increase the thickness of the coating, additional contacting steps can be performed. When such additional contacting is performed, it is necessary to permit the coating to dry preferably in an oxygen containing atmosphere at a temperature of at least 100° C. for a period of at least 0.1 hours to preferably about 1 hour. It is preferred to preheat the coated surface to a temperature of about 300° C. before additionally contacting the surface with the slurry.
When the desired coating thickness has been obtained, the adsorbent coated surface is heated to a temperature and for a period of time sufficient to cause hardening of the coated surface. This temperature should be at least about 200° C., preferably between about 400° C. and 650° C., and most preferably between about 550°-650° C. The time required to cause hardening of the coated surface is desirably at least 0.1 hours and less than about 1 hour.
The resulting adsorbent-substrate composite comprises an underlying metallic layer and another layer bonded to the surface of the metallic substrate consisting essentially of adsorbent and binder. These coatings provide a high surface area as well as a minimum diffusion path for the components adsorbed on the adsorbent and hence, superior rates of adsorption compared to pelleted or beaded forms of adsorbent. Moreover, the adsorbent coatings have excellent physical durability and are resistant to chipping and flaking. Furthermore, despite differences in the thermal expansion properties between the adsorbent and the metallic substrate, the adsorbent coatings of the present invention advantageously retain their physical integrity even after repeated thermal cycling. In addition, when the present invention is employed in heat transfer equipment, and the adsorbent layer has a uniform thickness ranging from 0.6 to 3.0 mm, and preferably ranging from 1.0 to 1.2 mm, the adsorbent coating provides an acceptably small thermal resistance. Without wishing to be bound to any particular theory, it is thought that the heating step performed prior to the contacting step, in addition to causing oxidation of the substrate, may change the grain structure of the substrate to advantageously provide improved bonding properties.
In accordance with the present invention, adsorbents such as natural zeolites, synthetic zeolites, binders, and mixtures thereof may be applied to the inside surfaces of tubes for use in devices for cooling and heating by adsorption of a refrigerating fluid on a solid adsorbent. The preferred tubes are thin-walled and may have a plurality of fins disposed on the outside surface of the tubes. The inside surface of the tube is coated with a thin layer of solid adsorbent between about 0.1 and less than 3 mm thick. Preferably, the layer of solid adsorbent, such as zeolite, has a uniform thickness of between about 0.6 and about 1.6 mm, and most preferably, the uniform thickness of the solid adsorbent layer is between about 1.0 and 1.2 mm. The coated tubes are typically evacuated to a high vacuum of at least 1 micron of mercury at a temperature of at least 350° C. for a period of at least about 2 to 4 hours, filled with a refrigerant, such as water, propane, butane, ammonia, CO 2 , SO 2 , sulfur hexafluoride, Refrigerant 11, Refrigerant 12, Refrigerant 21, and Refrigerant 22, light alcohols and mixtures thereof, and sealed in a closed system by either sealing both ends of the tube or by providing a closed refrigerant circuit comprising a reservoir, an evaporator, and a condenser.
Particularly with respect to FIG. 1A of the drawings, one embodiment of the desiccant cooling apparatus of the present invention is indicated generally at 10. The desiccant cooling apparatus 10 comprises a housing 16 having a first fluid inlet 14 and a first fluid outlet 18 and a second fluid inlet 20 and a second fluid outlet 22 and an interior 11. A plurality of zeolite-lined exchanger tubes 24 extend longitudinally within the interior of the housing. The tubes are aligned with each other and spaced to permit transverse fluid flow. Header plates 12 and 28 are disposed on each end of the tubes. A partition 40 divides the interior of the housing into a first zone and a second zone. The first zone is in fluid communication with the first fluid inlet and first fluid outlet for the flow of a first fluid therethrough. The second zone is in fluid communication with the second inlet and the second outlet to permit the flow of a second fluid therethrough. End cap 32 is disposed at the ends of the housing in sealing contact with the header plates defining a third zone which is in fluid communication with the interior space of the tubes. A valve 34, disposed on the end cap is in fluid communication with the third zone.
Referring to FIG. 1B which is a detail of FIG. 1A, a partition 40 is shown at a point between the ends of the tubes. The partition and the header plates have a plurality of holes 42 for inserting the tubes therethrough and are aligned generally transverse to the tubes. The header plates 12, 28 and the partition 10 are disposed in sealing contact with the tubes.
Referring to FIG. 1C which is a detail of FIG. 1B, a view of a zeolite-lined tube is shown. A zeolite composition 52 is slip-coated, or bonded directly to the inside surface 50 of the zeolite-lined tube. The zeolite-lined tube has an interior space 53 containing a refrigerant. A sealing means 43 disposes the tubes in sealing contact with the header plates and the partition prevents fluid flow beyond the header plates or the partition. A second sealing means 45 disposed on the partition prevents fluid flow from one side of the partition to another.
With respect to FIG. 2, another embodiment of the desiccant cooling apparatus is shown at 70. The desiccant cooling apparatus is configured in a manner as described with respect to FIG. 1 with the overall shape of the apparatus arranged to permit vapor or gas flow through the first and second zones. Similar elements between FIGS. 1A, 1B, 1C and FIGS. 2A and 2B are shown with the same numbers. Fins 54 are shown disposed on the tubes in FIG. 2B.
The zeolite coated heat exchanger tube may be employed in a heat pump or refrigeration cycle which operates between a hot fluid temperature and a cold fluid temperature. The solid adsorbent and refrigerant combination is selected according to those boundary conditions of the heat pump or refrigeration cycle, so that at least a portion of the refrigerant will be desorbed from the solid adsorbent at the hot fluid temperature and at least a portion of the refrigerant will be adsorbed at the cold fluid temperature. Preferably, the hot fluid temperature selected for the operation of the process will be relatively constant and range from about 80° C. to about 250° C. In the practice of the invention, the hot fluid may be an exhaust gas from any industrial process or an internal combustion engine. Generally, any fluid or gas stream at ambient conditions can be employed as the cold fluid. Preferably, the cold fluid temperature will be less than the hot fluid temperature and range from about 20° C. to about 50° C. Preferably, the lower desired temperature to which the feedstream is to be cooled will range from about 20° C. to about 0° C.
The process of the invention to refrigerate a feedstream from an available temperature to a lower desired temperature will comprise a series of sequential steps. A first fluid at a hot fluid temperature is passed to a first zone of a desiccant cooling apparatus containing at least one zeolite-lined tube. The zeolite-lined tube has a first portion in the first zone and a second portion in a second zone of the desiccant cooling apparatus. The zeolite tube is prepared in the manner of the present invention and has a uniform lining of an adsorbent. The zeolite-lined tube has an inner space containing a refrigerant. The passing of the hot, first fluid on the outside of the zeolite-lined tube causes the refrigerant adsorbed thereon to be desorbed to produce a vaporized refrigerant stream. The vaporized refrigerant stream is passed to the second tube portion. Simultaneously, a second fluid at a second temperature, preferably at the cold fluid temperature is passed to the second zone of the desiccant cooling apparatus. In the second zone, the second fluid contacts the outside of the zeolite-lined tube, cooling the second portion of the zeolite-lined tube and resulting in the condensation and readsorption of at least a portion of the refrigerant within the second portion of the zeolite-lined tube. These simultaneous steps are terminated at a point midway in the cycle. At this point the flows are switched such that the second cold fluid is passed to the first zone to heat the second fluid, thus removing heat from the first zone. Simultaneously, the feedstream to be cooled is passed to the second zone and the feedstream at the lower desired temperature is withdrawn. These later steps are terminated after a period of time and the cycle is complete. To provide continuous cooling, at least one other desiccant cooling apparatus may be operated with a cycle which is offset from the above cycle by at least one-half of the cycle. In an automobile, the at least one other desiccant cooling apparatus may be insulated from the first desiccant cooling apparatus and be contained within a common housing. In practice, the second fluid may be a portion of the feedstream which may be ambient air or a process stream comprising light hydrocarbons or air. Furthermore, it is within the scope of the present invention to separate the adsorption and generation sections of the process whereby the first zone contacting the first tube portion and the second tube portion are physically separated and refrigerant flows thereinbetween through any number of conduits and heat exchangers.:
Furthermore, each solid adsorbent and refrigerant combination will have a saturation value which refers to the equilibrium amount of refrigerant which will be adsorbed by the solid adsorbent as the vapor pressure in equilibrium with the adsorbent approaches the saturation vapor pressure of the refrigerant at the adsorbent temperature. For example, a Zeolite 13X-water system has a saturation value from about 20% to about 28% weight of the zeolite. For the operation of the zeolite-lined heat exchanger tube, the tube is filled up to about 50% of the saturation value to permit at least half of the tube to operate in the hot fluid region and the remaining portion to operate in the cold fluid region. In this manner, desorption will take place at the hot fluid, or first end of the tube while adsorption and any condensation will take place at the cold fluid, or second end of the tube. Thus, for the Zeolite 13X-water system, about 50% of the saturation value of the zeolite layer is from about 10% to about 14% weight of the zeolite layer.
Therefore, in the process of preparing a zeolite coated heat exchanger tube, following the activation of the zeolite layer by heating and evacuation for a sufficient time, the tube is cooled to an appropriate temperature and brought into equilibrium at an appropriate pressure with a refrigerant vapor such that the level of refrigerant vapor in the tube is up to about one-half the saturation value of the zeolite layer. At this point the tube is sealed at the first and second ends, or the system is closed.
The outside surfaces of the tubes may be provided with fins or similar devices to facilitate the heat transfer between the shell side fluids and the refrigerant. Preferably, the tubes will be thin-walled and constructed of aluminum or similar high heat conductivity material with a low mass. Preferred high heat conductivity materials include aluminum, copper, steel, ceramics, glass, aluminized steels, and alloys thereof.
EXAMPLES
The following examples are provided for illustrative purposes and are not intended to limit the scope of the claims that follow.
EXAMPLE I
A low cerium rare earth exchanged Y-84 was prepared from zeolite Y-84. Y-84 is the ammonium form of stabilized Y zeolite with an A o of 24.55 Angstroms, an NH 4 /Al of 0.3 and a Na/Al of less than 0.1. The Y-84 was obtained from UOP in Des Plaines, Ill. The Y-84 was subject to a rare earth chloride exchange with a mixed rare earth chloride salt coning 24.5 wt. % Lanthanium and 0.8 wt. % cerium. The material was water washed at a rate of 6 pounds of hot water per pound of Y-84. The product was subjected to calcining in dry air at a temperature of about 650° C. The resulting product had an A o of 24.51, a rare earth loading of about 5.5 wt. %, a Si/Al 2 O 3 ratio of 5.2, an oxygen capacity of 28.1, a water capacity of 24.08 and a cerium content of less than 0.2 wt. % on a dry basis.
EXAMPLE II
The inside surface of a 12 inch length of copper tube, 3/4" in diameter, was lined with the low cerium rare earth exchanged Y-84 adsorbent. Example I, according to the coating method of the present invention. The inside surface tube was sand blasted to clean the surface. The tube was heated to a temperature of about 300° C. in an oxygen containing atmosphere and one end of the tube was stoppered. A slurry with the following composition: 80% Adsorbent, 15% Kaolin and 5% Silica was poured into the tube. After about 1 minute, the stopper was removed and the slurry permitted to flow out of the tube. The solids content of the slurry was about 35 wt. % in water, the suspending liquid. No dispersion agent was added. It was found that the addition of the silica (SiO 2 ) to the binder was critical to obtaining a uniform bonding of the adsorbent to the inside surface of the copper tube. The coated tube was then dried in air at about 100° C. for about 1 hour. Following the drying step, the tube was preheated to a temperature of about 300° C., stoppered and refilled with slurry for about 1 minute. This procedure was repeated 4 times to obtain a uniform coating of adsorbent with a thickness of about 1.0 to 1.2 mm on the inside of the tube. On removing the slurry from the tube after the final coating, the tube was heated at about 550° C. for a period of about one hour to calcine the adsorbent and harden the adsorbent coating. It was found that preheating the tube between slurry applications improved the bonding. However, it was discovered that heating the clay above 500° C. between applications could convert the Kaolin to a metaKaolin structure which would prevent further application.
EXAMPLE III
A 12 inch length of a tube with an inside copper substrate was lined with zeolite Y-85 by following the method of the present invention and the procedure of Example II.
EXAMPLE IV
A modified BET adsorption apparatus to measure the volumetric adsorption of an adsorbent was employed to produce an adsorption isotherm for the adsorbent coated tube. Temperature and pressure measurements in a vessel of known volume were made and a weight loading was calculated. The results were plotted as a function of pressure over a range from 10 -6 tort to about 1 atmosphere. FIG. 3 presents the adsorption isotherms for the low cerium rare earth exchanged zeolite Y-84 and water developed at 25°, 50°, and 80° C. FIG. 4 presents adsorption isotherms for zeolite Y-85 and water at 25°, 50°, and 80° C. FIG. 5 presents the adsorption isotherms for a rare earth exchanged LZ-210 and water at 25° and 80° C. A comparison of the delta loadings between 80° C. and 25° C. at a pressure of 0.5 kPa for these three adsorbents is shown in the Table 1 below:
TABLE 1______________________________________DELTA LOADING WT % AT PRESSURE OF 0.5 kPaADSORBENT @ 80° C. @ 25° C. Δ LOADING, WT %______________________________________Y-85 4 20 16CRE-84 3 19 16RE-LZ210 4 20 16______________________________________
The above adsorbents exhibit a similar tendency for the adsorption of water at ambient conditions and the desorption of water at the relatively low temperature of 80° C. with delta loadings of about 16 wt % between 25° C. and 80° C.
EXAMPLE V
The zeolite-lined tubes of Example II and Example III were used to construct two single tube, tube in shell, heat exchangers by enclosing the outside of the zeolite-lined tubes in separate steel jackets, each jacket having a fluid inlet and a fluid outlet. The zeolite-lined tubes, 110 and 120, were assembled as shown in FIG. 6 to operate in a sorption cooling process with water as the refrigerant. The major components of the process were the condensing heat exchanger 130, the condenser receiver 140, the evaporating heat exchanger 160 and the refrigerant reservoir 150. The condenser receiver was a 10 ml vial and the refrigerant reservoir was a calibrated vessel with a 50 ml capacity. The flow of water to the evaporating heat exchanger 160 was controlled by needle valve 170. The first zeolite-lined tube 110 was connected to the condensing heat exchanger 130 by line 111 valve 112 and lines 113 and 114. Similarly, the second zeolite-lined tube was connected to the condensing heat exchanger by line 116, valve 115 and lines 113 and 114. The first zeolite-lined tube is connected to the evaporating heat exchanger 160 by line 123, valve 122 and lines 121 and 119. The second zeolite-lined tube 120 by line 117, valve 118 and lines 121 and 119.
During the experiments, a heated fluid was supplied to one zeolite-lined tube while supplying ambient temperature fluid to the other tube. Ambient temperature fluid was continuously supplied to both the condensing heat exchanger and the evaporating heat exchanger. The experiments were begun with a full evaporator reservoir and an empty condenser receiver. One tube was activated at a regeneration temperature of about 80° C. while the other was brought to near a saturated state by exposure to the evaporator reservoir. The entire system was evacuated so that the total pressure of the system was in equilibrium with the adsorbent loading at ambient temperature. This value is approximately equal to the vapor pressure of water at the ambient temperature.
The experimental cycle was begun by applying heated fluid at a per selected regeneration or desorption temperature to the saturated tube, putting it in generation mode, while the activated tube was maintained at ambient temperature by cooling stream, putting this tube in the adsorber mode. After one-half the cycle time had elapsed, the heating and cooling streams and the valve settings were switched so that the tube which was in the generation mode was now in fluid communication with the evaporator, and the tube which was in the adsorber mode was put in fluid communication with the condenser and an amount of condensable was collected in the condenser receiver. The remainder of the cycle was carried out and the procedure was repeated until the receiver was full.
The tubes were cycled between heating mode and cooling mode in a cycle that required a total time of about 6 minutes, equally divided between heating and cooling. The results of the experiments are summarized in Table 2. Each entry in Table 2 represents a separate run at increasing regeneration temperatures ranging from 65° C. to 96° C. below:
TABLE 2__________________________________________________________________________Ave. Amt. of Ave. Water Regen CoolingWater Loading/Cycle/ Temp, °C. Evap CapacityCondensed ml Tube wt % (Ave) Temp, °C. BTU/Hr/Ft.sup.3__________________________________________________________________________A 0.5 3.6 65 17.5 3761B 0.63 4.5 70 16.5 4751C 0.73 5.2 76.7 16.5 5496D 0.76 5.4 80.7 14.5 5733E 0.76 5.4 85.5 16.5 5737F 0.78 5.4 85.5 15.8 5899G 0.85 6.1 89.6 15.5 6406__________________________________________________________________________
The cooling capacity was derived from the amount of condensate adsorbed and the heat of vaporization of the refrigerant, water. The measured cooling capacities for the zeolite-line tubes of the instant invention were at least twice that reported in the literature. The average overall heat transfer coefficient for the zeolite-lined tubes was approximately 175 W/m 2 /K. | A desiccant cooling apparatus and process using a solid adsorbent and refrigerant wherein the solid adsorbent is selected from the group consisting of zeolite Y-85, a low cerium rare earth exchanged Y-84 and a rare earth exchanged LZ-210, and the adsorbent is bonded directly to the heat exchange tubes within the device by a novel slip coating process resulted in significant improvements in thermal efficiency and overall performance. | 5 |
RELATED APPLICATION
The present application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application Ser. No. 61/228,779, filed Jul. 27, 2009, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present invention relates generally to the field of process equipment used in the semiconductor, data storage, flat panel display, as well as allied or other industries. More particularly, the present invention relates to etching closely-spaced features on substrates in plasma-based process equipment.
BACKGROUND
Semiconductor device geometries (i.e., integrated circuit design rules) have decreased dramatically in size since integrated circuit (IC) devices were first introduced several decades ago. ICs have generally followed “Moore's Law,” which means that the number of devices fabricated on a single integrated circuit chip doubles every two years. Today's IC fabrication facilities (i.e., “fabs”) are routinely producing 65 nm (0.065 μm) feature size devices, and future fabs will soon be producing devices having even smaller feature sizes.
In most IC fabrication facilities, part of the fabrication process involves employing plasma in process equipment to either react or facilitate a reaction with a substrate such as a semiconductor wafer. Plasma processing is used for a wide variety of applications including etching of materials from substrates, deposition of materials onto substrates, cleaning of substrate surfaces, and modification of substrate surfaces.
As feature sizes have become smaller, the aspect ratio, or the ratio between the depth and the width of the feature has steadily increased. Fabrication facilities are currently etching materials into features having aspect ratios of from about 50:1 to 100:1 or greater. Traditionally, features having aspect ratios of about 10:1 were produced by anisotropic etching dielectric layers to a predetermined depth and width. However, when forming higher aspect ratio features, anisotropic etching using conventional sidewall passivation techniques has become increasingly difficult to control. Resulting features have non-uniform spacing or non-uniform profiles, thus losing designed critical dimensions (CDs) of the features.
Etching deeply-recessed features is a principal technology used to fabricate capacitive storage nodes, contact vias, and trench features into semiconductor structures. Strict control of etch profiles is needed to provide deeply etched features having required CDs.
Due to the ever-decreasing size of device structures, the thickness of a photoresist layer must be carefully controlled to meet critical feature dimensions. The thickness of the photoresist is often in the range of about 250 nm or less. A hard masking material is used under the photoresist to provide sufficient time for deep-etching of an underlying substrate without etching through the patterned mask.
A carbon-containing gas is frequently used as at least one of the etchant gases during plasma deep-etching into a substrate underlying the photoresist mask and the hard mask. The carbon-containing gas contributes polymer-forming materials onto various exposed surfaces fabricated on the substrate. The polymer-forming materials can frequently plug openings in features being etched and have deleterious effects on parameters such as top CD and CD bias uniformity. In the worst case, openings to smaller CD features which are to be etched may become completely plugged if a resulting polymeric residue is sufficiently thick. Once plugged, the etching stops. Using increased power to drive the etch plasma, for purposes of increasing etch rate, typically leads to an increase in the amount of hard, silicon-containing polymeric residues that are re-deposited on various surfaces. Thus, concerns about formation of the residues affects an ability to increase the etch rate during etching of a deeply recessed structure.
Yet another challenge associated with etching features with high aspect ratios is controlling the etch rate in features formed through multiple layers and having different feature densities. In such a case, each layer may etch at a different rate depending on feature density.
With reference to FIG. 1 , a substrate 101 includes a dielectric film layer 103 with a plurality of high density features 109 and an isolated feature 111 formed from an underlying film 105 or bulk material (not shown). Each of the features 109 , 111 is capped with a combination photoresist layer/hard mask 107 . Faster etch rates occur proximate to the isolated feature 111 and often result in selectively over etching the dielectric film layer 103 . In contrast, slower etch rates occurring proximate to the high density features 105 frequently have unetched portions 113 .
As features move toward even higher aspect ratios and densities, maintaining efficient etching rates over the low and high feature density regions without either under-etching the upper layers or over-etching into the lower layers has become increasingly difficult to control. The failure to form the features or patterns on the substrate as designed may result in unwanted defects. Further, subsequent process steps are adversely affected, ultimately degrading or disabling the performance of the final integrated circuit structure.
Another problem in etching features with high aspect ratios is the occurrence of a micro-loading effect. Micro-loading is also known as “aspect ratio dependent etch” or “RIE lag” and is a measure of the variation in etch dimensions between regions of high and low feature densities. Low feature density regions (e.g., isolated regions) receive more reactive etchants per surface area compared with high feature density regions (i.e., dense regions) due to larger total openings of the surface areas, thereby resulting in a higher etching rate in the low density regions. Sidewall passivation layers generated from etch by-products exhibit similar pattern density dependence where thicker passivation layers are formed for the isolated features due to more by-products being generated in the region. The difference in reactants and the passivation per surface area between these two regions increases as feature density differences increase.
Referring now to FIG. 2A , differences in etch rates and formation of by-products between high and low feature density regions cause various differences in sidewall etch. An isolated or low feature-density region 203 typically etches with a desired shape and controlled lateral dimensions. In contrast, a high feature-density region 201 has sidewall regions 205 which are frequently bowed or undercut by the lateral etching due to insufficient sidewall passivation.
The bowing of the device feature can cause various deleterious effects including increased difficulty in performing subsequent process steps after the plasma etch. For example, if features in a shallow trench isolation (STI) are bowed due to a damage caused by the plasma etch process, a subsequent chemical vapor deposition (CVD) process used to fill the space between the STI features with an electrically insulating layer will leave a seam or void in the layer.
To avoid the lateral etching of sidewalls, an oxidation step (e.g., thermally formed or deposited silicon dioxide, SiO 2 ) is typically used to avoid insufficient sidewall passivation and a resulting lateral sidewall etch. However, the SiO 2 layer is formed by combining oxygen with silicon. In a thermal oxidation process, 44% of the SiO 2 layer is consumed silicon. Thus, the oxidizing step comes at the expense of the remaining silicon resulting in additional bowing and CD enlargement once the oxidized layer is removed.
As indicated by FIG. 2B , other process techniques result in a low feature-density region 253 etching at a faster rate with more passivation than a high feature-density region 251 . The higher etch rate results in a tapered top portion 255 on etched sidewalls. Therefore, insufficient sidewall protection associated with the different etch rates in high and low feature-density regions with high aspect ratios often results in an inability to hold critical dimensions of the etch features and a resulting poor pattern transfer.
The tapered top portion 255 eventually leads to an etch depth micro-loading problem at a location where a multitude of features are closely populated thus affecting an overall CD of the features. Thus, it is becoming increasingly more difficult to etch closely populated features with small space CDs using contemporary continuous plasma etch processes.
Therefore, what is needed is an improved method to simultaneously etch high aspect ratio features of high and low feature-density regions while maintaining uniform CDs of the features.
SUMMARY
In an exemplary embodiment, a method of producing a plurality of etched features in an electronic device is disclosed. The method comprises performing a first time-divisional plasma etch process step within a plasma chamber to a first depth of the plurality of etched features, performing a flash process step to remove any polymers from exposed surfaces of the plurality of etched features without requiring an oxidation step, and performing a second time-divisional plasma etch process step within the plasma chamber to a second depth of the plurality of etched features.
In another exemplary embodiment, a method of producing a plurality of etched features in an electronic device is disclosed. The method comprises performing a first time-divisional plasma etch process step within a plasma chamber to a first depth of the plurality of etched features, evacuating the plasma chamber of any etchant chemicals, performing a flash process step to remove any polymers from exposed surfaces of the plurality of etched features without requiring an oxidation step, evacuating the plasma chamber of any cleaning chemicals, and performing a second time-divisional plasma etch process step within the plasma chamber to a second depth of the plurality of etched features.
In another exemplary embodiment, a method of producing a plurality of etched features in an electronic device is disclosed. The method comprises performing a first time-divisional plasma etch process step within a plasma chamber to a first depth of the plurality of etched features, and performing a flash process step to remove any polymers from exposed surfaces of the plurality of etched features without requiring an oxidation step. The flash process step is performed independently of the time-divisional plasma etch step. A second time-divisional plasma etch process step is performed within the plasma chamber to a second depth of the plurality of etched features.
BRIEF DESCRIPTION OF THE DRAWINGS
Various ones of the appended drawings merely illustrate exemplary embodiments of the present invention and must not be considered as limiting its scope.
FIG. 1 is a cross-sectional view of etched features of high and low feature-density regions of the prior art.
FIG. 2A is a cross-sectional view of etched features of high and low feature-density regions of the prior art where the high density-feature regions exhibit pronounced bowing.
FIG. 2B is a cross-sectional view of etched features of high and low feature-density regions of the prior art where the low density-feature regions exhibit pronounced tapering.
FIG. 3 is a simplified flowchart of an exemplary process flow of the present invention.
FIG. 4 is a cross-sectional view of high density features etched using the exemplary process flow of FIG. 3 .
DETAILED DESCRIPTION
The novel etch process described herein is effective in controlling both the vertical nature and the CDs of etched features as compared with prior art methods which involve a continuous plasma etch process and produce non-vertical and non-uniform sidewalls. As discussed above, typical high aspect ratio features, typically etched with a continuous plasma etch process, exhibit either pronounced bowing or tapering as the plasma etch proceeds. Additionally, the continuous plasma etch method exhibits substantial micro-loading.
In contrast, high aspect ratio features etched with various embodiments of the present invention, described below, have more vertical profiles combined with a minimal micro-loading depth and improved CDs.
Various embodiments of the present invention provide a novel plasma etch process comprising at least two cycles of time-divisional plasma etch (TDPE) steps, and one or more polymer-removal process (i.e., flash process) steps. The flash process step is performed at least once after an initial TDPE step is performed. Further, each of the various embodiments described herein alleviates the problem of micro-loading as structures are uniformly etched regardless of structural density on the substrate.
With reference to FIG. 3 , an exemplary TDPE process 300 employed in, for example, a plasma etch chamber (not shown) includes an optional flash process step 301 prior to beginning a plurality of time-divisional plasma etch (TDPE) process steps. The optional flash process step 301 may be used as, for example, a break-through (BT) process step. If used, the BT process step, described in more detail below, is often used to remove various materials from the features to be etched. The various materials include dielectric layers formed such as silicon dioxide (SiO 2 ), silicon nitride (Si 3 N 4 ), and so on. Dielectric layers may be removed with a halogen-containing gas such as hydrobromic acid (HBr).
Either as an initial step or after the optional flash process step 301 , a first TDPE process step 303 is performed to etch the features to a first depth. The first TDPE process step 303 etches features on a substrate (not shown) to a first level. The plasma etch chamber is evacuated of any etchant gases. A flash process step 305 (i.e., a cleaning step) is next performed to remove any polymers or polymer residues that may remain on the features undergoing etch. The plasma chamber is then evacuated of any flash process feed gases. A second TDPE step 307 is performed to etch the features to a second depth. A determination 309 is then made whether the etch process is complete. If not, additional TDPE and flash process steps may be performed. If the etch is complete, the process ends. A skilled artisan will realize that after a determination 309 is made that an etch process is not complete, only one additional TDPE process step may be needed without any additional flash process steps.
In a specific exemplary embodiment involving formation of a shallow-trench isolation (STI) structure formation, the process recipe indicated in Table I, below, may be employed.
TABLE I
Process
Chamber
Plasma
Chuck
Gas &
Process
Pressure
Power
Voltage
Flow
Time
Temp
Step
[mT]
[Watts]
[V]
[SCCM]
[sec]
[° C.]
BT
10
500
200
CF 4 @ 100
5
30
STI
10
600
200
NF 3 @ 10
25
30
1 st Etch
HBr @ 500
1 st
10
800
0
CF 4 @ 100
10
50
Flash
STI
10
600
200
NF 3 @ 10
25
30
2 nd Etch
HBr @ 500
2 nd
10
800
0
CF 4 @ 100
10
50
Flash
STI
10
600
200
NF 3 @ 10
25
30
3 rd Etch
HBr @ 500
3 rd
10
800
0
CF 4 @ 100
10
50
Flash
STI
10
600
200
NF 3 @ 10
25
30
4 th Etch
HBr @ 500
4 th
10
800
0
CF 4 @ 100
10
50
Flash
As indicated by the specific exemplary process recipe of Table I, four TDPE STI etch steps are employed, each using two feed gases with each feed gas flowing at a different volumetric flow rate (standard cubic centimeters per minute, sccm). Additionally, a flash process step is performed initially as a BT step (for 5 seconds) and a separate flash process step (at 10 seconds each) is performed subsequent to each TDPE STI etch step. All process steps are performed at a chamber pressure of 10 milliTorr (mT).
Thus, in this specific exemplary embodiment, a TDPE process step is repeatedly performed for a pre-determined number of cycles while alternately performing a flash process step after each TDPE step. The alternate TDPE and flash process steps allow formation of a feature of pre-determined dimension and shape. Moreover, multiple flash processes may be modulated or adjusted for various desirable effects.
In other embodiments, the flash process step may be performed either with or without employing a plasma. Other energy types, such as, for example, thermal energy or photon energy may optionally be supplied to a flash process chamber during the flash process step. Additionally, the flash process can be performed either with or without a bias voltage applied to the substrate. The flash process step can be performed in either the process chamber employed for the TDPE process steps or may, alternatively, be performed in any other chamber.
Unlike prior art process steps in which intermittent cleaning steps are inserted into a continuous etch process, embodiments of the present invention avoid mixing etch and flash chemistries. Prior art chemical mixing can cause detrimental effects, such as a bowed profile (e.g., see FIG. 2 ) since some advantageous polymer layer formed in the etch process is immediately removed by coexisting cleaning chemistries. A proper amount of polymer layer avoids damage to features undergoing etch.
Further, prior art process steps frequently employ an oxidation step followed by an intermittent cleaning step with a fluorine-containing gas. As disclosed herein, the present invention does not require an oxidation step following the etch step. Thus, a throughput of, for example, an STI etch process maintains vertical feature profiles and reduces or eliminates micro-loading since the oxidizing process is not required.
Referring now to FIG. 4 , an exemplary high density structure 400 incorporates a plurality of features formed on a substrate 409 . Each of the plurality of features is capped with an etching mask 401 , such as photoresist or a hard mask. Various types of etching masks, usable in different etching environments, are known independently in the art.
With concurrent reference to the exemplary TDPE process 300 of FIG. 3 , described above, effects of TDPE process steps are reflected in the exemplary high density structure 400 . After a first TDPE process step, a first depth 403 is reached. A process chamber (not shown) in which the substrate 409 is placed is evacuated and a subsequent first flash process step is performed. A second TDPE process step increases the amount of etch to a second depth 405 . The process chamber is again evacuated and a second flash process step is performed. A third TDPE process step increases the amount of etch to a third depth 407 .
Contrary to many prior art continuous plasma etch processes in which formation of a polymer and its removal occur simultaneously on a surface of an etched feature, the present invention provides one or more flash steps before and/or after the time-divisional plasma etch (TDPE) step until a feature of a desired dimension is formed. Thus, any polymer layer formed, which can result in tapering as described above, can effectively be removed and the subsequent tapering prevented. Consequently, the combined TDPE/flash process results in a feature having increased verticality that is less prone to micro-loading profile effects than possible under continuous plasma processes of the prior art.
Further, by performing a pre-determined number of TDPE and flash process steps, the etch depth can accurately and precisely be controlled. By modulating the process time of the TDPE and flash process steps, the shape, the CD of the feature, and the CD spacing can readily be controlled.
Additionally, by modifying portions of the two main elements of the present invention, other detrimental effect of a plasma etch process, such as bowing of the feature, can be controlled.
The present invention is described above with reference to specific embodiments thereof. It will, however, be evident to a skilled artisan that various modifications and changes can be made thereto without departing from the broader spirit and scope of the present invention as set forth in the appended claims.
For instance, particular embodiments describe a number of chemical types used in various amounts and configurations. A skilled artisan will recognize that these chemical types may be varied and those shown herein are for exemplary purposes only in order to illustrate the novel nature of the time-divisional plasma etch concepts. A skilled artisan will recognize that, for example, fluorine- and chlorine-based etchant feed gases may readily be employed along with or instead of halogen-based feed gases.
Moreover, the term semiconductor should be construed throughout the description to include data storage, flat panel display, as well as allied or other industries. These and various other embodiments are all within a scope of the present invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | A method of producing plurality of etched features in an electronic device is disclosed that avoids micro-loading problems thus maintaining more uniform sidewall profiles and more uniform critical dimensions. The method comprises performing a first time-divisional plasma etch process step within a plasma chamber to a first depth of the plurality of etched features, and performing a flash process step to remove any polymers from exposed surfaces of the plurality of etched features without requiring an oxidation step. The flash process step is performed independently of the time-divisional plasma etch step. A second time-divisional plasma etch process step is performed within the plasma chamber to a second depth of the plurality of etched features. The method may be repeated until a desired etch depth is reached. | 7 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a flexible curtain rapid door.
BRIEF DISCUSSION OF RELATED ART
Flexible curtain doors, whether they be vertical folding or roller or horizontal retraction doors, have the particular feature of being operated at high linear speeds. These high opening and closing speeds are made possible by the low inertia of the flexible curtain usually made of PVC or a similar flexible material.
It is therefore essential to protect the operation of these doors and prevent, during an accidental collision between a person or an object and the curtain, crushing or damaging the person, the object or the curtain.
There are several systems providing a certain protection of the operation of flexible screen rapid doors by the detection of objects or of people that are accidentally under the curtain or immediately next to the latter when it closes.
A first detection system provides for fitting a perimeter of presence detectors around the door. Usually several presence detectors are necessary to protect a sufficient perimeter to detect the presence of a person or an object during a closing phase of the door, which then has a risk of collision and crushing or of damaging the curtain. These systems are however costly and may be sensitive to false alarms.
There are also detection systems operating on the principle of detection of a contact. The detection of a contact during the closing phase of the curtain generates a signal, usually electric, that causes the closure phase of the curtain to stop.
In the case of a curtain fitted with reinforcing bars particularly in its bottom portion, a known detection system consists in adding a detection means beneath the bottom rigid reinforcing bar. This detection means which, for example, may be an air bolster, is squashed against the rigid bar during a collision with a person or an object.
The squashing of the detection means against the rigid bar is converted into an electric signal that causes the curtain to stop and immediately reopen.
In the case of an air bolster that collides with a person, the latter is squashed against the bottom rigid bar of the curtain. This squashing causes an excess pressure in the bolster that is detected by a pressure switch.
This type of protection system has many disadvantages in use.
In the first place, they can detect only objects that are accidentally situated in the opening plane of the curtain, that is to say in the vertical of the bottom bar.
A second major disadvantage is that the detection means are in the bottom portion of the curtain beneath the bottom rigid bar. Consequently, these detection means are exposed to much damage. The first damage is repeated contact with the ground in the case of a vertical folding or roller door, or with an upright in the case of a horizontal retraction door. This leads to extremely rapid wear of these detection means. In addition, when the door is open, the detection means may be caught or damaged by machines passing through the door. In the event of a malfunction of the detection system, the curtain can only descend, crushing the person or the object that is in its trajectory and itself being damaged as might happen.
An additional disadvantage of this type of detection means is that, in the case of a collision on a horizontal component, the collision occurs between a person, for example the head of this person, and the bottom bar that is heavy and rigid, which may cause possibly serious injuries. Similarly, a collision with a machine may also have major consequences for the object or the machine passing through the door, and for the contact detection means that are directly exposed since they are suspended on the bottom bar.
In addition, these detection means have a response time that may be relatively long, which renders them ineffective when they are fitted to flexible curtain rapid doors. Specifically, the detection means are placed in a flexible band suspended beneath the bottom bar; the thinness of this band that covers the detection means causes this band to be squashed before the drive motor of the curtain stops. Despite the action of the detection means, a contact inevitably occurs with the bottom rigid bar, which may, possibly have serious consequences.
BRIEF SUMMARY OF THE INVENTION
The invention proposes a flexible curtain rapid door having means for detecting a collision between a flexible curtain and a person or an object that are reliable and largely insensitive to wear.
The invention further proposes a flexible curtain rapid door having detection means that may detect a collision occurring in a horizontal direction between a flexible curtain and a person or an object.
In a manner known per se, a rapid door comprises:
a structure comprising uprights and a transverse element making it possible to guide a curtain, electromechanical means supported by the structure making it possible to maneuver the curtain between an open position and a closed position, the curtain having, at its free end, a ballast and sealing element.
According to the invention, the door has obstacle detection means supported at least partly by the reinforcing element, said obstacle detection means being adjacent to the ballast and sealing element and situated upstream of the latter, on the closing trajectory of the curtain, between the reinforcing element and the ballast and sealing element and in that said obstacle detection means are incorporated inside the bottom portion of the curtain.
Thus, the idea at the basis of the invention is to incorporate into the curtain itself obstacle detection means for protecting the operation of the door.
This is done by placing them upstream of the ballast and sealing element. “Upstream” means above the ballast and sealing element in the case of a vertical-opening door and behind the ballast and sealing element in the case of a lateral-opening door, the term “upstream” having to be understood relative to the closing trajectory of the curtain. The detection means are protected mechanically by the ballast and sealing element. They are triggered, when appropriate, by the deformation of the ballast and sealing element when the curtain comes into contact with an obstacle that is beneath the curtain when it closes, in the case of a vertical-action door, or when the curtain comes into contact with an obstacle that is on the closing trajectory, in the case of a horizontal-action door.
It is also noted that, in the case where the ballast and sealing element is flexible, it deforms and triggers the detection means during a collision irrespective of the direction in which the collision occurs. In other words, a collision on a vertical or horizontal component or in a component of any orientation will be detected.
According to a preferred embodiment of the invention, the obstacle detection means have a normal operating position of the curtain in which the detection means are parallel to the ballast and sealing element and an abnormal operating position of the curtain in which the obstacle detection means are diverted or interrupted from their axis parallel to the ballast and sealing element by a deformation or a movement of the ballast and sealing element when it encounters an obstacle.
According to a preferred embodiment of the invention, the curtain has at least one reinforcing element parallel to the ballast and sealing element, the detection means being situated between the reinforcing element and the ballast and sealing element. This disposition clearly demonstrates the integration of the detection means in the curtain.
To adjust the sensitivity of the detection means, particularly according to the speed of the curtain, provision is made for the obstacle detection means to be situated at a programmable distance from the ballast and sealing element.
In one embodiment of the obstacle detection means, the latter consist of a cell for emitting a beam supported at one end of the reinforcing element and a cell for receiving the beam supported at the other end of the reinforcing bar, the beam between the emitting cell and the receiving cell being parallel to the ballast and sealing element, and being able to be cut by a deformation of the ballast and sealing element when it encounters an obstacle.
In one embodiment, the ballast and sealing element comprises, on its face opposite to the beam, at each of its ends, at least one flag that cuts the beam, when the ballast and sealing element is deformed when it encounters an obstacle.
According to one possibility, each end of the flexible reinforcing bar receives a stay to which is attached the receiving cell and the emitting cell.
To make it possible to adjust the distance between the ballast and sealing element and the beam, each stay has several locations for the reception of the emitting and receiving cells.
Depending on the case, the beam defined between the emitting cell and the receiving cell is a beam from the group consisting of an optical beam, an acoustic beam, a laser beam, and a narrow sweep angle radar beam.
In another embodiment of the obstacle detection means, the latter consist of a cable, stretched parallel to the ballast and sealing element, capable, of being deformed by a deformation or a movement of the ballast and sealing element when it encounters an obstacle.
To hold the cable, the reinforcing bar has a stay at each of its ends, the cable being stretched between the two stays.
It is noted according to one embodiment that the cable is held at one stay by a spring and at the other stay by a pull rod contact that can be triggered in the event of deformation of the cable.
In another embodiment, the detection means are connected via a wire connection to the control electronic or electromechanical elements of the electromechanical means for operating the curtain.
The invention relates to several types of door, particularly:
the door is a roller door having a single-apron curtain, the door is a folding door having a single-apron curtain, the door is a folding door having a double-apron curtain.
In a preferred manner, the ballast and sealing element consists of a spring covered by a foam sleeve free at its ends or having at each of its ends an end-piece able to engage in a slider of an upright. This embodiment of the ballast and sealing element is of value to the extent that this element with this structure may deform just as well in a direction indistinguishable from the plane of the curtain as in a direction perpendicular to the plane of the curtain and any other direction lying between the plane of the curtain and a perpendicular plane. The ballast and sealing element could also consist of a bolster filled with sand, fine gravel or any other filling material ensuring that it can deform.
In one embodiment, the end portion of the curtain has a U-shaped cover being attached to the outer faces of the curtain that incorporates a sheath in which the ballast and sealing element is engaged.
To prevent superfluous triggering, that is to say triggering that is not a consequence of a collision of the detection means with an obstacle, the bottom portion of the door is fitted with retractors situated around the detection means.
In terms of action following an incident, the triggering of the detection means generates at least one action from the group consisting of:
a stopping of the curtain, an opening of the curtain, the transmission of a signal, the transmission of an audible signal, the transmission of a light signal, the transmission of a microwave signal, the triggering of an action, the triggering of an item of information, an incrementation of an incident history.
This group is nonlimiting and the action engaged could even be the transmission of an electronic or telephonic message, or the activation of a cinecamera or a still camera.
According to one possibility, the reinforcing element situated upstream of the ballast and sealing element is guided at least one of its ends in normal operation of the door.
Advantageously, the reinforcing element consists of a flexible bar having an overall flexibility allowing it not to sustain permanent deformation in the event of a collision.
In the case of a flexible curtain with two aprons, the reinforcing element consists of two parallel bars connected by struts.
Advantageously, the obstacle detection means are incorporated inside the bottom portion of the curtain.
BRIEF DESCRIPTION OF THE DRAWINGS
For a good understanding thereof, the invention is described with reference to the appended drawing representing, as a nonlimiting example, several types of curtain incorporating obstacle detection means according to the latter:
FIG. 1 is a side view of a double curtain of a folding door,
FIG. 2 is a view in section along II-II of FIG. 1 ,
FIG. 3 is a side view of the bottom portion of the curtain of a vertical roller door,
FIG. 4 is a view in section along IV-IV of FIG. 3 ,
FIG. 5 is a view of a lateral retracting door,
FIG. 6 shows another embodiment of obstacle detection means on a vertical roller door,
FIG. 7 is an exploded view in perspective of another embodiment of obstacle detection means on a horizontal roller door.
DETAILED DESCRIPTION OF THE INVENTION
As the figures show, the obstacle detection means may be included in flexible curtain rapid doors. Usually, they are doors having a structure comprising uprights and a transverse element making it possible to guide the curtain, and electromechanical means (electric motor, reduction gear, control electronic or electromechanical elements) supported by the structure making it possible to maneuver the curtain between an open position and a closed position. The structure of these doors is widely known and will not be described further. It will however be specified that certain rapid doors are fitted with a curtain that has, at its free end, a ballast and sealing element. This flexible ballast and sealing element has the function of tensioning the curtain and, when the door is closed, of ensuring a good seal of the door by pressing against the ground without being damaged by the repeated contacts with the ground.
For simplification purposes, it is specified that the elements that are in the various embodiments are indicated by the same reference numbers.
For the description of the invention, reference will first be made to FIG. 1 .
The latter represents the bottom portion of a double-curtain 2 folding door. Naturally, the top portion of this door comprises an electric motor system that makes it possible to raise and lower this curtain.
On the bottom portion of this door, it can be seen that the curtain 2 has two aprons 4 and 5 that each support a horizontal stiffener bar 7 and 8 . These two stiffener bars 7 and 8 are connected together by a connecting strut 9 that can be clearly seen in FIG. 1 .
At the end of the curtain, a U-shaped cover 10 is provided that is attached to each of the aprons 4 , 5 . This cover 10 is usually made of a thick material that withstands repeated contacts with the ground. The U-shaped cover 10 receives a sheath 12 into which a ballast and sealing element 13 is slid. This ballast and sealing element 13 comprises two bob ballast weights 14 at each end of the bar. A spring 15 is placed between these bob ballast weights 14 , the assembly being engaged in a foam sleeve 16 . Note also that the ballast and sealing element 13 has guide end-pieces 17 that can engage in slides with which the uprights 18 of the door are fitted.
When reference is made to FIG. 2 , it can be seen that the curtain is fitted with a stay 20 that is bolted into the strut connecting the two stiffeners.
It should be noted that the curtain 2 has a symmetrical structure and there is the same construction at the other end of the stiffener bars 7 , 8 .
The absolutely characteristic point of this curtain is that the stay supports a cell 21 that emits an optical beam 23 that is parallel to and upstream of the ballast and sealing element 13 . Facing this emitting cell 21 , the second supporting stay is fitted, for its part, with a receiving cell. In another possibility, one of the stays 20 is fitted with an emitting/receiving cell while the other stay simply receives a passive cell for sending back the beam. The receiving cell is connected via a wire connection 22 to the control electronic or electromechanical elements of the curtain 2 .
Note furthermore that the ballast and sealing element 13 receives, on its face that is opposite the supporting stays 20 , at each of its ends, a detection flag 24 that consists of an L-shaped section.
The operation of the detection device is therefore as follows. When the ballast and sealing element 13 encounters an obstacle during its descent, it deforms since it consists, for its essential part, of a spring and a foam sleeve. The deformation of the ballast and sealing element 13 changes the trim of one or both flags 24 which then cut the beam that is usually parallel to the ballast and sealing element 13 . The beam 23 being cut, a signal is sent to the control electronic or electromechanical elements of the door that then give the instruction, on the one hand, to stop the descent of the curtain, and on the other hand, to raise the latter.
It can be seen therefore that, during a collision for example with a person, this collision occurs with an element that is essentially flexible and that, during its deformation, gives an instruction for the curtain to be raised.
It is noted, in a completely interesting manner, that the stay 24 has two reception zones 26 , 27 for the cell 21 emitting the beam 23 , so that the space existing between the ballast and sealing element and the axis of the beam can be made to vary. Therefore, in the case of a slow door, it will be possible to have a relatively large space, while, in the case of a door descending at great speed, it will be necessary to have a sensitive device and, in this case, the space between the ballast and sealing element and the axis of the beam will be as small as possible in order to have the quickest possible detection.
FIGS. 3 and 4 show the device fitted to a vertical roller door. The detection means are fully comparable to those that have just been described.
As shown in FIG. 3 , a vertical roller door has a curtain having a single apron 28 which, at its bottom end, has a U-shaped cover 10 that is attached to each of the faces of the apron 28 . A sheath 12 is formed in the U-shaped cover in which a ballast and sealing element 13 is engaged having the same structure as that described above, that is to say an element having a certain weight to ballast the curtain, but having a certain flexibility so as to deform during an impact.
FIG. 3 shows that the curtain incorporates a transverse stiffener bar 29 , this transverse stiffener bar 29 being a conventional element of the curtains of a vertical roller door. This stiffener bar supports, at each of its ends, a stay 20 ; one of these stays receives an emitting cell 21 , while the other receives a receiving cell. These two cells 21 therefore define a beam axis 23 parallel to the axis of the bottom ballast and sealing element.
In normal operation, the axis of the beam 23 is strictly parallel to the axis of the ballast and sealing element 13 .
As can be seen in the figure, note that the ballast and sealing element supports, at each of its ends, a flag 24 , that is to say an L-shaped section. When the ballast and sealing element 13 encounters an obstacle, it deforms and the flag 24 cuts the optical beam. The cutting of this optical beam 23 is indicated to the control electronic or electromechanical elements of the door that instruct the curtain to raise.
It should be noted that the control electronic or electromechanical elements may trigger any other visual or audible signal making it possible to give the alert of an accident. In addition, the accidents can be counted in order to ascertain the history of the door.
FIG. 5 shows a door operating according to a different principle in that the curtain 2 retracts laterally between its open position and its closed position.
The structure of the detection means is fully comparable with that used for vertical folding or roller doors. Specifically, this door has a ballast and sealing element 13 which, naturally in the present case, is oriented in the vertical direction; this ballast and sealing element has a structure that is fully comparable with that of the ballast and sealing element of the doors previously described, that is to say a spring sleeved in foam.
A stiffener bar 30 parallel to the end bar supports two stays 24 , one being fitted with an emitting cell 21 , the other being fitted with a receiving cell, so that a beam 23 parallel to the end bar is defined between these two cells.
When the curtain 2 collides with an obstacle, whether it be a person or an object, the ballast and sealing element 13 deforms and one or the flags 24 cuts the beam 23 defined between the two cells; this then triggers in the control electronic or electromechanical elements an appropriate and predetermined action that is usually the stopping of the motor and the opening of the door accompanied, where necessary, by an audible or visual signal. Although the drawing represents a laterally retracting door having a single curtain, it is of course quite conceivable to fit a contact detection device to a laterally retracting door having two flexible curtains.
It should be noted that the detection device according to the invention may take another embodiment represented in FIG. 6 since it is possible to provide, parallel to the axis of the ballast and sealing element, a cable 30 which, at one of its ends, is held by a spring 31 to a supporting stay 20 and, at its other end, is held by the supporting stay by means of a pull rod contact 32 .
During a deformation of the ballast and sealing element 13 following a collision with an obstacle, the ballast and sealing element comes into contact with the cable and changes its tension. This change of tension is converted at the pull rod contact 32 into an electric signal that is transmitted to the control electronic or electromechanical elements which, here again, take the appropriate predetermined action.
FIG. 7 illustrates another embodiment of the obstacle detection means in which a cell 21 is connected to a transverse reinforcing bar 29 by a stay 24 . In the embodiment illustrated, the stay 24 comprises two symmetrical supports 34 that each have a concave portion that can grip the transverse reinforcing bar 29 . The two supports 34 furthermore grip a plate 35 . The plate 35 has, as can be seen in FIG. 7 , two threaded rods 37 ; these threaded rods have the function of receiving a fitting 38 . Note that the fitting 38 to which the cell 21 is attached has an oblong slot 39 that can be engaged on the threaded rod 37 . This arrangement makes it possible to adjust the position of the cell 21 relative to the element 13 . Naturally, another stay symmetrical to that which has just been described may be placed at the other end of the transverse reinforcing bar 29 .
The invention, in its various embodiments, therefore has the many advantages indicated. Specifically, the detection device is fully protected since it is, relative to the ballast and sealing element or the end bar, on its face opposite to its face that is in contact with the ground or an upright. This very favorably contributes to the general reliability of the device.
Furthermore, this device may be very easily programmed since different positions for the emitting and receiving cells are provided in the supporting stays 20 .
In addition, the device operates in the case of a collision in a direction other than vertical, for example horizontal or on any component lying between these two directions since, in all the situations that have been described, when the bottom bar is moved along a horizontal component, the beam or the cable, depending on the case, is cut or slackened, which has the effect of triggering the opening of the curtain.
Naturally, the invention is not limited to the embodiment described above as a nonlimiting example, but, on the contrary, it embraces all the variant embodiments thereof. | The inventive flexible curtain rapid door comprises a structure consisting of two posts and a transverse element for guiding a flexible curtain and electromechanical means supported by said structure for displacing the curtain between open and closed positions, wherein the flexible curtain ( 2 ) comprises a weight and sealing element ( 13 ). According to the invention, the door comprises obstacle detecting means which are carried at least partially by an reinforcing element, are adjacent to the weight and sealing element ( 13 ) and are disposed upstream thereof on the curtain closing path between the reinforcing element and the weight and sealing element ( 13 ) and said obstacle detecting means are integrated inside the lower part of the curtain ( 2 ). | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional of co-pending U.S. patent application, Ser. No. 09/429,550, filed on Oct. 28, 1999, which is assigned to the same assignee as the present application and which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of data entry and retrieval. Specifically, the present invention relates to a method and system having the capability to organize an annotation structure and to query both data and annotations in computer systems. More particularly, the present invention enables the annotation of stored information, and permits the capture, sharing, and querying of data and annotations.
BACKGROUND OF THE INVENTION
[0003] Successful planning and decision making in many technical and other industries depends on the expeditious and correct interpretation of complex information. For example, in the drug industry the data may have origins as diverse as high throughput screening experiments, clinical trials, patent information and research journals. In the petroleum industry the data may span seismic measurements, aerial surveys, laboratory data and economic forecasts. A system capable of providing unified access to disparate data sources and applications reduces the time spent finding, accessing, preparing, transforming and reformatting data, and allows professionals to focus on the interpretation and extraction of knowledge for planning and decision making.
[0004] However, one complication with providing this type of unified access is that the data inevitably spans several disciplines, with an attendant probability of misinterpretation. Extensive knowledge of multiple domains is required if misuse is to be avoided.
[0005] Therefore, there is still an unsatisfied need for an information management system that clarifies the generation, use, and purpose of the data. The information management system can capture knowledge about the genesis and history of the data, how analyses are done, how decisions are made, and what the outcomes are. This “corporate memory” forms the basis for the analysis required to make better technical and business decisions.
[0006] Several attempts have been made to access information based on annotations. Illustrative attempts are described in the following references:
[0007] U.S. Pat. No. 5,404,295 to Katz et al.
[0008] U.S. Pat. No. 5,600,775 to King et al.
[0009] U.S. Pat. No. 5,832,474 to Lopresti et al.
[0010] U.S. Pat. No. 5,548,739 to Yung.
[0011] For example, U.S. Pat. No. 5,404,295 describes a method and apparatus for computer retrieval of database material. Annotations are provided for selected database subdivisions and are converted to a structured form and stored in that form along with connections to corresponding subdivisions. Searching for relevant subdivisions involves entering a query in natural language or structured form, converting natural language queries to structured form, matching the structured form query against stored annotations, and retrieving database subdivisions connected to matched annotations.
[0012] However, the teaching of this patent is limited to a system with the capability to search the annotations to locate the database material. The system does not have the capability to search the stored information based on both the annotations and database material, or to search on database material to retrieve the annotations. As a result, the system is not suitable for directly locating a subset of data where the filter has predicates on both the annotations and database material. Rather, it will locate all database material that corresponds to the annotation predicates and it would require a second step to filter this subdivision and to apply the data predicates.
SUMMARY OF THE INVENTION
[0013] The present invention contemplates a method and apparatus for capturing annotations about database material in a way that allows queries with conditions or predicates on both the database material and the annotations. Database material may be text, graphics, spreadsheets, relational tables or any other material which may be stored and indexed. An annotatable data item (i.e. the subsection of database material that can be annotated) is any entity referenced by an index (e.g. by an object identifier) or any attribute or subcomponent of such an entity, or any arbitrary set of such items. Examples include a table such as a relational table or spreadsheet, a view such as a relational view, a row within a table, a cell within a table (i.e. the intersection of a column and a row), a column within a table, an object, an attribute of an object, a set of rows or columns from one table, or a set of rows from different tables. The annotatable data items may be in a single source or multiple sources, or span such sources. Multiple annotations may be entered for a single annotatable data item.
[0014] The annotations, together with the pointer information that relates them to the original database material, may be stored in a separate source so that the data model and operation of the sources containing the original database material is not affected. It is the pointer information that allows formulation of the queries to retrieve either annotations related to specific database material or database material related to specific annotations.
[0015] Annotations may be used to capture information such as additional facts about the database material, the opinions and judgments of experts about the database material, and/or links to other related material. Annotations may be entered manually or automatically by an application. Henceforth, the person or application that enters an annotation will be referred to as an annotation author, and the person or application that retrieves annotation and/or database material will be referred to as the reader.
[0016] Annotations may be captured in structured form to enhance queryability and semantic interpretation as well as to provide some order for users to enter this additional information content. The entry of comments in an unorganized and undisciplined way can often lead to more data with little useful content. The structure is comprised of labeled categories, to aid semantic interpretation. The annotation structure could be as simple as a “header” category containing attributes (or fields) about whom and when the person or application wrote the annotation, together with a “business meaning” category containing a single “Comment” field for a textual description of the data item being annotated. In this example, the title of the latter category, “business meaning” can aid in the interpretation of the “Comment” field. An annotation structure may be more complicated than the one illustrated above and contain many categories, each of which contains a number of attributes. Some or all of these attributes may have constraints placed on their values. For example, the constraints may be on the datatype (e.g. numeric, character) and/or on their values, so that users have to enter values consistent with a particular datatype or consistent with an input list or pick-list. The constraints enforce more structure and consistency in the annotation content and also enhance the queryability with today's query engines.
[0017] It is the capture and query of information from experts represents one important feature of the present invention. To this end, the present method offers the capability to allow standardized structure of annotations based on the “group” to which the author and reader belong, as well as on the data item being annotated. A group can be as small as one person, in which case there can be a personalized annotation structure, or it can contain a “related” set of people, such as people of a particular discipline or performing a particular role. Henceforth, group will be referred to as a “context”. There is a context associated with the annotation author as well as the reader. Thus, it is permitted for the structure for the entry of an annotation about any one data item to be different depending on the context of the author, and for this information to be presented differently on retrieval depending on the context of the reader. These structures that are associated with contexts, can be used to give a level of credibility to the annotations. That is, the annotation structure may be set up such that only experts in a given discipline (context) can enter information or advice pertaining to the expertise understood by that discipline. Filtering and transforming the entered annotation content based on the context of the reader can be used to retrieve only relevant information, or to “hide” information to which this reader context is unauthorised, or to present the information in a form easily understood by the discipline or role of the reader. Multiple annotations from authors with different contexts or within the same context can be attached to a single annotatable data item.
[0018] It should be understood that the foregoing capabilities encompass a single annotation structure containing an attribute such as “Comment” or “URL” for every annotatable data item, wherein annotations of this type are entered and retrieved in the same way by all author/readers.
[0019] The method of the present invention is outlined as follows: The type of annotatable data item is identified and the allowed structures for this type are registered. A type may include, but is not limited to, “set of rows of table x” or “any cell in column y of spreadsheet z”. This registration step can be done as a pre-processing step or may be done immediately before annotation entry.
[0020] For annotation entry, an annotatable data item is chosen (e.g. a 5th cell in column y of spreadsheet z) and an annotation is entered and stored. The annotation is associated with the annotatable data item at the time of entry by including pointer information to the annotatable data item with the annotation. Optionally, the annotation may be “propagated” or automatically associated with additional annotatable data items using extra information defined in the registration step. Once annotations have been stored, queries may be issued to retrieve both the annotation content and/or the database material.
[0021] There are a number of query modes possible. In the first mode, the reader may browse the annotations in the context of the database material. That is, the reader identifies the specific database material of interest and all accompanying annotations are retrieved. This is achieved by issuing a query using the pointer information stored with the annotations. This mode is useful when the reader is perusing database material and wants to read annotations that contain related information or links to related information.
[0022] A second mode refers to querying for particular annotations in the context of the data. That is, the reader first identifies the database material of interest. This may include identifying an annotatable data item or a type of annotatable data item. In the case of an annotatable data item, the reader asks for the accompanying annotations with particular characteristics, (e.g. where the author field contains Smith). In the case of a type, the reader may ask for elements of the type whose annotations have particular characteristics. A query is issued that uses the pointer information and specifies a filter on the annotation content.
[0023] The reader may alternatively ask for only the elements of the type and their annotations where the elements of the type and their annotations both have filters on their content. In this case, a query is issued that uses the pointer information and specifies a filter on the annotation content and also a filter on the data content.
[0024] The second mode is useful when the reader wishes to review only certain annotations that relate to the data (e.g. all those by expert X) or when the reader wishes to focus on particular database material and annotation content (e.g. find all the data and annotations about drug molecules that have biological activity greater than x (data content) and for which the experts said the experimental measurement was reliable (annotation content)).
[0025] The third mode involves querying across the full body of annotations, regardless of the database material being annotated. This may be used, for example, for locating all annotations containing a particular category or for locating annotations containing particular content. For example, an exemplary query can be: How many times has Simulation package x been used to generate production estimates?
[0026] The fourth mode involves querying for particular data in the context of the annotations, is an extension of the third mode. In this case, the query retrieves not only the annotations of interest but also the database material that they annotate. For example, in the fourth mode, the answer to the above exemplary query: “How many times has Simulation package x been used to generate production estimates?” might include not only how many times the package x has been used but also the values of the production estimates. This mode also uses the pointer information in order to formulate the query to retrieve the appropriate database material.
[0027] According to a preferred embodiment, an information management method is implemented by the information management system, whereby one or more users such as administrators, annotation authors, readers, and/or applications, start the information management method of the present invention by setting up an annotation structure. Using the information management system, a user is capable of performing any one or more of the following tasks or processes:
[0028] Enter annotations about the data or fields by various input means.
[0029] Browse annotations in the context of data.
[0030] Simultaneously query for both annotations and data.
[0031] Query for particular annotations in the context of data.
[0032] Query across the full body of annotations.
[0033] Query for particular data in the context of the annotations.
[0034] It is therefore clear that the information management system is not domain specific, in that it can be used in combination with any application regardless of the complexities of the underlying technical or professional fields. The data model for the annotations (i.e., the annotation metadata model) is generic, self-describing, and self-contained.
[0035] The information management system is adaptable to the user's query preferences in that the information management system provides the ability to operate in a data-centric mode or in an annotation-centric mode. The data centric-mode will be explained in connection with FIGS. 5 and 6, and allows the user to select desired data items and to subsequently query and retrieve data and annotations based on these data items. The annotation-centric mode will be explained in connection with FIGS. 7 and 8, and allows the user to select the annotation categories and to subsequently query and retrieve data and annotations based on the content of the selected annotation categories. As a result, the information management system allows both data and annotations to be queried, in that queries can be made over the data content, over the annotation content, or over both simultaneously. This provides the ability to query the annotations, or the annotations and the data, and further provides the ability to retrieve the annotations when their associated data is retrieved.
[0036] Yet another feature of the information management system is its ability to allow annotations to be targeted to, or associated with data at different levels of granularities, such as: collection/view/table, attribute/column, instance/row, cell, arbitrary combinations thereof, and so forth.
[0037] Still another feature of the information management system is its ability to support storage and retrieval of annotations with a generic structure or a more specific structure, where the structure can depend on the nature of the data being annotated and the context of the author of the annotation.
[0038] In addition, the information management system is capable of supporting annotations of data in a variety of sources, formats, and/or data models. The information management system can annotate data in multiple sources when coupled with a data integration engine, in only one source, or in any source regardless of the source's data model (diverse sources). Further, the information management system can annotate views on the data in these sources, without requiring the data sources being annotated to be modified. The information management system can have multiple annotations for the same data object, and different annotations on the same data item can be entered by different people/applications or by the same person/application at different times. Moreover, when the annotations are retrieved, they can be filtered or modified in a way that depends on the context of the reader. The annotations can also be propagated to specific target data items that can be selected from a drop down list, or by entering a free format text, numeric, document, URL, and so forth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items.
[0040] [0040]FIG. 1 is a high level architecture of an information management system according to the present invention.
[0041] [0041]FIG. 1A is a diagram of an exemplary embodiment of the information management system of FIG. 1;
[0042] [0042]FIG. 2 is a schematic of an exemplary computer screen that can be generated using the information management system of FIG. 1.
[0043] FIGS. 3 A- 3 D represent a flow chart that illustrates a process of setting up the annotation structure using the information management system of FIG. 1.
[0044] [0044]FIG. 4 is a flow chart that illustrates a process of writing an annotation using the information management system of FIG. 1.
[0045] [0045]FIG. 5 is a flow chart that illustrates a process of browsing an annotation in the context of data, using the information management system of FIG. 1.
[0046] [0046]FIG. 6 is a flow chart that illustrates a process of querying for particular annotations in the context of data, using the information management system of FIG. 1.
[0047] [0047]FIG. 7 is a flow chart that illustrates a process of querying across the full body of annotations, using the information management system of FIG. 1.
[0048] [0048]FIG. 8 is a flow chart that illustrates a process of querying for particular data in the context of the annotations, using the information management system of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0049] [0049]FIG. 1 illustrates a system 1 that might be utilized to practice the teachings of the present invention. The system 1 includes a plurality of computers or processors 2 , 3 , 4 . While for purposes of illustration the computers 2 , 3 , 4 are described as possessing specialized functions, it should be clear that any one, or a combination of the computers 2 , 3 , 4 can be used to generate the annotations, and to search the data and annotations sources (e.g. databases) as described herein.
[0050] As further illustrated in FIG. 1A, computer 2 hosts an information management system 10 of the present invention, and includes, or is connected to one or multiple databases 14 , 16 to be searched. Computer 2 is interconnected to computer 3 via an annotation input link 5 for allowing annotations to be inputted from computer 3 to computer 2 . The annotation input can be from a user of, for example, a graphical user interface (GUI) application, or from a software application, running for example on computer 3 . One or more input devices 7 can be used to provide information to computer 3 . These input devices may include, but are not limited to, keyboard devices, pointing devices, monitors, scanners, modems, inputs from other systems, microphones and voice recognition applications, and like devices.
[0051] Computer 2 is interconnected to computer 4 via an annotation output link 8 for allowing annotations to be outputted from computer 2 to computer 4 . The annotations and/or other data can be retrieved on the request of a user of, for example, a GUI application, or on the request of a software application running for example on computer 4 . The annotations and/or other data that are retrieved from the system 1 may be utilized of displayed by means of one or more of output devices 9 . These output devices 9 may include, but are not limited to, monitors, printers, modems, outputs to other systems, speakers and audio synthesizers, robots, storage systems, and like devices.
[0052] [0052]FIG. 1A portrays the overall environment in which the information management system 10 can be used according to the present invention. The information management system 10 uses a data integration engine 12 that permits users and/or applications to pose queries against data that may reside in multiple data sources, such as databases 14 and 16 . As used herein, an integration engine can be any application system that can accept a query against one or multiple data sources in any form and that returns the requested data from one or multiple data source in any desired form. An exemplary data integration engine 12 is available from International Business Machines under the trademark DataJoiner®. Using the data integration engine 12 , annotations can be made on data from a broad variety of existing sources, regardless of their locations. It further enables the independent storage of annotations, such as in an annotation database 20 , without impacting the users' applications 22 , or databases 14 , 16 . In the case where the user/application only wishes to annotate data in a single datasource, it is possible to writes the annotations in the same datasource, and a data integration engine is not needed.
[0053] A query/browser/annotator 25 is a separate application that provides users (represented by computer 27 ) with a graphical user interface (GUI) to facilitate the interaction with the information management system 10 . Using the query/browser/annotator 25 , the users can find, view, and annotate data.
[0054] [0054]FIG. 2 is a schematic of an exemplary computer screen 50 that can be generated using the information management system 10 of FIG. 1. The screen 50 provides an example of how a user 27 can query data in the business area of oil exploration and production. The screen 50 shows a data collection that describes the company's oil fields. The names of the oil fields are displayed in the first column 88 . The different attributes of the view are shown in the first row 89 . A complex query can be posed by placing predicates in the second row 92 and in block 91 . The query illustrated in FIG. 2 asks for rows that have a Reserve value that is greater than 300, Units in Bcf, and a Certainty factor that is greater than 70%, as well as a Usage appropriate for Tax Purposes. Usage is actually an annotation category on cells in the Reserve data column. As a result, this exemplary query combines attributes of the data along with the annotation content to qualify the results.
[0055] The result of this query is shown in the third row. Various annotations on the retrieved values or data of this row are shown attached to the bar. It should be understood that one value or data may have multiple annotations, of multiple types, and that different values may have different sorts of annotations. The formats of the annotations depend on the discipline or context of the persons or applications writing, reading, or entering the annotations. For example, a reservoir engineer might add an annotation about a reserve simulation, but an accountant would add annotations about the financial analysis.
[0056] In operation, one or more users, such as an administrator 27 , or the client application 22 , start the information management method of the present invention by setting up an annotation structure, as illustrated in FIGS. 3 A- 3 D The information management system 10 is capable of performing any one or more of the following tasks or processes, with the understanding that it can perform other tasks as well:
[0057] Entering annotations about the data or fields by various input means, as illustrated in FIG. 4. These annotations are preferably stored in a separate database 20 . It should however be understood that the annotations can be stored in the same data sources (i.e., 14 , 16 ) as the data.
[0058] Browsing annotations in the context of data, as illustrated in FIG. 5.
[0059] Simultaneously query for both annotations and data.
[0060] Querying for particular annotations in the context of data, as illustrated in FIG. 6.
[0061] Querying across the full body of annotations, as illustrated in FIG. 7.
[0062] Querying for particular data in the context of the annotations, as illustrated in FIG. 8.
[0063] The foregoing tasks will now be described in greater detail with reference to their respective drawings. Starting with the process of setting up or organizing the annotation structure 100 (FIG. 3A), an administrator 27 , for example, identifies data items or data item types to be annotated, as shown in block or step 105 . An annotatable data item can be a table, a view, a row, a cell, a column or any entity referenced by an index (e.g., by an object identifier), or any attribute or subcomponent of such an entity, or any arbitrary set of such items. Specification of an annotatable data item allows any of a whole set of similar annotatable data items to have the same annotation structure. For example, “any object in class y”, “any row in table x”, “any cell in column a of table b”. This greatly facilitates the annotation structure setup and registers the availability of annotation structures for data that has not yet been input, such as the addition of rows to a table or objects to a class. The data items and data item types can originate from a single source or from multiple sources 14 , 16 . In the example of FIG. 2, one of the data item types to be annotated is any cell which is listed in the column whose attribute is “Reserve”.
[0064] The annotatable data item to be annotated can be selected by selecting an attribute or attributes of an entity, where the entity can be referenced, for example, by an index, a schema object or objects, or any arbitrary set of such attributes and/or schema objects. As used herein, a schema object can be, for example, a table, a class, an attribute of a class, a view, a column, a function, or any combination thereof.
[0065] The administrator 27 then selects or enters a context, if one does not already exist, for the annotation author as illustrated in block 110 . The term “context” denotes a discipline, or a role being performed by a person of a particular discipline. In the above example, it is possible to allow persons of different disciplines to annotate various data items. For illustration purposes, it is possible to allow reservoir engineers, geologists and/or chemists to enter different types of information in their annotations.
[0066] Since multiple types of information can be captured in an annotation about each data item, the administrator 27 can enter a category of information to be captured about the data item, as illustrated in block 115 . These categories can be factual or interpretive in nature. Examples include, but are not limited to the origin of the data (factual), the quality of the data (interpretive), and appropriate use of the data (factual and/or interpretive). The administrator 27 enters a desired category (block 115 ).
[0067] The method 100 then automatically determines if the selected category already exists (block 120 ). If the selected category does not exist, the administrator 27 enters the list of attributes for this category and how the annotation content will be defined for these attributes (block 125 ). As an example, for the category origin of data, three attributes might be: vendor name, install date, and the name of the person who performed the installation.
[0068] Annotation content can be associated with these attributes, during subsequent annotation entry, by any of several mechanisms, including but not limited to the following mechanisms:
[0069] A list of values (pick-list) from which an annotation author can select.
[0070] Qualifying datatypes for the values, e.g. text, numeric, document, URL, and so forth.
[0071] The method 100 then automatically inquires the administrator 27 at block 130 if another category is required for the selected data item. If the administrator 27 determines that another category is needed, the method 100 repeats the set of steps or blocks 115 , 120 , 125 , and 130 , until the administrator 27 determines at block 130 that no additional categories are needed for the selected data item.
[0072] If at block 120 the method 100 determines that the selected category already exists, the method 100 proceeds to block 130 and inquires if an additional category is required for the selected data item. If at block 130 the administrator 27 instructs the method 100 that no additional category is needed, the method 100 proceeds to block 135 (FIG. 3B), for allowing the administrator 27 to define the annotation structure from the selected categories, to assemble the categories, and to associate the annotation structure with the annotatable data items.
[0073] In the example of FIG. 2, the administrator 27 defines the annotation structure by identifying the desired categories and the order in which the annotation content will be entered and/or displayed. For illustration purposes, the annotation structure for cell 75 includes three categories: The first category 77 represents the annotation author's category, and provides information (in the form of annotations), for instance, about the author's name, the context or author's discipline, and the entry date. The second category 78 represents the simulation category, and provides information about the person who ran the simulation, e.g. reservoir engineer's name, the type of oil well simulation, the location of the simulation reference files, and the simulation date. The third category 79 represents the usage category, and provides information about the usage of data in cell 75 that can be used for tax purposes, the person who authorized this use of the data, and further comments about the use. While the foregoing example is explained in light of certain specific entries, it should be clear that alternative entries and/or categories can be used.
[0074] Once the annotation structure is defined at block 135 , the method 100 automatically determines at block 140 whether this annotation structure already exists, since annotation structures can be reused. If the method 100 determines that the annotation structure does not exist, the administrator 27 builds a new annotation structure from the selected categories (block 145 ), as explained above in connection with block 135 . The annotation structure can be built automatically from concatenation of the annotation categories. If the method 100 determines that the annotation structure already exists, it proceeds to block 150 .
[0075] The method 100 associates the annotation structures with the annotatable data item. Annotation structures can vary according to the data item being annotated and/or to the context of the annotation author. Multiple annotations with differing or identical structures can be assigned to the same data item. It should be clear that the contexts can be defined for groups of people (or applications) or on an individual basis.
[0076] When the annotation structure assignment is completed at block 150 , the method 100 can proceed to decision block 155 (FIG. 3C). Optionally, the method 100 can perform a template transforming (or filtering) loop illustrated by blocks 155 , 160 , 165 , 170 , and/or an annotation propagation loop illustrated by blocks 175 , 180 .
[0077] The template transforming loop can be automatically initiated by the method 100 at the decision block 155 , whereby, the method 100 inquires whether the administrator 27 (or application 22 ) wishes to specify a filter or modify a template to reflect the reader's context. The administrator 27 indicates which categories are to be retained, which attributes within these categories are to be retained, which attribute names are to be changed and how, and more generally transformations that should be applied to the annotation content.
[0078] For illustration purposes, if the reader is a reservoir engineer, he or she might not be interested in retrieving annotations by accountants, since these may not be relevant to their work. Alternatively, a reader who is a project manager might not be interested in, or may not be allowed to see the simulation category of the annotation.
[0079] If the administrator 27 determines at decision block 155 that a filter and/or a template is needed, the administrator 27 enters a reader context, such as “Reservoir Engineer” (FIG. 2), as shown by block 160 . The administrator 27 then specifies a corresponding reader template at block 165 , and the method 100 inquires at decision block 170 whether templates for additional reader contexts are desired.
[0080] If the administrator 27 determines at block 170 that a template for an additional reader context is desired, the method 100 proceeds to block 160 and repeats the reader selection loop comprised of steps 160 , 165 , 170 , until the administrator 27 determines at block 170 that no additional templates are desired.
[0081] When the reader selection loop terminates, or if the method 100 determines at step 155 that neither a filter nor a template is needed, the method 100 proceeds to decision block 175 and inquires whether or not the administrator 27 wishes to propagate the annotations about the selected data item. When the annotation structures are assigned to the data items, the method 100 enables the annotations written through these structures to be propagated to other data items. For example, a data item that describes the depth of an oil well could appear in many views pertaining to oil wells. Annotations about a depth value could be propagated to all of these views, not just the one against which the annotation was entered. In the example of FIG. 2, the data in cell 75 could appear in different views suitable for accountants, geologists, chemists, reservoir engineers and/or viewers of other disciplines. In many of these cases, the viewers might also want to see the annotations entered by the reservoir engineer in their views. If at step 175 the administrator 27 determines that no propagation is desired, the method 100 proceeds to decision block 185 and inquires whether or not additional contexts for the annotation authors are desired, as it will be explained later.
[0082] If at block 175 the method 100 determines that the annotations need to be propagated, the method 100 allows the administrator 27 to specify the target data items or data item types to receive the propagated annotations (block 180 ). These target data items can be selected from a drop down list and/or by entering text. The method 100 then proceeds to decision block 185 and inquires whether or not additional contexts for the annotation authors are desired. If the answer to this inquiry is in the affirmative, the method 100 loops back to block 110 , and performs the loop comprised of the steps between blocks 110 and 185 , as described above, until the administrator 27 determines that no additional context for the annotation authors is needed.
[0083] When the latter condition is satisfied, the method 100 proceeds to block 190 and inquires whether or not the user 27 needs to select additional data items. If no additional data items need to be selected, the method 100 is terminated at block 195 . If, on the other hand, additional data items need to be selected, the method 100 loops back to block 105 , and performs the loop comprised of the steps between blocks 105 and 190 , as described above, until the method 100 is terminated at step 195 .
[0084] Once the information management system 10 is set up according to the method 100 , the system 10 will be ready to be used by the annotation authors, readers, and applications. FIGS. 4 through 8 illustrate exemplary methods of using the information management system 10 . In summary, FIG. 4 illustrates the process of writing or inputting an annotation, FIG. 5 illustrates the process of browsing an annotation in the context of data, FIG. 6 illustrates the process of querying for particular annotations in the context of data, FIG. 7 illustrates the process of querying across the full body of annotations, and FIG. 8 illustrates the process of querying for particular data in the context of the annotations.
[0085] [0085]FIG. 4 illustrates a method 200 of writing an annotation using the information management system 10 of FIG. 1. The user, such as an author 27 (and/or the application 22 ) starts at block 205 by selecting the data item to be annotated, and further enters the annotation content corresponding to a predefined annotation structure at block 210 . The method 200 then stores the annotations in the data store 20 (FIG. 1), for subsequent retrieval using the browse or query capabilities of the information management system 10 .
[0086] [0086]FIG. 5 illustrates a method 250 for reading or browsing the annotations in the context of the data. For example, if a reader 27 (and/or an application 22 ) wishes to review or browse annotations about members of the data collection or view of interest, the information management system 10 is capable of retrieving and displaying the requested annotations. Structured Query Language (SQL) is an example of a language that can be used to search for, and return the annotations.
[0087] The method 250 begins at block 255 by having the reader 27 select the data of interest. The method 250 then inquires at block 260 if the reader wishes to view the annotations. If not, the method 250 terminates at block 263 . If the reply to this inquiry is in the affirmative, the annotations corresponding to the data items within the data collection are retrieved on request from the data storage 20 . The annotation content can be returned as written or, alternatively, filtered or modified in a way that depends on the context of the reader.
[0088] The method 250 proceeds to the decision block 270 and inquires if the requested annotation content is subject to filtering, transformation or modification. If it is, the method 250 proceeds to block 275 and performs the necessary filtering, transformation and/or modification, and then returns or displays the requested annotations at block 280 . If on the other hand, the method 250 determines that filtering, transformation and/or modification is not required, it returns or displays the requested annotations at block 280 . The loop comprised of blocks 270 , 275 , and 280 will hereinafter be referred to as the transforming loop 290 .
[0089] [0089]FIG. 6 illustrates a method 300 for querying annotations in the context of the data, or in other terms. The method 300 performs a “combined” query, with conditions (predicates) on both data and annotation content. A reader 27 selects a data item type or data collection of interest (block 305 ), and enters query predicates conforming to predefined annotation structures for annotations on the data items in the selected data collection or associated with the data item type (block 310 ). If the reader 27 wishes to enter query predicates on the data items themselves (decision block 315 ), the reader specifies the data item queries (block 320 ). In response, the method 300 retrieves the annotations and data conforming to the reader's query predicates (block 325 ). The annotation content can be returned as written or, alternatively, filtered or modified in a way that depends on the context of the reader. If the reader 27 does not wish to query predicates on the data items themselves (decision block 315 ), the method 300 proceeds to block 325 . If needed, the method 300 performs the transforming loop 290 as discussed above in connection with FIG. 5.
[0090] [0090]FIG. 7 illustrates a method 350 for querying annotations across the full body of available annotations. The reader 27 selects the annotation category or categories of interest (block 355 ), and enters query predicates based on the definition of the selected category or categories (block 360 ). The method 350 retrieves all the annotations that obey the query predicates regardless of the annotation structure (block 365 ). The annotation content can be returned as written or, alternatively, filtered or modified in a way that depends on the context of the reader. If needed, the method 350 performs the transforming loop 290 as discussed above in connection with FIG. 5.
[0091] [0091]FIG. 8 illustrates a method 400 for querying for particular data in the context of the annotations, which method 400 is therefore said to be annotation-centric. The reader 27 selects the annotation category or categories of interest (block 405 ), and enters query predicates based on the definition of the selected category or categories (block 410 ). The method 400 retrieves all the annotations and the data items associated with the annotations that obey the annotation query predicates (block 415 ). The annotation content can be returned as written or, alternatively, filtered or modified in a way that depends on the context of the reader. Optionally, the method 400 can sort the retrieved data and annotations by the type of the data collection (block 420 ). If needed, the method 400 performs the transforming loop 290 as discussed above in connection with FIG. 5.
[0092] It is to be understood that the specific embodiments of the invention that have been described above are merely illustrative of one application of the principles of the present invention. Numerous modifications may be made to the information management system and associated methods described herein without departing from the spirit and scope of the present invention. For example, while the information management method is described in terms of a computer, it should be understood that this method can be implemented without the use of a computer, and as such it can cover a method of conducting business and other information management tasks. | A method and apparatus for capturing annotations about database material in a way that allows queries with conditions or predicates on both the database material and the annotations. Database material may be text, computer programs, graphics, audio, spreadsheets, or any other material which may be stored and indexed. Database material may be in one or multiple sources, and annotations may be stored together with the original material or in a separate store. Annotations can be used to capture information such as additional facts about the database material, the opinions and judgments of experts about the database material, and/or links to other related material. Annotations may be captured in a structured form to enhance queryability and semantic interpretation. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. §119, of German Utility Model application DE 20 2005 017 780.6, filed Nov. 11, 2005; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to an article, in particular a writing implement having a gripping zone on which raised structures are provided in order to improve the grip and the handling. Such structures usually are formed by a non-slip and possibly also sweat-absorbing material, mostly based on plastics. The material of the raised structures also has to meet further requirements, for example, in respect of visual appearance, durability and safeness from a toxicological point of view. Furthermore, the material of the raised structures also has to be of such a nature that it adheres firmly to the surface of the article. The surfaces of the articles, for example, used on a daily basis are of very different configurations, for example they are of natural wood, painted wood, metal or various plastics. It is thus often difficult to select a material for raised structures that satisfactorily combines with all of these material properties. Problems often also arise in applying the raised structures, in particular if the articles are of irregular shape.
SUMMARY OF THE INVENTION
[0003] It is accordingly an object of the invention to provide an article, in particular a writing implement, having a gripping zone with raised structures that overcomes the above-mentioned disadvantages of the prior art devices of this general type, which is improved, in particular, in the adherence of the raised structures to the surface of the article.
[0004] With the foregoing and other objects in view there is provided, in accordance with the invention, an article. The article contains an article body having a gripping zone, and a film coating the article body in a region of the gripping zone. The film has a surface with raised structures disposed on the surface.
[0005] In the region of the gripping zone, the article is coated with a film that has the raised structures on its surface. Since the haptic properties of the gripping zone are defined by the raised structures, the material of the film may be selected primarily such that the material of the raised structures adheres well to it. In respect of the adherence of the film to the surface of the article, the problems are on a considerably smaller scale than in the case of the raised structures themselves. This is because the film is connected to the gripping region of the article over a large surface area, so that, in relation to a surface-area unit of the film, a lower retaining force is necessary than, for example, in the case of a structure with protuberances. Added to this is the fact that there are a multiplicity of adhesives available which are suitable for more or less any desired material combinations. It is therefore irrelevant as to whether the article if formed of wood, of plastic or of metal. For processing reasons alone, the use of an adhesive technique is scarcely viable for raised structures.
[0006] In the case of a further preferred exemplary embodiment, the film, rather than being adhesively bonded, is a shrink film. Such a film can be used, in particular, for cylindrical articles such as pencils, handles of playthings and the like. In these case, a tubular shrink film is pushed over the gripping zone and shrink-fitted under the action of temperature, so that it then butts firmly against the outer circumference of the article or of the gripping zone.
[0007] The raised structures can be produced in a variety of different ways for an article according to the invention. In the first instance, conventional techniques are conceivable here, for example by the raised structures being applied to the film in the form of an initially free-flowing and subsequently solidifying plastic substance. Raised structures that are preferred here are ones that are formed substantially from a water-based polymer dispersion that cures to be water-resistant. Pencils with such structures are known from European patent EP 1 177 108 B1 (corresponding to U.S. patent disclosure No. 2002/0098029 A2), which is herewith incorporated by reference in the application. An alternative way of producing the raised structures is described in German Utility Model 203 14 274.8 (corresponding to U.S. Pat. No. 6,837,637), the disclosure contents of which are likewise herewith incorporated herein: in order to produce the raised structures, use is made of a preparation which contains a radiation-curable plastic. Use is preferably made of such a plastic that can be cured with the aid of UV light.
[0008] In the case of a further preferred configuration, the raised structures are formed integrally with the film. Such a film may be formed, for example, by a stamping die, which has cavities complementing the raised structures present in its die surface, being pressed, possibly under the action of temperature, onto a region of the film that corresponds to a gripping zone. Film material is then forced into these cavities by the stamping operation. It is also conceivable, however, for a raised structure or protruding film regions to be produced with the aid of stamping carried out from the rear side of a film. The rear side here is that side of the film which is to be fixed on the surface of a gripping zone.
[0009] In the case of a further preferred exemplary embodiment, it is provided that the film is a plastic film containing expandable particles, the raised structures being formed by film regions with expanded particles. The raised structures can be produced either prior to the article being coated with the film or after the article has been coated with the film. In both cases, certain areas of the film are treated, for example brought into contact with a heated body, such that the expandable particles end up expanding. On account of the larger amount of volume required, the material in the treated areas protrudes out of the film surface. Thermally expandable particles, in particular hollow micro-spheres formed of plastic, are particularly preferred. These contain inside them a liquid that is capable of evaporating. During heating, the polymer material and the hollow micro-spheres are inflated to a multiple of their original size by the evaporating liquid. The expanding hollow micro-spheres thus result in an increase in volume in the coating in the thermal-treatment regions, raised structures or raised surface regions forming as a result. A process for producing raised structures with the aid of expandable particles is described in published, European patent application EP 05 005 101.0-2113 which is incorporated herein by reference.
[0010] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0011] Although the invention is illustrated and described herein as embodied in an article, in particular a writing implement, having a gripping zone with raised structures, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0012] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a diagrammatic, perspective view of a wood-encased pencil in which a gripping zone is produced with an aid of a shrink film according to the invention;
[0014] FIG. 2 is a diagrammatic, perspective view corresponding to FIG. 1 of the pencil in which the gripping zone is produced in an alternative manner;
[0015] FIG. 3 is a diagrammatic, perspective view of a detail of a film with a raised structure located on it;
[0016] FIG. 4 is a diagrammatic, perspective view of a detail of a plastic film which contains expandable particles;
[0017] FIG. 5 is a diagrammatic, perspective view of detail V shown in FIG. 4 ; and
[0018] FIG. 6 is a diagrammatic, sectional view of a detail of a film with integrally formed raised structures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 4 thereof, there is shown, as an example of an article, a pencil with a wooden casing 1 containing a core 2 . A gripping zone 3 with raised structures in the form of ribs 4 extending in the longitudinal direction of the pencil is provided on a circumferential surface of the wooden casing 1 , the circumferential surface being provided, for example, with a coating of paint. The ribs 4 , rather than being provided directly on the pencil surface, are provided on a shrink film 5 which, in a state of prefabrication, loosely encloses the subsequent gripping zone, as is shown in FIG. 1 . During heating, the film contracts and then adheres firmly to the pencil surface. The ribs 4 need not necessarily be provided on the shrink film. They may also be produced subsequently by conventional processes, for example in accordance with European patent EP 1 177 108 B1 or published, non-prosecuted German patent application DE 203 14 274.8. A shrink film is a cold-stretched thermoplastic film, for example based on PETP, PE or PVC.
[0020] A further possible way of producing the gripping zone 3 is indicated in FIG. 2 . Here, a blank 6 a of a film 6 is wound around a pencil-surface region forming the subsequent gripping zone 3 and is fixed thereon, for example, by adhesive bonding. It is particularly expedient in such a procedure for the raised structures—which in the present case are protuberances 7 —to be produced before the film 6 is applied, rather than being applied to the article itself. This is because the task of applying raised structures to planar films 6 can be carried out considerably more easily than the task of applying them to articles having gripping zones with often complicated curvature. Large film surfaces can easily be provided with raised structures in an extremely short period of time, for example, by screen printing. Examples of possible films are those made of PE, PVC, PA, PC and the like.
[0021] Adhesive bonding is preferably a possible way of fixing a film 6 of the abovementioned type on the surface of an article. For this purpose, the film is provided with an adhesive layer 9 on its rear side 8 as shown in FIG. 3 . FIG. 4 shows a film 6 that contains expandable particles with an average size of 2 μm to 45 μm. Use is preferably made of so-called hollow micro-spheres. These are spherical particles that contain inside them a liquid that can easily be evaporated. If, then, an area of a film is heated, for example, by direct thermal contact with the aid of a die or by radiation, for example infrared radiation, the liquid evaporates, as a result of which the hollow micro-spheres inflate. The inflation is made possible by the polymer material used being a thermoplastic. Hollow micro-spheres of the type mentioned above are available, for example, under the trade name “Expancel 551 DU40” from Akzo Nobel Chemicals GmbH, D-46446 Emmerich. Expanded hollow micro-spheres 10 increase the volume of a heated area of the film 6 such that, in the area, the film material goes beyond the film surface and forms a raised structure. The operations of heating and expanding the hollow micro-spheres best take place on the article itself since, here, the film 6 is fixed to the surface of the article, so that the increase in volume can cause a protrusion to form only on a top side 11 , but not on the rear side 8 , of a film.
[0022] FIG. 6 shows the film 6 in which raised structures, for example in the form of protuberances 7 , are formed by a non-illustrated stamping tool being forced in from the rear side 8 of the film 6 in arrow direction 12 , a female die with complementary cavities possibly being used for abutment purposes. Use is expediently made here of a fill material made of thermoplastic and the stamping operation is carried out under increased temperature. | An article, in particular a writing implement, has a gripping zone with raised structures. In which case, in a region of the gripping zone, the article is coated with a film which has the raised structures on its surface. In particular, the adherence of the raised structures to the surface of the article is improved. | 1 |
[0001] This application is a continuation of U.S. patent application Ser. No. 09/917,256, filed on Jul. 27, 2001, which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to systems and methods for managing direct current (“DC”) power. More specifically, this invention relates to DC to DC converters and power management systems and methods.
[0003] Today, most hybrid fuel cell/battery power systems, and other systems having multiple DC power sources and batteries, are arranged as shown in FIG. 1. The arrangement shown in FIG. 1 is referred to as the “battery node” approach because the power must pass through the battery output node at the battery voltage. This configuration therefore uses battery charge controller and inverter ratings that match the capacity of the fuel cell.
[0004] Conventional DC to DC converters and their associated inverter designs and products have several deficiencies that make it difficult for them to adequately meet the functional requirements of modem hybrid power systems. These conventional converters are therefore unable to satisfy the needs of a typical energy user. Among other problems, conventional DC to DC converters typically generate electrical noise and high frequency ripple currents on the input (source) and output (load) busses. They are also poorly adapted to the regulation of input current. Furthermore, they typically exhibit energy conversion efficiencies of only around 80-90%.
SUMMARY OF THE INVENTION
[0005] According to one aspect of this invention, a DC to DC Buck and Boost Converter is provided. “Buck” power conversion refers to a reduction in voltage from an input side of the converter to an output side. “Boost” power conversion refers to an increase in voltage from the input side to the output side of the converter. According to one embodiment of this invention, the Buck and Boost DC to DC Converter includes an electrical circuit that allows batteries and other electrical energy storage devices to be charged from or to discharge to a variable voltage DC bus. This electrical circuit can also be configured to enable seamless integration with other energy storage devices and/or DC power sources, such as fuel cells, to provide DC power for a Power Management System.
[0006] Improved Boost DC to DC Converters are also provided which reduce noise and ripple currents in low voltage/high current applications. According to one embodiment, a resonant capacitance is provided by two resonant capacitors which store voltage using switches that permit zero voltage switching. According to another embodiment, an input capacitor is provided to maintain a constant voltage input to a resonant circuit. The addition of the input capacitor reduces voltage stress in a switching circuit.
[0007] A DC to DC Converter is provided in a module of a Power Management System. The Power Management System preferably provides both full power source management and power conditioning. In other words, the Power Management System preferably manages power flow to and from multiple, isolated DC power sources and energy storage devices, while delivering high quality alternating current (“AC”) power to a load.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing features and advantages of the present invention will become more readily apparent from the following detailed description, made with reference to the following figures, in which:
[0009] [0009]FIG. 1 is a schematic block diagram of a conventional “battery node” hybrid power configuration according to the prior art.
[0010] [0010]FIG. 2 is a schematic block diagram of a series power management system configuration according to one embodiment of the present invention.
[0011] [0011]FIG. 3 is a schematic block diagram of a parallel power management system according to another embodiment of the present invention.
[0012] [0012]FIG. 4 is a schematic circuit diagram of a Buck and Boost DC to DC Converter according to another aspect of this invention.
[0013] [0013]FIG. 5A is a schematic circuit diagram of a Boost DC to DC Converter according to a further aspect of this invention.
[0014] [0014]FIG. 5B is a schematic circuit diagram of a Boost DC to DC Converter according to a still further aspect of this invention.
[0015] [0015]FIG. 5C is a schematic circuit diagram of a Boost DC to DC Converter according to the prior art.
[0016] [0016]FIG. 6 is a graph illustrating the current flow over time through an inductor of the Buck and Boost DC to DC converter of FIG. 4.
DETAILED DESCRIPTION
[0017] There are presently two preferred Power Management System configurations according to this invention, including a series converter configuration, illustrated in FIG. 2, and a parallel converter configuration, shown in FIG. 3. In FIGS. 2 and 3, the hybrid power systems 10 , 110 of these two embodiments are shown having only a fuel cell 20 and a battery bank 25 . It should be noted, however, that the fuel cell 20 could easily be replaced by any other DC power source, by a rectified AC source, or by an energy storage unit, as desired. Similarly, the battery bank 25 could be replaced by a flywheel energy storage unit or other energy storage device that is charged with and discharges direct current. It should also be noted that any number of fuel cells 20 and DC to DC Converters 14 can be arranged in parallel to supply current to the inverter. And furthermore, the single battery bank 25 could be replaced by any number of parallel battery banks or strings connecting to the common bus.
[0018] As noted above, the schematic block diagrams in FIGS. 2 and 3 illustrate a series and a parallel Power Management System 10 , 110 , respectively, according to preferred embodiments of the present invention. Referring to FIGS. 2 and 3, each of the Power Management Systems 10 , 110 includes three main modules: the Controller Module 12 ; the DC to DC Converter Module (including the current control circuit) 14 , 114 ; and the Inverter Module 16 . Any number of independent power sources, such as fuel cell 20 and battery bank 25 , are also included.
[0019] The independent power sources 20 , 25 can operate over different voltage ranges. The Controller Module 12 senses and analyzes the operating output of the power sources 20 , 25 . The DC to DC Converter Module 14 , 114 in conjunction with the Controller Module 12 , manages and consolidates the power from these sources 20 , 25 into a DC bus 13 for processing by the Inverter Module 16 . The system 10 , 110 delivers AC electrical power to a load through an output 18 of the Inverter Module 16 . The system 10 , 110 also automatically controls the charging and discharging of the battery bank 25 .
[0020] The DC to DC converter 14 , 114 operates with its own current control circuit 15 . It also communicates with the system controller 12 and receives input signals from the fuel cell controller 22 . Therefore, the terms “DC to DC Converter” and “DC to DC Buck and Boost Converter” can be used to refer to not only the actual DC to DC Converter switch related hardware, but also to the current control circuit 15 and the integration of these subsystems with the system controller 12 and the fuel cell (or photovoltaic array, or rectified AC, etc.) controller 22 .
[0021] In both the series and parallel configurations, each DC bus 13 can operate at its optimum voltage. In the relatively low voltage and high current examples shown in FIGS. 2 and 3, the converter circuits 14 , 114 use power MOSFETs to charge and discharge inductors to transfer power to and from the DC power sources. Both the series and parallel power management configurations 10 , 110 are preferably configured to operate fully automatically between zero and full power throughput in any of their various operating modes. The transition between these modes can be seamless. Various possible modes include a first mode (e.g., Startup/Shutdown Mode) in which the battery 25 is supplying all of the power to the DC bus 13 and inverter 16 ; a second mode (e.g., Normal Operation Mode) in which the fuel cell 20 is supplying all of the power to the inverter 16 ; a third mode (e.g., Recharge Mode) in which the fuel cell 20 is supplying all of the power to the inverter 16 and is also charging the battery 25 ; and a fourth mode (e.g., Transient Mode) in which the fuel cell 20 is supplying less than the total amount of desired power to the inverter 16 and the battery 25 is supplying the balance of the power.
[0022] The series configured Power Management System 10 , shown in FIG. 2, will now be described in more detail. Referring specifically to FIG. 2, the term “series” refers to the fact that the DC to DC Converter 14 is located in series with the Fuel Cell 20 and the Inverter 16 . The series configuration illustrated in FIG. 1 has an input to the inverter that is at the battery output node voltage. Unlike the conventional Hybrid Power configuration, the series Power Manager 10 includes a Controller Module 12 in addition to the DC to DC Converter Module 14 and the Inverter Module 16 . The combination of these modules can be referred to as a Power Manager or Power Management System 10 .
[0023] The Controller Module (or System Controller) 12 manages both the Inverter Module 16 and the Converter Module 14 to provide an integrated control system. The primary functions of the Controller Module 12 are to control the current drawn out of the fuel cell and to operate the Inverter Module 16 . The Controller 12 (in combination with the DC to DC Converter 14 ) controls the voltage of the variable voltage DC bus. The Control Module 12 thereby provides coordinated control of the Power Management System 10 . All of the modules, or subsystems, of the Power Management System 10 can be physically integrated together into a single hardware package.
[0024] [0024]FIG. 3 shows one possible embodiment of a parallel Power Management System configuration 110 . Referring to FIG. 3, in this parallel system embodiment 110 , the current control circuit 15 detects and controls the DC voltage on the buses for both the battery 25 and the power converter 114 . As shown, one of the primary advantages of the parallel system 110 shown is that the voltage output from the fuel cell 20 goes directly into the inverter 16 . Because only a relatively small amount of the power is required to travel through the DC to DC converter (i.e., during battery charging or transient conditions), this configuration significantly reduces losses (such as switching losses) and improves efficiency. This configuration also reduces noise and ripple currents.
[0025] Referring now to FIGS. 4, 5A, and 5 B, three DC to DC Converter circuits 114 , 214 , 314 , respectively, have been developed to perform the functions of the invention. Of course, many other circuit arrangements could be developed to perform the same functions and the invention is therefore not limited to any particular circuit arrangement. Circuit A, shown schematically in FIG. 4, provides a fully bi-directional buck and boost (and buck-boost) converter 114 . Circuits B and C, illustrated in FIGS. 5A and 5B, respectively, are DC to DC converters 214 , 314 with a boost capability only.
[0026] Referring to FIG. 4, Circuit A consists of an “H” switch bridge having four switch and diode pairs S A and D A , S B and D B , S C and D C , and S D and D D , coupled to the buck/boost inductor L BB . In this arrangement, the DC to DC converter 114 circuit allows both buck and boost current in both directions. This converter 114 provides a current-controlled type of converter that follows the current demanded from the fuel cell by the inverter (or other load). This circuit provides excellent control of both bucking and boosting voltages with a minimum number of components.
[0027] Although FIG. 4 shows the DC to DC Converter 114 installed in series with a fuel cell 20 and inverter 16 , such as in the Power Management System configuration shown in FIG. 2, because the converter can transfer power in either direction, the Circuit A converter 114 can also operate in the parallel configuration of FIG. 3. In the parallel Power Management System configuration 110 shown in FIG. 3, bi-directional buck and boost capabilities, such as those provided by this converter 114 , are required. In the series configuration 10 illustrated in FIG. 2, however, only a single direction boost capability is required. Of course, many other multi-source power systems are possible which would require the fully bi-directional buck and boost capabilities of the Circuit A converter 114 or a similar converter.
[0028] [0028]FIG. 6 is a graph illustrating the current flow over time through the inductor L BB of Circuit A of FIG. 4. Referring to FIGS. 4 and 6, Circuit A operates as follows. When switch S A is closed (on) and switch S D is closed (on), current flows from the fuel cell 20 through the inductor L BB to ground. The circuit remains in this state until the inductor L BB is charged to a threshold voltage. This state is shown as stage 1 in FIG. 6. A voltage (or current) monitoring circuit (not shown) monitors the voltage across (or current through) the inductor L BB .
[0029] Once the inductor L BB has been charged to the threshold voltage, switch S D is opened (off) and switch S C is closed (on), while switch S A remains closed (on). This state is shown as stage 2 in FIG. 6. During this stage, current is flowing from the fuel cell 20 to the inverter 16 and battery 25 . If the voltage at the output of the converter 114 (i.e., the input to the inverter 16 ) is raised (or boosted) above the voltage at the input of the converter 114 (i.e., the output terminal of the fuel cell 20 ), then the circuit is in the boost configuration. In the boost configuration, the slope of the line in FIG. 6 representing stage 2 is downward and is proportional to the voltage delta across the inductor L BB (i.e., the difference between the input and output voltages), and the current through the inductor L BB is being dissipated.
[0030] If the voltage at the output of the converter 114 is lower than the voltage at its input, then the circuit is in the buck configuration (i.e., voltage at the inverter input is reduced below the voltage at the fuel cell output). Current and power are still flowing from the fuel cell 20 to the inverter 16 and battery 25 , but the slope of the line in FIG. 6 representing stage 2 will be upwards, again in proportion to the voltage delta across the inductor L BB . In this state, the current through the inductor continues to ramp up until switch S A is opened. The converter 114 can be kept in the buck configuration simply by cycling switch S A to allow the current to maintain a steady level.
[0031] In the boost configuration, after the energy in the inductor L BB is substantially dissipated, switch S A is opened (off) and switches S B and S C are closed (on). Closing switches S B and S C discharges the remaining energy in the inductor L BB fast without stressing the two diodes D B and D C . At the same time, however, some current is also flowing through the diodes D B and D C . When the current through (or voltage across) the inductor L BB drops below a threshold value (i.e., current less than 5 A), switches S B and S C are opened (off), allowing the diodes D B and D C to complete the discharge of the inductor L BB . Once the current through the inductor L BB reaches zero, another cycle is started by closing switches S A and S D .
[0032] The inductor L BB should be discharged after reaching the end of stage 2 before beginning a new cycle (stage 1 ). A current from right to left may still be passing through the inductor L BB at the end of stage 2 . In other words, a reverse current may still exist in the inductor L BB at this point. If switches S A and S D were simply turned back on and switches SC and S B turned off, a large forward current would be generated from the fuel cell through the inductor L BB to ground. These two oppositely directed currents could damage the diodes. Accordingly, the inductor L BB is completely discharged before the next boost cycle is started.
[0033] It should also be noted that the converter 114 of Circuit A maintains a high current level during stage 2 . This high current level increases the RMS current and eliminates the need for generating a large current peak. The bi-directional aspect of the converter 114 of Circuit A allows the inductor L BB to be discharged faster (i.e., during stages 3 and 4 ) between boost cycles (stages 1 and 2 ).
[0034] Power flow to the fuel cell 20 , although not wanted in practice, is also possible using the bi-directional converter 114 of FIG. 4, and is explained here for illustration. This reverse power flow is potentially desirable for rechargeable DC power sources. Power flow to the fuel cell 20 (from right to left) is enabled in the boost configuration by closing switch S C and cycling S B . It is enabled in the buck configuration by cycling switch S C . A practical application of where power flow from the inverter/battery would be desirable is where the fuel cell is replaced by a second storage device such as a battery. For example, a battery bank operating at nominally 24VDC can be used to replace the fuel cell 20 . In this circumstance, in the conventional direction (left to right), the DC to DC converter 114 boosts that voltage to nominally 48VDC, which is the operating voltage of the original battery bank. In the opposite direction (right to left), the DC to DC converter 114 bucks the voltage of the original battery bank to 24VDC, for instance, to recharge the battery that replaced the fuel cell.
[0035] As noted briefly above, a novel method of substantially decreasing the peak to RMS current ratio is also provided. This method is enabled, for instance, by using four parallel gate (or switch) and diode pairs. Again referring to FIGS. 4 and 6, the use of four parallel gate and diode pairs allows the converter 114 of Circuit A to reduce the current peak and tailor the shape of the current flowing through the inductor L BB during each cycle. This is accomplished by operating pairs of switches for the first three stages of the cycle. During stage 1 , the switches S A and S D are on. During stage 2 , the switches S A and S C are on. And, during stage 3 , switches S B and S C are on. During the fourth and final stage (stage 4 ), current is conducted through diodes D B and D C only. Alternatively, the cycle can be constructed of three stages rather than four, with the first two stages being the same as the first two stages described previously and with the third stage being that of conducting current through diodes D B and D C only. In other words, the third stage of the four stage process could be eliminated, if desired, to create a three stage process.
[0036] “Boost only” DC to DC Converter circuits 214 , 314 are shown in FIGS. 5A and 5B, respectively. These converter circuits represent a significant improvement to the conventional converter circuit design described in the technical paper: Duarte, Claudio Manoel da Cunha and Ivo Barbi, “A New Family of ZVS-PSW Active-Clamping DC-to-DC Boost Converters: Analysis, Design, and Experimentation” IEEE Transactions on Power Electronics , Vol. 12, No. Sep. 5, 1997, pp 824-831 (the “Duarte paper”) (see FIG. 5C).
[0037] Circuit B, shown in FIG. 5A, and Circuit C, shown in FIG. 5B, are designed to be zero-voltage switching (ZVS) pulse-width modulation (PWM) active-clamping DC to DC boost converters. The circuits are based on the “boost-buck-boost” circuit shown in FIG. 1( c ) of the Duarte paper. The general circuit configuration shown in FIG. 1( c ) of the Duarte paper is reproduced here as FIG. 5C. In each of the circuits shown in FIGS. 5A, 5B, and 5 C, power is transferred to the load during a boost stage, while the clamping action is performed during a buck-boost stage. The converter circuits of FIGS. 5A, 5B, and 5 C differ from earlier conventional boost pulse-width modulation (PWM) converters because of the incorporation of an additional auxiliary switch (S 2 ), a resonant inductor (L R ), a resonant capacitor (C R1 ) (which includes the output capacitance of the power switches), and a clamping capacitor C C . In each of these circuits, switch S 1 is the main switch. Voltage V S is the input voltage and voltage V 0 is the output voltage. Inductor L R and capacitor C R1 are the resonant circuit inductor and capacitor, respectively. Inductor L B is the boost inductor.
[0038] Despite the similarities between these converter circuits, the converters 214 , 314 of Circuits B and C, respectively, each offer an improved design over that of the prior art circuit 414 . More specifically, an additional capacitor is included in each of Circuits B and C to achieving soft switching and reliable current control for low voltage (e.g., less than about 100V) and high current (e.g., up to around 150 A) applications. The circuits developed and described by Duarte and Barbi are primarily aimed at high voltage (i.e., around 300V-400V), low current (i.e., around 5 A) applications, and because of the low current involved, do not contemplate the need for additional capacitors for satisfactory switching. By recognizing and addressing this need, the two converters 214 , 314 of FIGS. 5A and 5B are able to offer improved performance over prior art DC to DC converter circuits, such as the one 414 illustrated in FIG. 5C, in low voltage/high current applications.
[0039] Referring to FIG. 5A, the DC to DC converter 214 of Circuit B includes the addition of a capacitor C R2 on the output side of the resonant circuit across the auxilliary switch S 2 . The second resonant capacitor C R2 is beneficial in low voltage and high current applications such as fuel cell and battery systems because it substantially reduces output DC current ripple and switching losses and provides better control for combined low voltage/high current applications.
[0040] The principle of operation of Circuit B is as follows. The inductance in the boost inductor L B is assumed to be large enough for the inductor to act as a current source (I S ). The clamping capacitor C C is selected to have a large capacitance so that the voltage V C across this capacitor can be considered a constant. The main and auxiliary switches S 1 and S 2 , respectively, are switched in a complementary way. The main switch S 1 is turned off at time (t)=t 0 , when the switching period starts.
[0041] Before time t 0 , the main switch S 1 is on and the auxiliary switch S 2 is off. When S 1 is turned off at time t 0 , the resonant capacitor C R1 is linearly charged, by the boost inductor current I S , to a base voltage V 0 . Due to the presence of the resonant capacitor C R1 , the main switch S 1 is turned off with no switching loss. When the voltage V CR1 reaches the voltage V 0 , the boost diode D B begins conducting. The current through the resonant inductor L R and the resonant capacitor C R1 then evolves in a resonant way, and the resonant capacitor voltage V CR1 rises from the base voltage V 0 up to a increased voltage equal to V Cc +V 0 . At that point, the voltages are clamped. As the capacitor voltage V CR1 becomes equal to V Cc +V 0 , the voltage across the auxiliary switch S 2 is zero, and the switch S 2 turns on with a no loss zero-voltage switching (ZVS). The resonant inductor L R current then ramps down until it reaches zero, when it changes its direction and rises again.
[0042] This stage ends when the auxiliary switch S 2 is turned off with zero volts on the switch S 2 due to the presence of the added capacitor C R2 at time t 3 (t=t 3 ). The voltage across the resonant capacitor C R1 falls, due to resonance between inductor L R and the first or second resonant capacitor C R1 or C R2 , until it reaches zero at time t 4 (t=t 4 ). In stage 5 , the main switch S 1 is turned on without any switching losses (ZVS), because the first resonant capacitor voltage V CR1 became null. During this stage, the current through the resonant inductor L R changes its polarity and ramps up to reach the boost inductor current I S . At time t 5 (t=t 5 ), the diode D B becomes reversibly biased and power is not transferred to the load. This stage ends when the main switch S 1 is turned off at the end of the first switching cycle to start the next switching cycle.
[0043] Circuit B offers an improvement over the prior art by splitting its resonant circuit capacitance between two capacitors C R1 and C R2 to allow zero or low voltage switching by both switches S 1 and S 2 . More particularly, the second resonant capacitor C R2 acts as part of the resonant control circuit that includes the resonant inductor L R and the first resonant capacitor C R1 . The oscillation that occurs when the main switch S 1 is switched on and off can be neutralized using the second capacitor C R2 by selectively switching the auxiliary switch S 2 . When the second capacitor C R2 is substantially smaller than the first capacitor C R1 , oscillation control can be provided at low voltage. By dividing the capacitance between the two resonant circuit capacitors C R1 and C R2 , the voltage on switches S 1 and S 2 can be ramped down to allow zero voltage switching. Furthermore, because the capacitors store the voltages with no voltage losses, they provide efficient power transfer between the input and the output nodes of the converter 214 .
[0044] Referring now to FIG. 5B, the DC to DC converter 314 of Circuit C is another boost converter embodiment capable of use in the Power Management System 10 of FIG. 2. In this converter 314 , an input capacitor C 1 has been added to the input side of the resonant circuit of the prior art converter 414 of FIG. 5C. Without the capacitor C 1 , the voltage at node A dips in high current applications, and large voltage swings occur at that node. These voltage swings cause a large voltage stress on switch S 1 and result in an inability to achieve reliable control of the current through the resonant inductor L R .
[0045] With the addition of capacitor C 1 in the circuit, the voltage at node A can be held steady during switching. Because the input capacitor C 1 maintains a constant voltage at node A, the voltage stress on the main switch S 1 is reduced. Specifically, by dampening the voltage swings at node A, the input capacitor C 1 filters out high voltage swings and keeps them from affecting the switch S 1 . This steady voltage at node A helps achieve soft switching and good current control.
[0046] Having described and illustrated the principles of the invention in various preferred embodiments thereof, it should be apparent that the various implementations of the invention described above can be modified in arrangement and detail without departing from such principles. We claim all modifications and variations coming within the spirit and scope of the following claims. | A DC to DC Converter includes an electrical circuit that allows batteries and other electrical energy storage devices to be charged from or to discharge to a variable voltage DC bus. This electrical circuit also enables seamless integration with other energy storage devices and/or DC power sources, such as fuel cells, to provide DC power for a Power Management System. A Power Management System preferably provides both full power source management and power conditioning. The Power Management System is able to manage power flow to and from multiple, isolated power sources and energy storage devices to deliver high quality alternating current (“AC”) power to a load. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns the preparation of novel curable, ethylenically unsaturated polymers formed by reacting a polycarbodiimide having free isocyanate groups with compounds having active hydrogens and copolymerizable ethylenic unsaturation. The ethylenically unsaturated, active hydrogen compounds can be partially replaced with saturated compounds.
2. Description of the Prior Art
Vinyl copolymerizable thermosetting resins are in widespread commercial use. Of special interest are those resins, which are capable of rapid cure, and which have outstanding physical and thermal properties.
Most commercially available resins are products of polyester or epoxy chemistry. In general, the preparation of these resins requires high temperatures, several process steps, and long processing time.
U.S. Pat. No. 4,148,844 to von Bonin et al, discloses casting resins consisting of a mixture of polycarbodiimides in vinyl monomers which cure by heating to a temperature above 40° C. The polycarbodiimides are prepared by reacting polyfunctional or monofunctional isocyanates with a phospholane oxide catalyst. The unreacted or free terminal isocyanate groups of the resulting polycarbodiimides can be eliminated by reaction with an amine or alcohol.
U.S. Pat. No. 4,463,158 to O'Connor et al discloses a liquid polymer composition which comprises a modified polyurethane oligomer containing ethylenic unsaturation and a free radical generating catalyst. The polyurethane oligomer is prepared by reacting an organic polyisocyanate with an isocyanate reactive group containing unsaturated monomer to obtain an isocyanate-terminated prepolymer of controlled molecular weight having a free isocyanate content of from about 0.5% to about 30%. The isocyanate-terminated prepolymer is then reacted with a polyol to produce a polyurethane oligomer of controlled molecular weight with terminal reactive unsaturation.
U.S. Pat. No. 4,367,302 to Le Roy et al discloses crosslinkable thermoplastic polyurethanes having isocyanate end groups and containing ethylenic side groups. These polyurethanes are obtained by reacting an organic diisocyanate with a saturated diol and an unsaturated diol. The ethylenic side groups in the polyurethane product are branched over the entire whole length of the linear skeleton of the polyurethane molecule.
U.S. Pat. No. 4,758,625 to Boyack et al discloses urethane crosslinked acrylic coatings. The polymer backbone exhibits the basic characteristics of acrylic polymers and contains at least 50% by weight of acrylic monomer.
U.S. Pat. No. 4,028,310 to Shafer et al relates to the preparation of polyisocyanate containing acylurea groups and, optionally, carbodiimide groups in the polyisocyanate polyaddition reaction carried out in the presence of diamine chain extenders.
U.S. Pat. No. 4,077,989 to Shafer et al relates to the production of modified isocyanates wherein compounds containing isocyanate and carbodiimide groups are reacted with carboxylic acids.
U.S. Pat. No. 4,174,433 and U.S. Pat. No. 4,192,925, both to Shafer et al, relate to polyols modified by guanidine groups, which are used as starting components for the preparation of polyurethane plastics.
U.S. Pat. No. 4,192,926 to Shafer et al relates to polyols modified by acylurea groups used as starting components in the preparation of foamed polyurethane plastics.
U.S. Pat. No. 4,192,927 to Shafer et al relates to polyols modified by phosphonoformamidine groups, for use as a starting component in the preparation of foamed polyurethane plastics.
U.S. Pat. No. 4,321,394 to Shafer et al relates to a process for producing addition compounds of compounds containing hydroxyl groups and carbodiimides substantially free from isocyanate groups, by reacting the components in the presence of an inorganic or organic tin compound used as the catalyst.
Ulrich et al, Journal of Cellular Plastics, September-October 1985, pages 350 to 357 reviews the chemistry and properties of low density polycarbodiimide foams and discloses suitable formulations, processing conditions, physical properties and small scale flame test results of the resultant polymers.
Williams et al, "Carbodiimide Chemistry: Recent Advances", Chem. Rev., Vol. 81, pages 589 to 636 (American Chemical Society 1981) is a comprehensive literature review of carbodiimide chemistry covering synthesis, structure and physical properties, chemical properties, metal insertion reactions, formation of heterocycles, carbodiimides in biological and polymer chemistry, and their application in photography, dyeing and related subjects, and analysis.
Kurzer et al, "Advances in the Chemistry of Carbodiimides", Chemical Reviews, Vol. 67, No. 2, pages 107 to 152 (Mar. 27, 1967) reviews carbodiimide chemistry including synthesis, physical properties, structure, chemical properties and various carbodiimide compositions.
Wagner et al, "Alpha, Omega-Diisocyanatocarbodiimides, Polycarbodiimides, and Their Derivatives", Angewandte Chemie (International edition in English), Vol. 20, No. 10, pages 819-898 (October 1981) discusses the synthesis and properties of these carbodiimides and various reactions particularly the in situ production of polycarbodiimides via matrix reactions in flexible polyurethane foams.
Khorana, "The Chemistry of Carbodiimides", Chemical Reviews, Vol. 53, pages 145 to 166 (1953) is a review article covering the preparation and properties of carbodiimides, as well as base catalyzed addition reactions and comparison of carbodiimides with similar systems.
SUMMARY OF THE INVENTION
In accordance with the present invention, saturated and ethylenically unsaturated compounds containing carboxylic, amino or alcohol groups are reacted under mild conditions and in short process times with polycarbodiimides containing free isocyanate units to provide polymers with excellent properties. The unsaturated groups bonded to the polymers are particularly important because these groups provide reactive centers that can be crosslinked, either thermally or in the presence of catalysts that initiate polymerization or by radiation. The polymers can also be crosslinked either alone or by copolymerization with various unsaturated monomers. The resulting crosslinked or cured resins provide excellent properties such as hardness, high elongation, excellent toughness, high heat distortion temperatures and good corrosion resistance.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polymers of this invention, containing isocyanate and carbodiimide, can also be partially branched or crosslinked by reacting the isocyanate groups with the carbodiimide segments, and also by dimerization of the carbodiimide groups.
The combination of polycarbodiimides containing free isocyanate groups and their reaction products with carboxylic acids, amines and alcohols can lead to polymers with segments corresponding to the following general formulae: ##STR1## wherein, X represents a hydrogen, chlorine, bromine, an aliphatic, cycloaliphatic, aromatic, or araliphatic radical containing from about 1 to 12 carbon atoms;
R represents a difunctional aliphatic, cycloaliphatic, aromatic, or araliphatic radical having from about 4 to 25 carbon atoms, preferably 4 to 15 carbon atoms, and free of any group which can react with isocyanate groups;
R 1 represents a hydrogen, an aliphatic, cycloaliphatic, aromatic, araliphatic radical having from about 1 to 12 carbon atoms;
R 2 represents a hydrogen or a monovalent radical that can be aliphatic, cycloaliphatic, araliphatic, aromatic, alkyl substituted aromatic, alkyl substituted cycloaliphatic, which can contain one or two double bonds, and which can contain any one or a combination of halogen, phosphorus, silicon, or oxygen groups in any form that does not react with NCO;
R 3 represents a divalent radical that can be aliphatic, cycloaliphatic, araliphatic, aromatic, alkyl substituted aromatic, alkyl substituted cycloaliphatic, and can contain any one or a combination of halogen, phosphorus, silicon, or oxygen in any form that does not react with NCO. These groups impart flame retardancy and improve physical and thermal properties. R 3 can be derived from various sources including polyether diols, saturated polyester diols, hydroxy terminated polyurethanes and other hydroxy terminated polymers such as polythioethers, polycarbonates, polyacetals, polybutadiene, polybutadiene copolymers and the like.
A represents a divalent group such as: ##STR2## wherein, R 4 is a divalent hydrocarbon radical that can be aliphatic or alicyclic; y is an integer from 1 to 8, preferably from 2 to 5, and most preferably 2 or 3.
The aforementioned definitions of R, R 1 , R 2 , R 3 , R 4 , R 5 , X and A are consistent with all subsequent formulations represented herein.
The synthesis of these resins can be carried out in the presence or absence of a suitable inert solvent and in general is completed in relatively short times varying from 2 to 10 hours.
Suitable inert solvents include hexane, cyclohexane, benzene, toluene, xylene, chlorobenzene, chloroform, methylene chloride, tetrahydrofuran, ethyl acetate, acetone, styrene, alpha-methyl styrene, divinyl benzene, 4-methyl styrene, 4-ethyl styrene, 4-n-butyl styrene, 4-isopropyl styrene, tert-butyl styrene, 4-chlorostyrene, 3,4-dichlorostyrene, methyl methacrylate, methyl acrylate, n-butyl acrylate, n-butyl methacrylate, allyl methacrylate, isopropyl methacrylate, and solvent mixtures.
The synthesis can be performed in solution, at low temperatures on the order of about 30° C. to 190° C. and preferably about 50° to 80° C. This is particularly advantageous when using ethylenically unsaturated monomers such as styrene, or methyl methacrylate as solvents or copolymerizable monomers.
In one aspect of the invention, these resins can be prepared with pendant and terminal vinyl groups. The first step in preparing resins with terminal vinyl groups is the formation of a polycarbodiimide intermediate with free isocyanate groups starting from a diisocyanate or a mixture of diisocyanates in the presence of a catalyst such as ring or linear pentavalent phosphorus compounds, aluminum alkoxides, arsenic oxides, antimony oxides, sodium alkoxides, naphthenates of Mn, Fe, Co and Cu, and acetyl acetonates of Be, Al, Zn, and Cr, and preferably substituted phospholene oxide or dioxo-oxa-phospholane. Alternatively, ionizing radiation or photochemical initiation, such as ultraviolet light can also be used to effect crosslinking.
The diisocyanates which can be used include aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic diisocyanates of the type described, for example, by W. Siefken in Justus Liebigs Annalen der Chemie, 562, pages 75 to 136, (1949) for example, those corresponding to the following formula:
OCN--R--NCO (XI)
wherein, R is as already defined.
Suitable diisocyanates include 1,4-tetramethylene diisocyanate; 1,4 and/or 1,6-hexamethylene diisocyanate; 1,12-dodecane diisocyante; cyclobutane-1,3-diisocyanate; cyclohexane-1,3- and 1,4-diisocyanate and mixtures of these isomers; 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl cyclohexane; 2,4- and 2,6-hexahydrotolylene diisocyanate and mixtures of these isomers; hexahydro-1,3- and/or 1,4-phenylene diisocyanate; perhydro-2,4'- and/or 4,4'-diphenyl methane diisocyanate; 1,3- and 1,4-phenylene diisocyanate; 2,4- and 2,6-tolylene diisocyanate and mixtures of these isomers; diphenyl methane-2,4'- and/or 4,4'-diisocyanate; naphthalene-1,5-diisocyanate; 1,3- and 1,4-xylylene diisocyanates, 4,4'-methylene-bis(cyclohexyl isocyanate), 4,4'-isopropyl-bis-(cyclohexyl isocyanate), 1,4-cyclohexyl diisocyanate and 3-isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate (IPDI); 1-methyoxy-2,4-phenylene diisocyanate; 1-chloropyhenyl-2,4-diisocyante; p-(1-isocyanatoethyl)-phenyl isocyanate; m-(3-isocyanatobutyl)-phenyl isocyanate, and 4-(2-isocyanate-cyclohexyl-methyl)-phenyl isocyanate, and mixtures thereof.
It is also possible in principle to use aliphatic or aromatic diisocyanates of the type which are obtained by reacting excess diisocyanate with difunctional compounds containing hydroxyl or amine groups and which, in practical polyurethane chemistry, are referred to either as "modified isocyanates" or as "isocyanate prepolymers".
In the formation of the polycarbodiimide intermediate, once the polymer has reached a desired molecular weight on the order of about 800 to 40,000 the isocyanate groups and the carbodiimide segments are reacted with saturated or unsaturated monomers having active hydrogens such as carboxylic, amino, alcohol or thio groups.
Examples of these materials include acrylic acid, methacrylic acid, acetic acid, phenylacetic acid, phenoxyacetic acid, propionic acid, hydrocynnamic acid, lauric acid, oleic acid, 4-pentynoic acid, propyolic acid, 2-butynoic acid, acrylamide, methacrylamide, phenethyl amine, propargylamine, diethylamine, dipropylamine, piperazine, n-butylamine, propargyl alcohol, 2-phenoxy ethanol, phenethyl alcohol, 2-butyne-1-ol, 3-butyne-1-ol, 2-pentyne-1-ol, 3-pentyne-1-ol, 4-pentyne-1-ol, and hydroxyalkyl acrylates or methacrylates, such as hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, hydroxypropyl methacrylate, hydroxybutyl acrylate, hydroxybutyl methacrylate, and the like, and mixtures thereof.
The saturated or unsaturated monomers can include any one or a combination of halogen, phosphorus or silicon groups.
The use of ethylenically unsaturated compounds bonded to the polymer is of particular importance because they provide reactive centers that can be crosslinked. However, the unsaturation can be partially replaced with saturated compounds depending on the desired properties of the resulting resin. Such properties can be tailored in a way that the degree of hardness, elongation, toughness, heat distortion temperatures and corrosion resistance will be dependent on the amount of crosslinking and the percentage of saturated compounds added. This is important for applications such as in bulk molding compounding, sheet molding compounding, resin transfer molding, pultrusion and printed wiring boards.
The polycarbodiimide can then be represented as follows:
OCN--R--N═C═N--R].sub.n NCO (XII)
wherein n=1 to 25, preferably 1 to 15, and wherein R is as previously defined.
The polycarbodiimide intermediate is then further reacted with saturated or unsaturated monomers having active hydrogens as already described. This further reaction can be conducted in the presence of an organotin catalyst such as dibutyl tin diacetate, or dibutyl tin di-2-ethylhexoate, dibutyl tin dilaurate, dibutyl tin oxide or tertiary amines, such as triethylamine, tributylamine, triethylanediamine tripropylamine, and the like, to form an acrylic derivative of a carbodiimide which is a copolymerizable thermosetting resin with pendant and terminal vinyl groups and which can be represented by the following structural formulae: ##STR3## wherein n and m independently=0 to 25, preferably 0 to 15, and m+n are always at least 1. ##STR4## wherein, n, m and s independently=0 to 25, preferably 0 to 15 and m+n+s are always at least 1. X, R, R 1 , R 2 , and A, are as already defined.
Another aspect of this invention is the preparation of resins with terminal vinyl groups containing urethane and carbodiimide segments along the polymer backbone. The process begins with prepolymers containing isocyanate terminal groups. These isocyanate prepolymers are prepared from diisocyanates or diisocyanate mixtures with any diol or triol ordinarily used as chain extender to make urethanes corresponding to the following general formula:
R.sub.3 (OH)p
wherein R 3 is as already defined and p is 2 or 3, which includes polyhydric alcohols having a molecular weight of from about 60 to 250 and also polyester and polyether polyols having a molecular weight of about 150 to 6000, preferably from about 500 to 5000, and most preferably from about 1000 to 4000, of the type known for the preparation of homogeneous and cellular polyurethane plastics.
Examples of such compounds include: ethylene glycol, 1,2-and 1,3-propylene glycol; 1,4 and 2,3-butylene glycol; 1,5-pentane diol; 1,6-hexane diol; 1,8 octane diol; neopentyl glycol; 1,4-bis-hydroxymethyl cyclohexane; 2-methyl-1,3-propane diol; glycerol; trimethylol propane; 1,2,6-hexane triol; trimethylol ethane; pentaerythritol; quinitol; mannitol; sorbitol; diethylene glycol; triethylene glycol; tetraethylene glycol; 1,4-butanediol; polyethylene glycols having a molecular weight of up to 400; dipropylene glycol; ethoxylated and propoxylated bisphenol A; polybutylene glycols having a molecular weight of up to 400; methyl glycoside; diethanolamino-N-methyl phosphonic acid ester; castor oil; diethanolamine; N-methyl ethanolamine; and triethanolamine.
The diols or triols can also include any one or a combination of halogens, such as chlorine, fluorine, bromine, or iodine; or phosphorus, or silicon groups.
The diisocyanates or diisocyanate mixtures are in excess of the diol or trihydric alcohol and react in accordance with the following general equation to form a prepolymer that contains urethane segments and terminal isocyanate groups which can be represented in the following structure: ##STR5## wherein p=2 or 3.
The prepolymer that is formed is then further reacted with the excess diisocyanate remaining from the initial reaction step in the presence of a catalyst such as substituted phospholene oxide or dioxo-oxa-phospholane to form a polycarbodiimide having carbodiimide segments and urethane segments with isocyanate terminal groups in accordance with the following structure: ##STR6## wherein q=1 to 40, preferably 1 to 25.
The polycarbodiimide is then further reacted with a hydroxyalkyl methacrylate wherein the alkyl is ethyl, propyl or butyl in the presence of an organotin catalyst as above mentioned, to form the resin containing the terminal vinyl groups in accordance with the following structure: ##STR7## wherein, q=1 to 40, preferably 1 to 25.
The synthesis of these resins is illustrated by the following examples 1 to 11 which show resins containing pendant and terminal unsaturated groups. Example 12 shows preparation of a resin with only terminal vinyl groups. All parts and percentages are by weight unless otherwise noted.
EXAMPLE 1
In a 500 ml three neck flask, 100 grams (0.4498 mole) of isophorone diisocyanate were mixed at room temperature with 0.092 grams (47.87 millimoles) of 3-methyl-1-phenyl-2-phospholene-1-oxide. The temperature was increased to 185° C. and maintained for two hours to form the polycarbodiimide intermediate. Cooling was then applied with a water bath. At 85° C., 80 grams of methyl methacrylate were added, allowing the mixture to cool to 60° C. At this temperature, 25 grams of methacrylic acid were added. Cooling was continued using a water bath to control the exotherm of reaction below 90° C. The temperature was allowed to decrease slowly to 75° C. using a water bath and 71.5 grams (0.4959 mole) of hydroxypropyl methacrylate and two drops (approx. 0.032 grams) of dibutyl tin dilaurate were added. The reaction was continued at 70° C. for 2 hours. 4.0 milligrams of toluhydroquinone (THQ) were added and the mixture was cooled to room temperature.
The resulting resin had a light yellow color and was free of NCO or NCN groups as determined by an infrared spectrophotometer model 1310 from Perkin Elmer. Viscosity was measured with a Brookfield viscometer model RVF. Average number and weight number molecular weights were determined by HPLC model 510 from Waters connected to a wisp model 712, a differential difractometer model 410, a Digital computer model 350 and a printer model LA 50. During times were measured by a modified SPI gel test at 180° F. using 1%, 2,5-dimethyl-2,5-bis(2-ethylhexanoylperoxy)hexane (USP 245 from Witco). Perkin Elmer DSC-4 differential scanning calorimeter was used to determine the thermal transitions, using heating rates of 20° C./min. The data is summarized in Table 1.
This reaction can also be carried out in the presence of an inert solvent. The advantage of using an inert solvent such as styrene or methyl methacrylate, is that the extent of side reactions is reduced, and a greater yield of linear polymer rather than branched polymer is obtained. After preparation of the acrylic derivative of carbodiimide resin is completed, it is already in the presence of unsaturated monomers and is ready to be catalyzed for end use applications. In addition, the reaction in solution can occur at low temperatures on the order of 80° C.
EXAMPLE 2
In a two liter reactor, 400 grams (1.6 mole) of diphenylmethane diisocyanate (MDI) was dissolved in 320 milliliters of styrene. At 75° C., 0.328 grams (1.707 millimole) of 3-methyl-1-phenyl-2-phospholene-1-oxide catalyst was added. Evolution of CO 2 began immediately. The reaction was continued for two hours at 75° C. 312 grams (2.39 mole) of hydroxyethyl methacrylate (HEMA) was added allowing the mixture to cool to 45° C. Two drops (approx. 0.032 grams) of dibutyl tin dilaurate were added. Cooling was applied with a water bath to control the exotherm at 75° C. to 80° C. At 55° C., 80 grams (0.93 mole) of methacrylic acid was added. The temperature was allowed to rise to 65° C. The reaction was continued at 60° C. for 1 hour. Heat was removed, and 1 part per million (ppm) of Cu naphthenate was added and mixed for 20 minutes. The mixture was then cooled to ambient temperature.
The resulting resin had a clear to light yellow color and was free of NCO or NCN groups as determined by infrared spectroscopy by the disappearance of IR bands at 2270 and 2120 cm -1 , corresponding respectively to these groups. Curing behavior for resins of this type is presented in Table 1.
EXAMPLES 3-8
The procedure of Example 2 was followed with the exception that different ratios of hydroxyethyl or hydroxypropyl methacrylate, methacrylic acid, styrene and methyl methacrylate were used. A mixture of diphenylmethane diisocyanate:toluene diisocyanate in a 50:50 molar ratio was used instead of only diphenylmethane diisocyanate. The results of these experiments are summarized in Table 1.
EXAMPLES 9-10
The procedure of Example 2 was followed with the exception that different ratios between a mixture of 50:50 molar ratio of diphenylmethane diisocyanate:toluene diisocyanate, and acetic acid instead of methacrylic acid were used. The results of these experiments are summarized in Table 1.
EXAMPLE 11
The procedure of Example 2 was followed, with the following modifications. A mixture of a 50:50 molar ratio of diphenylmethane diisocyanate:toluene diisocyanate was used in this example. Methacrylic acid was not included in the reaction. Instead, only hydroxyethyl methacrylate was used to react the isocyanate groups and to partially react the carbodiimide segments. The resin had about 15% unreacted carbodiimide segments, as determined by infrared spectroscopy. The results of this experiment are summarized in Table 1.
EXAMPLE 12
Resins containing carbodiimide segments and ethylenically unsaturated terminal groups are shown in this example.
In a three liter reactor 214.4 grams (0.8576 mole) of diphenylmethane diisocyanate (MDI) and 149.35 grams of 2,6 and 2,4-toluene diisocyanate (80:20 mixture, TDI) were dissolved at 45° C. with 500 ml of styrene. To this mixture was added 62.5 grams (0.60 mole) of neopentyl glycol (NPG). The temperature slowly increased to 82° C. due to the exotherm of reaction between the isocyanate and hydroxy groups. The exotherm was allowed to subside and the temperature stabilized at 60° C. At this temperature, two drops of dibutyl tin dilaurate (approximately 0.032 grams) were added and the reaction allowed to exotherm to approximately 65°-70° C. The temperature was set at 75° C. and 0.30 grams (1.56 millimole) of 3-methyl-1-phenyl-2-phospholene-1-oxide was added. Evolution of CO 2 began immediately. The reaction was continued for 3 hours. 230 grams (1.767 mole) of hydroxyethyl methacrylate were added and the temperature was allowed to decrease to 48°-50° C., after which two drops of dibutyl tin dilaurate were added. The exotherm was then controlled between 65° to 70° C. Once the exotherm subsided, the reaction was continued for 30 minutes at 60° C., then, 92.7 milligrams of toluhydroquinone and 0.93 milligrams of Cu naphthenate 6% solution were added. Mixing was continued for 20 more minutes and the mixture was cooled to room temperature.
The resin had a clear to light yellow color and contained NCN groups as determined by infrared spectroscopy. Curing behavior for this type of resin is presented in Table 1.
Clear castings were prepared by curing the resins with 1% USP 245 (Witco Chemical Co.) at 150° F. for one hour and then post-cured at 250° F. for one more hour. Studies of these castings showed excellent mechanical and physical properties. Some representative results are presented in Table 2 together with properties of commercially available resins for comparison. A general comparison of these properties, showed that the polymers derived from polycarbodiimides can provide materials with higher tensile and flexural strength. In addition, the elongation can be modified according to the amount of crosslinking groups present in the polymer backbone. Table 2 summarizes all important physical properties and characteristics of resins from this invention as well as thermal properties including heat distortion temperature (HDT) and glass transition temperature (Tg). Values for commercial resins have also been included in the upper part of Table 2 for comparison.
TABLE 1__________________________________________________________________________COMPOSITION AND PROPERTIES OF RESINS EXAMPLES* 1 2 3 4 5 6 7 8 9 10 11 12__________________________________________________________________________DIPHENYLMETHANE -- 1.60 2.80 3.43 3.43 3.43 3.43 3.43 3.43 0.86 0.86 0.86DIISOCYANATE (MDI)2,4 & 2,6-TOLUENE -- -- 2.80 3.43 3.43 3.43 3.43 3.43 3.43 0.86 0.86 0.86DIISOCYANATE (TDI)ISOPHORONE 0.45 -- -- -- -- -- -- -- -- -- -- --DIISOCYANATE (IPDI)HYDROXYETHYL -- 2.39 7.53 7.30 5.38 5.38 -- -- 9.99 1.50 2.11 1.77METHACRYLATEHYDROXYPROPYL 0.42 -- -- -- -- -- 6.94 7.30 -- -- -- --METHACRYLATEMETHACRYLIC ACID 0.29 0.93 3.66 3.02 2.44 3.02 2.56 3.02 -- -- -- --ACETIC ACID -- -- -- -- -- -- -- -- 0.83 0.80 -- --NEOPENTYL GLYCOL -- -- -- -- -- -- -- -- -- -- -- 0.60WT. % STYRENE -- 29.7 31.4 30.1 37.5 34.7 31.4 -- 32.8 39.2 39.9 43.6WT. % METHYL 31.1 -- -- -- -- -- -- 29.6 -- -- -- --METHACRYLATEVISCOSITY (POISE) 4.00 4.30 2.30 9.00 102.0 13.0 12.5 7.2 4.6 2.7 2.6 6.5Mn 1,050 2,100 1,080 1,286 2,056 1,576 1,413 1,369 1,605 1,260 1,300 2,600Mw/Mn 1.2 2.2 1.2 1.5 7.7 2.0 1.9 1.9 2.8 1.5 1.9 3.0180° F. SPI GEL TEST.CATALYST 1% USP-245GEL TIME, MIN. 2.2 -- 6.1 3.2 4.4 3.6 3.4 3.3 1.9 3.2 1.5 2.8GEL TO PEAK, MIN. 1.8 -- 3.3 2.8 3.2 4.2 4.0 2.0 1.1 2.0 1.6 1.2PEAK TIME, MIN. 4.0 -- 9.4 6.0 7.6 7.8 7.4 5.3 3.0 5.2 3.10 4.0PEAK EXOTHERM, °C. 180 -- 225 220 2.3 213 2.5 191 250 224 242 239__________________________________________________________________________ *AMOUNTS IN MOLES/GRAM
TABLE 2__________________________________________________________________________ PHYSICAL PROPERTIES OF RESINS. KOPPERS DION FR ATLAC VER VER ATLAC DION CR ATLAC 3700-25 6695 797 9400 9420 382 6694 570__________________________________________________________________________HDT, °F. 338 277 239 250 266 231 277 302(°C.) (170) (136) (115) (120) (130) (110) (136) (150)Tg, °F. * 305 273 298 316 277 340 311(°C.) * (152) (134) (148) (158) (136) (171) (156)FLEX STRENGTH, PSI 10600 14800 11500 18300 13400 16500 10000 20200FLEX MODULUS, 0.57 0.52 0.56 0.52 0.53 0.46 0.48 0.5310.sup.6 PSITENSILE STRENGTH, PSI 5400 7000 7000 10900 8300 11300 6600 10500TENSILE MODULUS, 0.53 0.51 0.52 0.51 0.49 0.46 0.49 0.4910.sup.6 PSITENSILE ELON., % 1.07 1.59 1.48 2.63 1.98 3.6 1.55 2.70TOUGHNESS (FLEX.) 11.52 29.4 13.4 46.6 20.9 44.4 12.1 63(in-lb/in.sup.3)TOUGHNESS (TENSILE) 34.3 64.2 63.2 171.6 93.9 260.6 59.8 164(in-lb/in.sup.3)__________________________________________________________________________ PHYSICAL PROPERTIES OF RESINS. ATLAC ATLAC ATLAC EXAMPLES OF INVENTION 1041 1070 M-1070 3 10 11 12__________________________________________________________________________ HDT, °F. 293 311 273 250 250 259 273 (°C.) (145) (155) (134) (121) (121) (126) (134) Tg, °F. 302 320 320 295 342 329 302 (°C.) (150) (160) (160) (146) (172) (165) (150) FLEX STRENGTH, PSI 19100 17400 20000 22600 20000 19900 22100 FLEX MODULUS, 0.56 0.56 0.49 0.53 0.58 0.53 0.53 10.sup.6 PSI TENSILE STRENGTH, PSI 8600 7900 10200 9750 8500 10990 12500 TENSILE MODULUS, 0.55 0.56 0.50 0.56 0.59 0.51 0.50 10.sup.6 PSI TENSILE ELON., % 1.80 1.60 2.6 2.00 1.62 2.56 3.5 TOUGHNESS (FLEX.) 49 35 72.8 87 43.5 59 117 (in-lb/in.sup.3) TOUGHNESS (TENSILE) 88 68 174.6 105 76 167 316 (in-lb/in.sup.3)__________________________________________________________________________
Each of the comparative resin products included in the heading of Table 2 and identified by trademark designations were dissolved in styrene and are further identified as follows:
Koppers™ 3700-25 (Reichhold Chemicals, Inc.) is a propylene glycol maleate polyester resin.
Dion™ FR 6695 (Diamond Alkali Co.) is a brominated bisphenol A-fumarate polyester resin.
Atlac™ 797 (Atlas Chemical Industries, Inc.) is a neopentyl glycol-chlorendic polyester resin.
VER™ 9400 and VER™ 9420 (Reichhold Chemicals, Inc.) are highly cross-linked vinyl ester resins.
Atlac™ 382 (Atlas Chemical Industries, Inc.) is a bisphenol-fumarate polyester resin.
Dion™ CR 6694 (Diamond Alkali Co.) is a bisphenol-fumarate polyester resin.
Atlac™ 570 (Atlas Chemical Industries, Inc.) is an epoxy novalac vinyl ester resin.
Atlac™ 1041, Atlac™ 1070 and Atlac™ M-1070 (Atlas Chemical Industries, Inc.) are acrylic isocyanurate resins. | Saturated and ethylenically unsaturated compounds containing carboxylic, amino or alcohol groups are reacted under mild conditions and in short process times with polycarbodiimides containing free isocyanate units to provide polymers with excellent properties. The unsaturated groups bonded to the polymers are particularly important because these groups provide reactive centers that can be crosslinked, either thermally or in the presence of catalysts that initiate polymerization or by radiation. The polymers can also be crosslinked either alone or by copolymerization with various unsaturated monomers. The resulting crosslinked or cured resins provide excellent properties such as hardness, high elongation, excellent toughness, high heat distortion temperatures and good corrosion resistance. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Patent Application No. 101 62 313.5, filed Dec. 19, 2001, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a cylinder for a spinning preparation machine, for example a main carding cylinder, a doffer or the like on a carding machine. More particularly, the invention relates to such a cylinder where the outer shell of the cylinder at its ends rests against a hub mounted on a drive shaft.
[0003] A known cylinder for a carding machine is shown in German Unexamined Published Application 35 31 850 and is provided with a continuous shaft which transfers torque by means of tensioning elements. The cylinder is accommodated by hubs that are attached to outer steel plates and is connected with tensioning elements to the drive shaft. The tensioning elements can be annular springs, for example. Once the shaft is mounted, shaft journals and the outer shell are rotated during one operating cycle to create a trouble-free rotational movement. However, the known arrangement has the disadvantage that the tensioning elements create undesirable bending stresses in the projecting shaft journals, making a later, expensive reworking unavoidable. In addition, the continuous shaft results in considerable weight for the cylinder.
SUMMARY OF THE INVENTION
[0004] It is an object of the invention to create a cylinder of the above-described type that avoids the aforementioned disadvantages and, in particular, makes it easy to achieve a smaller deviation in the true running tolerance and lowers the weight considerably.
[0005] The above and other objects are achieved according to the invention by the provision of a cylinder for a spinning preparation machine. The cylinder has an outer shell having a hub at each end of the outer shell. A separate shaft journal is connected to each hub and the shaft journals are glued to the hubs.
[0006] In the invention, undesirable bending stresses are avoided because only two short shaft journals are used (for example, glued in place). In this example, axial and radial fastening is achieved with a glued connection that determines the torque and the bending moments. The weight of the cylinder is reduced considerably by using only two short shaft journals, so that shorter acceleration times and deceleration times and lower drive capacities are possible.
[0007] Another production/technological advantage is that completely finished shaft journals are glued in place. As a result, the cylinder bearing and the housing can be pre-mounted on the shaft journal before it is glued in place, thus simplifying and accelerating the assembly.
[0008] The glued connection is preferably created with an anaerobic hardening single-component adhesive, and is exclusively a glued connection with no play following hardening of the glue. As a result, no stresses are created in the components following the joining operation. In addition, this set up results in a more true running cylinder as compared to those with long operating journals. True running deviations of less than 0.15 can be achieved with glued-in shaft journals.
[0009] According to another aspect of the invention, there is provided a method of assembling a cylinder for a spinning preparation machine, the cylinder having an outer shell with a hub at each end of the outer shell. The method includes steps of first attaching cylinder bearings to the spinning preparation machine, then attaching a shaft journal to each of the cylinder bearings, and then gluing each shaft journal to a respective one of the hubs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention is explained below in further detail with the aid of exemplary embodiments shown in the drawings, wherein:
[0011] [0011]FIG. 1 is a side elevation schematic view of a carding machine with a main carding cylinder according to the invention; and
[0012] [0012]FIG. 2 is a cross section through the main carding cylinder according to the invention, comprising two short shaft journals.
DETAILED DESCRIPTION OF THE INVENTION
[0013] [0013]FIG. 1 shows a carding machine, for example a high-performance card DK 903 by the company Trützschler in Mönchengladbach, Germany. The carding machine has a feed roll 1 , a feed table 2 , licker-ins 3 a, 3 b, 3 c, a main carding cylinder 4 , a doffer 5 , a stripping roll 6 , crushing rolls 7 , 8 , a sliver guide element 9 , a web trumpet 10 , withdrawing rolls 11 , 12 , traveling flats 13 with clothed flat bars 14 , a can 15 and a can holder 16 . Curved arrows indicate the rotational directions of the rolls while the arrow A indicates the operating direction.
[0014] The exemplary main carding cylinder 4 , shown in FIG. 2, has an outer shell 17 made of, for example, sheet steel. The outer shell 17 is respectively supported at both ends with cylinder bottoms 18 and 19 on essentially hollow-cylindrical hubs 20 , 21 . The hubs 20 , 21 are preferably welded to the cylinder bottoms 18 , 19 with welded connections 22 , 23 . The hub 20 is glued to a short cylindrical shaft journal 24 such that it can rotate and the hub 21 is glued to an additional short cylindrical shaft journal 25 such that it can rotate. The internal front faces 24 a, 25 a of shaft journals 24 , 25 essentially end with the internal front face 20 a or 21 a of hubs 20 , 21 . The outer front faces 24 b, 25 b extend past the side surfaces of the cylinder 4 toward the outside. The outer ends of the shaft journals 24 , 25 are positioned in locally fixed bearings 26 and/or 27 that are attached to machine walls 28 , 29 . The main carding cylinder 4 has a circumferential speed of, for example, 40 m/sec.
[0015] In contrast to known cylinders, which are provided with a single continuous drive shaft, the invention provides two short shaft journals 24 , 25 that are, in this example, glued in place. The glued connection supports the torque, the axial fastening and the bending moments, resulting in a clear weight reduction for the cylinder 4 . The glued connection is characterized in that a completely finished cylinder journal 24 , 25 is glued in place. The cylinder bearings 26 , 27 and the housing (machine walls 28 , 29 ) can thus be pre-assembled before the respective journals 24 , 25 are glued in place.
[0016] The glued connection preferably is created with an anaerobic hardening single-component adhesive. Since, in this example, the connection is exclusively a glued connection, it has essentially no play following the hardening process. As a result, no material stresses are created in these components through the joining method. In addition, the invention results in a more true running cylinder as compared to those with long drive journals. Traditionally produced cylinders 4 have a deviation of 0.2 to 0.3 for the long drive journal, whereas the glued journals according to the invention have true running deviations of less than 0.15.
[0017] The invention has been described in detail with respect to preferred embodiments and it will now be apparent from the foregoing to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. The invention, therefore, is intended to cover all such changes and modifications that fall within the true spirit of the invention. | A cylinder is provided for a spinning preparation machine. The cylinder has an outer shell having a hub at each end of the outer shell. A separate shaft journal is connected to each hub and the shaft journals are glued to the hubs. | 3 |
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 61/244,667, which was filed on 22 Sep. 2009 and is incorporated herein by reference for all that it teaches.
FIELD OF THE INVENTION
The invention relates to agricultural harvesters. More particularly it relates to cleaning elements for agricultural harvesters. Even more particularly it relates to attachments for agricultural harvesters for cleaning corn cobs.
BACKGROUND OF THE INVENTION
Agricultural combines are configured to travel through an agricultural field, cutting the crop plants loose from the field, and gathering them. They also strip the crop portion (e.g. the grain) from the rest of the crop plant and discard the unwanted portion (also known as “material other than grain” or “MOG”).
Corn is harvested using an agricultural combine with a corn harvesting head or “corn head” attached on the front end thereof. The ears of corn are separated from the plant stalk itself, and are carried backwards into a threshing separating and cleaning system within the agricultural combine. In the combine the kernels of corn are separated from the corn cobs and are stored in a grain tank located in an upper portion of the agricultural combine.
The corn cobs and corn husks are then transmitted to a chopper disposed at the lower rear portion of the agricultural combine where they are chopped into small pieces, approximately 2 to 6 cm long, and are ejected from outlet of the chopper at the rear of the combine and spread over the ground.
In recent years, scientists have developed uses for corn cobs for such things as firing boilers or creating ethanol, plastics and other materials. It is desirable therefore to collect the corn cob pieces. It is not generally desirable to collect the husks. The technical problem, therefore, is providing some means for separating the corn cobs from the corn husks. Is also desirable to further direct the corn cob pieces to a storage location and to spread the husks over the ground.
US patent publication number 2009/0113867 describes a system for separating post-chopper MOG into lighter and heavier portions using an air blast. In this arrangement, the combine chopper empties into a conduit, which empties into a first blower 14 . The first blower 14 accelerates the MOG (which is already traveling very fast as it exits the chopper) and sends it up a chute 16 which empties into a wagon as the agricultural combine travels through the field. A second blower 22 is provided to provide a cross flow of air across and through the flow path of MOG established by the chopper and the first blower. This cross flow of air is of sufficient speed to blow the lighter material (i.e. the corn husks) out of the MOG flow path and permit the heavier portion of the MOG (i.e. the chopped corn cobs) to continue onward through chute 16 into a collection vehicle 52 . The lighter material ejected from the MOG flow is then spread over the ground, rather than collected in the vehicle 52
US patent publication number 2008/0248843 describes a system of dividing post-chopper MOG into two flow streams of variable proportions. The system includes a selectively steerable conduit 125 located between the combine chopper 118 and the blower 126 (described in US 2009/0113867) to separate a portion of the MOG that leaves the chopper and continues on to the blower. In this arrangement, the steerable conduit 125 has a flow dividing edge that is generally horizontal and moves up and down to mechanically direct the flow of material either into the blower 126 or downward toward the ground, depending upon the position to which it has moved.
In US 2009/0113867, the function of the air is to separate the flow of MOG based on its size, wind resistance, and density. When experiencing the air blast from the second blower 22 , the denser materials, such as corn cobs, will continue through the conduit and into the vehicle 52 . The lighter materials, such as corn husks, will be blown out of the conduit and directed over the ground.
In US 2008/0248843, the function of the conduit is to divide the flow of MOG into two streams. It does not separate the MOG flow into lighter or heavier portions.
Both of these arrangements suffer from a similar problem. Whether steered by a secondary air blast, or steered by movable conduit, the lighter material (i.e. the corn husks) is traveling so fast between the chopper and the blower that the blast of air is insufficient to steer it out of the vehicle entirely. Instead, the lighter material accumulates on the edge of the conduit that splits the flow, causing the corn husks to “hairpin” on the edge of the conduit and eventually plug the conduit.
Experimentation indicates that the problem is a function of the speed of the MOG flow traveling from the chopper through the first blower, and then up the chute and into the accompanying vehicle. At the high rates of speed the material travels from the chopper to the blower, there is a limited amount of time during which a cross flow air stream can separate the cobs from the husks. Given the limited amount of time for separation, the cross flow air separation arrangement of US 2009/113,867 A1, requires a substantial supply of high-speed air, and thus a powerful fan.
What is needed is a way to reduce the speed of the MOG, and while the speed is reduced, to separate the MOG into its lighter and heavier components using gravity as well as a secondary airflow.
It is an object of this invention to provide such a system.
SUMMARY OF THE INVENTION
In the description below, the terms “forward”, “front”, “ahead” “rear”, “rearward”, “behind” or other similar terms are defined in terms of the direction of travel of the agricultural combine in its straight line travel through an agricultural field during harvesting operations.
The terms “lateral”, “transverse”, “side-to-side” or other similar terms indicate a relative direction or orientation that is generally horizontal and perpendicular to the front-to-rear direction described in the previous paragraph.
In accordance with a first aspect of the Invention, a corn and MOG separator includes a housing having a decelerating and separating chamber for decelerating and separating corn MOG into a cob portion and a husk portion, the chamber having a first inlet configured to receive a flow of corn MOG including cobs and husks from an agricultural combine chopper, a second inlet configured to receive a flow of environmental air from outside the combine, a first outlet for transmitting non-cob MOG from the chamber, and a second outlet for transmitting cob MOG from the chamber.
In accordance with a second aspect of the invention, a corn MOG separator for an agricultural combine having a chopper for chopping MOG is provided, the separator comprising a housing defining a separating chamber for separating the cobs from the husks, the housing having a MOG inlet disposed to receive a stream of chopped corn cobs and corn husks from the chopper and to convey them into the separating chamber, the housing further having an air inlet configured to introduce a stream of separating air into the separating chamber and into corn MOG in said separating chamber and an air outlet disposed to remove air with entrained husks from the separating chamber; a fan configured to draw separating air into the air inlet, through the corn MOG and out the air outlet with entrained husks; and a mechanical decelerator disposed in the separating chamber and configured to decelerate the corn MOG in the chamber sufficient to let the stream of air and gravity, working in the opposite direction as the air flow, to separate the husks from the cobs. The fan may be disposed to suck the separating air upward through the corn MOG. The corn MOG separator may further comprise a mechanical conveyor disposed at the bottom of the chamber to convey cobs out of the separating chamber. The mechanical conveyor may be an auger disposed at the bottom of the separating chamber. The corn MOG separator may further comprise a MOG distributor configured to spread MOG over the ground, and an operator adjustable conduit disposed between the chopper and the MOG inlet and configured to separate the stream of MOG from the chopper into a first portion of corn plus husks directed into the MOG inlet and a second portion of corn plus husks into the MOG distributor. The MOG inlet may be disposed along a front side of the separating chamber and the mechanical decelerator may be disposed at the rear side of the separating chamber. The mechanical decelerator may be suspended inside a rear wall of the separating chamber and may comprise a sheet of rubber, plastic, metal or lengths of chain. The mechanical decelerator may extend across substantially the entire width of the separating chamber. The mechanical decelerator may be suspended from a rod member. The mechanical conveyor may be an auger disposed at the bottom of the separating chamber. The auger may extend transversely with respect to the combine across substantially the entire width of the separating chamber. The width of the separating chamber may be substantially the same as the width of an outlet of the chopper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an agricultural harvester with a corn MOG separator attached thereto.
FIG. 2 is a fragmentary left side detail view of the agricultural harvester of FIG. 1 with the plastic side covers of the combine removed to show the mounting arrangement of the corn MOG separator to the chassis of the agricultural combine.
FIG. 3 is a perspective view of the FIG. 2 arrangement.
FIG. 4 is a left side view of the corn MOG separator of FIG. 3 showing the internal construction of the separating chamber by removing the left side end wall 300 .
FIG. 5 is a right side view of the corn MOG separator.
FIG. 6 is a rear view of the corn MOG separator.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the description below, like numbers refer to like elements in the various embodiments of the invention.
FIG. 1 is a side view of an agricultural harvester in accordance with the present invention. In the arrangement shown in FIG. 1 , an agricultural combine 100 has a chassis 102 supported by wheels 104 to carry the combine over the ground.
A harvesting head 106 is mounted on the front end of the combine to gather corn plants 108 growing in the agricultural field and strip the ears of corn from the plant stalks. The plant stalks 109 , now stripped of their ears of corn, are left on the ground. The ears of corn are carried through the harvesting head 106 and rearward through a feederhouse 112 which supports the harvesting head on the combine. Once the ears pass through the feederhouse they go into a threshing system 114 which includes a rotor 116 disposed inside a concave 118 . The rotor rotates within the concave thereby threshing and separating corn kernels from the corn cobs and corn husks. The corn kernels fall downward into an oscillating cleaning shoe 119 which passes them through a sieve 120 and chaffer 122 , whereupon they are collected and conveyed upward into a grain tank 121 . Corn MOG residue including corn cobs and corn husks pass rearward through the rotor and concave arrangement and are deposited in a chopper 124 .
Chopper 124 includes a chopper rotor 126 with pendulous knives 128 affixed thereto that rotates at high speed. The pendulous knives 128 are interleaved with a row of stationary knives 130 which extend inward into the rotor housing 132 . The interaction of the pendulous knives 128 and the stationary knives 130 chops the corn cobs and corn husks into short pieces. Chopper rotor 126 generates an airflow that carries the entrained chopped corn MOG rearward through a chopper outlet 134 .
In traditional combines, the chopped MOG is then distributed over the ground by steering vanes or by rotating spreaders. In the present arrangement, however, a corn MOG separator 136 is mounted to the rear of the combine in a position to receive the chopped corn MOG from chopper outlet 134 .
Referring now to FIG. 2 , corn MOG separator 136 is bolted to and supported on rear portion 200 of the combine chassis 102 . For convenience of discussion, rear portion 200 of the chassis is shown with the side panels of the combine 100 removed. A cut off portion of rear panel 202 is attached to the combine chassis 102 . The pulley arrangement and jack shaft for driving the corn cob auger have also been removed.
A conduit 204 (preferably steerable) is disposed between the chopper outlet 134 and corn MOG separator 136 . Conduit 204 communicates the chopped MOG expelled from chopper outlet 134 to the inlet 206 of the corn MOG separator. Chopper outlet 134 has a lateral width of between 1-2 m and a height of 10-20 cm, thereby defining a vertically narrow and laterally elongate aperture through which the chopped corn MOG passes.
The conduit is repositionable by the operator from a first operating position 205 (shown in solid lines) in which all corn MOG is communicated to the corn MOG separator 136 , to at least a second position 207 (shown in dashed lines) in which a some or all of the corn MOG is communicated to a mechanical distributor 208 . Mechanical distributor 208 is fixed to the bottom of corn MOG separator 136 to direct the flow of corn MOG received from chopper outlet 134 over the ground.
In one arrangement, shown here, mechanical spreader 208 includes two counter-rotating rotary impellers 210 with paddles that are driven in rotation by two hydraulic motors 212 . Hydraulic motors 212 rotate rotary impellers 210 about substantially vertical axes 214 to spread the corn MOG in a wide and generally horizontal swath across the ground behind the agricultural combine 100 . Alternatively, mechanical distributor 208 may include (either in place of or in addition to rotary impellers 210 ) other non-motorized devices such as one or more stationary vanes that steer the corn MOG outward in both directions over the ground in generally the same manner as the rotary impellers 210 .
A separator fan 216 is fixed to the upper portion of a corn MOG separator housing 218 to create a flow of air upward through the corn MOG that flows from the inlet 206 of corn MOG separator 136 into a central chamber in housing 218 . Separator fan 216 moves air upward through an air inlet 220 disposed adjacent to the bottom of corn MOG separator housing 218 . Separator fan 216 draws air for separating the corn MOG from the ambient environment outside the agricultural combine 100 into inlet 220 , upward through an internal chamber in housing 218 , into separator fan 216 itself, and then expels the air out of the corn MOG separator through outlet 222 of separator fan 216 . Separator fan 216 includes two motors 224 , 225 disposed adjacent to each other in a transverse relationship that drive impellers 226 , 227 in rotation about generally vertical axes 228 , 230 (see FIG. 3 ).
Referring now to FIG. 3 , motors 224 , 225 of separator fan 216 are disposed adjacent to one another in a side-by-side relation such that their axes of rotation 228 , 230 , respectively, are generally parallel and laterally spaced apart from one another.
Corn MOG separator 136 housing 218 is generally in the form of a hollow box comprised of vertical and fore-and-aft extending planar end walls 300 , 302 to which generally vertically and laterally extending rear walls 304 and front walls (not shown) are fixed. The spacing between the left and right end walls 300 , 302 is preferably substantially the same as the width (e.g. 1-2 m) of opening 301 defined by chopper outlet 134 . In this manner, corn MOG can be directed generally rearward as a fast-flowing planar stream into the separator housing 218 without disrupting the flow of corn MOG in a lateral direction (i.e. steering part of the flow to one side of the combine or the other). This lateral steering can cause unnecessary lateral mixing, turbulence, and therefore the undesirable injection of corn cobs into separator fan 216 .
Outlet 222 of separator fan 216 preferably includes an outlet for each of the motor-driven impellers. These are shown in FIG. 3 as outlet 306 and outlet 308 , which are mirror images of each other, in which outlet 306 directs the flow of material from the impeller driven by motor 224 in a rearward direction and to the left side of agricultural combine 100 , and outlet 308 directs the flow of material from the impeller driven by motor 225 in a rearward direction and to the right side of agricultural combine 100 . Outlets 306 , 308 are defined by openings in generally cylindrical and horizontal housings 310 , 312 , that enclose impellers 226 , 227 , respectively.
FIG. 4 illustrates a cutaway of corn MOG separator housing 218 , indicating the internal construction of the housing and the flow of corn MOG during processing. The inner surfaces of housing 218 define a separating chamber 406 , including the inlets and outlets for air and MOG. The corncob auger, its pulley, the jack shaft and its pulley have been superimposed on the lower portion of the Figure.
A first planar sheet 400 forms the bottom surface of inlet 206 . It is removably fixed to and extends between end walls 300 , 302 . Planar sheet 400 extends from inlet 206 in a generally curved fashion until it abuts a top portion of corn cob auger 402 . Planar sheet 400 extends in a curve around the front side of corn cob auger 402 to partially define a channel in which corn cob auger 402 rotates.
Corn cob auger 402 is a spiral auger having a generally horizontal and laterally extending axis of rotation 404 that is disposed above the floor of separating chamber 406 . Corn cob auger 402 is driven by a pulley 408 that is mounted to the left end of the shaft of auger 402 extending outside end wall 300 . Pulley 408 is driven by belt 410 . Belt 410 is driven by pulley 412 which is mounted on the left end of a jack shaft 414 .
Jack shaft 414 extends across the width of corn MOG separator 136 from end wall 300 to end wall 302 just underneath planar sheet 400 and outside the flow path of corn MOG. Jack shaft 414 is supported on end walls 300 , 302 of housing 218 for rotation by a gearbox (See FIG. 5 ) that is disposed just outside the right end wall 302 .
An air permeable panel 416 defines a portion of the floor and the rear wall 304 of separating chamber 406 and also functions as air inlet 220 . It extends between end walls 300 and 302 to which it is fixed. Air permeable panel 416 serves to retain corn cobs within separating chamber 406 , and to provide a low-air resistance inlet for ambient air that is drawn into separating chamber 406 by separating fan 216 . Air permeable panel 416 is preferably a planar sheet of material, such as metal, that is provided with a plurality of apertures extending therethrough to permit the passage of air while denying the passage of chopped corn cobs. It may be a mesh or screen, such as a metal mesh or screen. It may comprise a plurality of interlocking rods, or of interconnected ribs and rods, such as a typical construction of a concave for a rotor in an agricultural combine. It may also comprise expanded metal or pierced metal.
The size of the apertures in panel 416 , however they are defined, are preferably configured to pass a spherical object no larger than 4 cm in diameter. More preferably they are configured to pass a spherical object no larger than 3 cm in diameter. Even more preferably they are configured to pass a spherical object no larger than 2.5 cm in diameter.
To provide strength sufficient to contain the cobs, yet also provide minimal air resistance to the flow of air for separating the cobs and husks, the ratio of the total membrane aperture area versus the overall surface area of the membrane should be 0.5 or greater, preferably 0.7 or greater, and more preferably 0.8 or greater.
Rear wall 304 extends laterally between the two end walls 300 , 302 and extends vertically from the top of air permeable panel 416 to just underneath separating fan 216 .
A mechanical decelerator 418 is disposed across substantially the entire lateral width of the separating chamber 406 just inside the rear wall 304 . Mechanical decelerator 418 is spaced just far enough ahead of rear wall 304 that it can absorb the kinetic energy of the corn cobs when it is hit and permit them to fall generally downward toward corn cob auger 402 where they will rest until they are gathered by corn cob auger 402 . If the kinetic energy of the corn cobs is not absorbed, the cobs will bounce off the rear wall and return toward the inlet colliding with other cobs, causing significant turbulence, and even directing corn cobs upward into the inlet of separating fan 216 where they could jam the fan or be mistakenly ejected from the corn MOG separator 136 and thrown onto the ground.
Mechanical decelerator 418 may be formed of rubber sheet, plastic sheet, wire mesh, chain, a chain wall, a metal sheet, steel, urethane, a pierced metal sheet, and expanded metal sheet or other media that is configured to absorb the impact of corn cobs thrown into separating chamber 406 .
The deflection sheet 418 is disposed directly in the path of corn MOG entering separating chamber 406 from inlet 206 on the side opposite inlet 206 . Corn cobs in corn MOG entering separating chamber 406 travel across the chamber and impact deflection sheet 418 .
A plurality of mounting points is shown in FIG. 4 as a series of holes in end walls 300 . An identical row of holes in a mirror image position is formed in end wall 302 . These mounting points support a rod that extends substantially across the entire width of the separating chamber and from which the mechanical decelerating material is suspended. The mechanical decelerator 418 is thereby suspended as a sheet across substantially the entire width of the chamber 406 and can be positioned either closer to or farther from the rear wall of the chamber by selecting a different set of mounting points (e.g. the holes) in the horizontal array. This permits the mechanical accelerator to be variously adjusted to different positions based upon the speed of the chopper rotor, the crop being harvested, and the size of the chopped cob pieces to be decelerated.
The corn cobs in separating chamber 406 pass through the stream of air that is pulled into and upward through separating chamber 406 from air inlet 220 to separating fan 216 . This upward airflow through the chamber and through the now (relatively) slowly falling corn cobs serves to more effectively separate the corn cobs from corn husks and other low density residue portions of corn MOG (for example dust, chaff, leaves, and the like).
Once the cobs have fallen into the bottom of separating chamber 406 The movement of corn cob auger 402 and the angle of inlet 220 and sheet 400 directs them toward the right end of the separating chamber 406 , where they pass-through an aperture in the bottom of separating chamber 406 into a blower (not shown). The blower accelerates the corn cobs, providing them with enough kinetic energy that they travel up a curved exit chute 420 and into a collection vehicle such as a truck, cart or wagon traveling alongside the agricultural combine 100 .
A second planar sheet 422 defines the upper wall of MOG inlet 206 , from conduit 204 to separating chamber 406 . Planar sheet 422 extends from and is fixed to end wall 300 and wall 302 to define (in conjunction with planar sheet 400 and end walls 300 , 302 ) a generally rectangular conduit having substantially the same width in a transverse direction and the same height as outlet 134 of the chopper.
Planar sheet 422 is configured to guide the stream of corn MOG entering the inlet 206 into a generally horizontal flow path as it enters separating chamber 406 . Once the stream of corn MOG is inside separating chamber 406 , it is traveling generally horizontally and also generally perpendicularly to the separating airflow (i.e. the airflow generated by separating fan 216 ) the separating airflow traveling generally vertically upward through separating chamber 406 from air inlet 220 to the inlet of separating fan 216 .
The housings 310 , 312 that enclose impellers 226 , 227 are fixed to the top of separating chamber 406 and define the top of the separating chamber. The housings 310 , 312 have downwardly facing central axial openings 424 , 426 , respectively, that receive air from separating chamber 406 and conduct it into impellers 226 , 227 near the central axes 228 , 230 , respectively, of the impellers.
Referring now to FIGS. 5-6 , a delivery conveyor 500 is fixed to the right end of corn MOG separator housing 216 . Corn cob auger 402 draws the corn cobs to the right across the bottom of separating chamber 406 and through an aperture 502 (that is circular, concentric with auger 402 , and has a slightly larger diameter than the diameter of the auger flights) into a lower portion of generally cylindrical housing 504 of delivery conveyor 500 .
A hydraulic motor 506 fixed to the outer planar wall 508 of housing 504 and drives an impeller 510 at high speed. Impeller 510 sweeps the corn cobs entering housing 504 through aperture 502 , around the inner surface of housing 504 and out through an exit chute 420 .
Motor 506 is coupled to a shaft that extends through housing 504 and into a gearbox 512 that is disposed between delivery conveyor 500 and end wall 302 . Gearbox 512 provides a gear reduction and drives jack shaft 414 at a reduced speed. Jack shaft 414 , as explained above, extends across the width of corn MOG separator housing 218 , through sidewall 300 , and is coupled to pulley 412 to drive auger 402 at an even slower speed.
Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | A corn MOG separator for an agricultural combine having a chopper for chopping MOG, the corn MOG separator being located after the chopper in the MOG flow stream and having a separating chamber for receiving the MOG and separating the lighter from the heavier components, the chamber having a mechanical decelerator for mechanically decelerating the corn MOG. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2006-038604, filed Feb. 15, 2006, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to brake apparatuses for two-wheeled vehicles and, more particularly, to a brake apparatus for two-wheeled vehicles used in an antilock brake system (ABS) that brakes front and rear wheels without letting the wheels lock up.
2. Description of Background Art
An example of a known brake apparatus for two-wheeled vehicles includes a front wheel modulator disposed forward of a handlebar and a rear wheel modulator disposed forward of a rear wheel (see, for example, Japanese Patent Laid-Open No. Hei 5-105174.)
The known art disclosed in Japanese Patent Laid-Open No. Hei 5-105174, however, has the following problems.
The first problem is as follows. Relative to a weight of the entire two-wheeled vehicle, the front wheel modulator that is relatively heavy in weight is disposed forward of the handlebar and the rear wheel modulator that is again relatively heavy in weight is disposed forward of the rear wheel. Each of the front and rear wheel modulators is therefore away from the position of a center of gravity of a vehicle body. As a result, maneuverability of the vehicle is degraded because of dispersed heavy items.
The second problem is as follows. Each of the front and rear wheel modulators has an internal mechanism thereof exposed to an outside. There is therefore a concern over thermal effect of an engine particularly on the front wheel modulator. This makes it necessary to prepare a modulator that offers outstanding heat resistance.
The third problem is as follows. The two modulators are disposed away from each other at front and rear. A control unit connected electrically to each of these modulators naturally has a long wiring harness. This results in an increased cost and poor maintainability.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention has been made to solve these problems and it is an object of the present invention to provide a brake apparatus for two-wheeled vehicles capable of promoting enhanced maneuverability, achieving sufficient durability performance, and improving electric connection performance.
To achieve the foregoing objects, a brake apparatus for a two-wheeled vehicle according to a first aspect of the present invention includes a hydraulic brake and a braking force control unit. The hydraulic brake receives a hydraulic force to thereby generate a braking force. The braking force control unit controls the braking force by increasing or decreasing the hydraulic pressure. The two-wheeled vehicle includes an engine disposed between a front wheel and a rear wheel. The engine includes a crankcase disposed downward thereof and a cylinder that extends upwardly from a front portion of the crankcase. Further, the braking force control unit is disposed in a space surrounded by the cylinder at a position forward thereof and the crankcase at a position downward thereof, respectively.
A brake apparatus for a two-wheeled vehicle according to a second aspect of the present invention includes a hydraulic brake and a braking force control unit. The hydraulic brake receives a hydraulic force to thereby generate a braking force. The braking force control unit controls the braking force by increasing or decreasing the hydraulic pressure. The two-wheeled vehicle includes an engine disposed between a front wheel and a rear wheel. The engine includes a crankcase disposed downward thereof and a cylinder that extends upwardly from a front portion of the crankcase. Further, the braking force control unit is disposed in a space surrounded by the crankcase at a position forward thereof and the rear wheel at a position rearward thereof, respectively.
According to a third aspect of the present invention, in addition to the arrangements according to the first or second aspect of the present invention, the braking force control unit is accommodated in a box body having a heat insulation property.
According to a fourth aspect of the present invention, in addition to the arrangements according to any of the first to third aspects of the present invention, the braking force control unit controls the braking force of the hydraulic brake disposed in the front wheel.
According to a fifth aspect of the present invention, in addition to the arrangements according to any one of the first to third aspects of the present invention, the braking force control unit controls the braking force of the hydraulic brake disposed in the rear wheel.
According to a sixth aspect of the present invention, in addition to the arrangements according to the third aspect of the present invention, the braking force control unit is supported in the box body via an elastic member included in the box body.
According to a seventh aspect of the present invention, in addition to the arrangements according to the third aspect of the present invention, the braking force control unit includes the box body supported by a vehicle body via an elastic member.
EFFECTS OF THE INVENTION
In the brake apparatus for the two-wheeled vehicle according to the first aspect of the present invention, the braking force control unit, which controls the braking force by increasing or decreasing the hydraulic pressure, is disposed in the space surrounded by the cylinder of the engine at the position forward thereof and the crankcase of the engine at the position downward thereof. Unlike the arrangement in the known art, therefore, the braking force control unit is not disposed far away from the center of gravity of the vehicle body. An inertia force that is generated during movement of the vehicle body is generated at a point with a small distance from the position of the center of gravity of the vehicle body. This enhances maneuverability. “Maneuverability” as the term is herein used means following. Specifically, if heavy articles are disposed at different parts in a vehicle, the vehicle body develops a motion in a pitch direction during acceleration or deceleration and that motion becomes large. During turning, the vehicle body is brought down to a side or pulled down, but this movement cannot be made at a fast pace. Further, when the vehicle body posture fluctuates because of bumps and indentations on road surfaces, it takes longer to bring the vehicle posture back to its original position.
In the brake apparatus for the two-wheeled vehicle according to the second aspect of the present invention, the braking force control unit, which controls the braking force by increasing or decreasing the hydraulic pressure, is disposed in the space surrounded by the crankcase of the engine at the position forward thereof and the rear wheel at the position rearward thereof. Unlike the arrangement in the known art, therefore, the braking force control unit is not disposed far away from the center of gravity of the vehicle body. The inertia force that is generated during movement of the vehicle body is generated at a point with a small distance from the position of the center of gravity of the vehicle body. This enhances maneuverability.
In the brake apparatus for the two-wheeled vehicle according to the third aspect of the present invention, the braking force control unit is accommodated in the modulator box having the heat insulation property. The braking force control unit is not, therefore, susceptible to heat generated in the engine. This eliminates the need for preparing a modulator offering high heat resistance, which contributes to a reduced cost.
In the brake apparatus for the two-wheeled vehicle according to the fourth aspect of the present invention, the braking force control unit controls the braking force of the hydraulic brake included in the front wheel. This allows the front wheel to be braked while rotating without developing a wheel lockup when the vehicle body is braked.
In the brake apparatus for the two-wheeled vehicle according to the fifth aspect of the present invention, the braking force control unit controls the braking force of the hydraulic brake included in the rear wheel. This allows the rear wheel to be braked while rotating without developing a wheel lockup when the vehicle body is braked.
In the brake apparatus for the two-wheeled vehicle according to the sixth aspect of the present invention, the braking force control unit is supported in the box body via the elastic member included in the box body. The elastic member can therefore prevent effect of heat from the engine.
In the brake apparatus for the two-wheeled vehicle according to the seventh aspect of the present invention, the braking force control unit includes the box body supported by the vehicle body via the elastic member. The elastic member, being disposed outside the box body, can be easily built largely, which facilitates improvement of shock absorbing performance.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a left side elevational view showing a motorcycle including a brake apparatus for two-wheeled vehicles according to an embodiment of the present invention;
FIG. 2 is a perspective view showing a braking force control unit and parts surrounding the control unit in the motorcycle shown in FIG. 1 ;
FIG. 3 is a partly cutaway perspective view showing a braking force control portion for a front wheel and parts surrounding the control portion in the braking force control unit shown in FIG. 2 ; and
FIG. 4 is a partly cutaway perspective view showing a braking force control portion for a rear wheel and parts surrounding the control portion in the braking force control unit shown in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A brake apparatus for two-wheeled vehicles according to a specific embodiment to which the present invention is applied will be described in detail below with reference to the accompanying drawings.
FIGS. 1 through 4 are views showing an embodiment of the present invention. FIG. 1 is a left side elevational view showing a motorcycle including the brake apparatus for two-wheeled vehicles according to the embodiment of the present invention. FIG. 2 is a perspective view showing a braking force control unit and parts surrounding the control unit in the motorcycle shown in FIG. 1 . FIG. 3 is a partly cutaway perspective view showing a braking force control portion for a front wheel and parts surrounding the control portion in the braking force control unit shown in FIG. 2 . FIG. 4 is a partly cutaway perspective view showing a braking force control portion for a rear wheel and parts surrounding the control portion in the braking force control unit shown in FIG. 2 . In the description that follows hereunder, “front,” “rear,” “right,” and “left” refer to corresponding directions as viewed from a rider riding the motorcycle.
Referring to FIGS. 1 and 2 , a motorcycle 10 includes, as main elements thereof, a frame 11 , a front fork 13 , a handlebar 14 , a front wheel 15 , a power unit 16 , a swing arm 19 , a rear wheel 20 , and a tandem seat 22 . The front fork 13 is attached to a head pipe 12 disposed at a front end portion of the frame 11 . The handlebar 14 is connected to an upper portion of the front fork 13 . The front wheel 15 is mounted to a lower portion of the front fork 13 . The power unit 16 includes an engine 17 and a transmission 18 mounted on a front lower portion of the frame 11 . The swing arm 19 is disposed at a rear lower portion of the frame 11 . The rear wheel 20 is attached to a leading end portion of the swing arm 19 . The tandem seat 22 is mounted to an upper portion in the rear of the frame 11 via a seat rail 21 . The motorcycle 10 is a sports type vehicle that uses the power unit 16 to drive the rear wheel 20 . The front wheel modulator 61 is fixed to a left main frame portion 26 of the frame 11 and is disposed in a space surrounded by the cylinder 32 at a position forward thereof and the crankcase 30 at a position directly downward thereof, respectively, and the rear wheel modulator 62 is located under where a forward end of the seat rail 21 is attached to the left and right sides of the center frame portion 27 .
The motorcycle 10 further includes a radiator 23 , a front cowl 24 , and an under cowl 25 . The radiator 23 is disposed at a front portion and downward of the frame 11 . The front cowl 24 covers the front portion and both side portions of the frame 11 . The under cowl 25 covers a lower portion of the frame 11 and a lower portion and both side portions of the power unit 16 . The front cowl 24 and the under cowl 25 are formed from a lightweight FRP or other synthetic resin.
The frame 11 includes a pair of left and right main frame portions 26 . The main frame portions 26 , which are formed, for example, of aluminum alloy castings into substantially an inverted U-shape, extend downwardly toward the rear. The head pipe 12 , of a cylindrical shape, is disposed at a front end of the main frame portions 26 . In addition, the frame 11 also has a center frame portion 27 that protrudes downwardly at a rear end of the main frame portions 26 .
The handlebar 14 includes a front brake lever 28 disposed on a rightward side thereof. The handlebar 14 further includes a front brake master cylinder 29 mounted thereon and connected to the front brake lever 28 . The front brake master cylinder 29 stores therein brake oil not shown.
Referring to the power unit 16 , the engine 17 is a water-cooled four-stroke DOHC four-cylinder engine. The transmission 18 is built into a crankcase 30 . The power unit 16 is fixed to the main frame portions 26 and the center frame portion 27 of the frame 11 . A fuel tank 31 is disposed above an air cleaner (not shown) in an upper portion of the power unit 16 . The engine 17 includes a cylinder 32 disposed upward of the crankcase 30 . An electronic fuel supply system (not shown) is connected to an intake port (not shown) in the cylinder 32 . An exhaust pipe 33 connected to an exhaust port (not shown) of the cylinder 32 is connected to a main muffler 34 at a lower portion of the engine 17 . The main muffler 34 is connected to a sub muffler 35 . An output from the transmission 18 is used for, what is called, a chain drive. The output from the transmission 18 is transmitted from a drive sprocket 36 mounted to an output shaft (not shown) of the transmission 18 to a driven sprocket 38 fixed to the rear wheel 20 via a chain 37 .
The front fork 13 has a front suspension 39 built therein. The front suspension 39 includes a coil spring and a damper. The front fork 13 also has a front caliper 41 assembled thereto. The front caliper 41 applies a braking force to a pair of front disc rotors 40 fixed to the front wheel 15 . A front fender 42 is attached to an upper portion of the front wheel 15 . The front caliper 41 has a twin-port caliper cylinder 43 . A pulsar ring (not shown) is coaxially mounted to the front wheel 15 . A front wheel speed sensor 44 for detecting a rotational speed of the front wheel 15 is assembled to an outer periphery of the pulsar ring in a non-contact fashion.
The swing arm 19 is swingably connected to the center frame portion 27 of the frame 11 . Shock otherwise applied to the swing arm 19 is absorbed by a rear suspension 45 disposed between the swing arm 19 and the center frame portion 27 . The rear suspension 45 includes a coil spring and a damper. Like the front wheel 15 , rear disc rotors 46 are mounted to the rear wheel 20 . A rear caliper 47 , which applies a braking force to the rear disc rotors 46 , includes a single-port caliper cylinder 48 . A pulsar ring (not shown) is coaxially mounted to the rear wheel 20 . A rear wheel speed sensor 49 for detecting a rotational speed of the rear wheel 20 is assembled to an outer periphery of the pulsar ring in a non-contact fashion.
A rear brake pedal 50 is depressibly journaled on a right side portion of the center frame portion 27 . A rear brake master cylinder 51 connected to the rear brake pedal 50 is mounted on a side portion. Brake oil not shown is stored in the rear brake master cylinder 51 .
The motorcycle 10 further includes a front wheel modulator 61 and a rear wheel modulator 62 . The front wheel modulator 61 , which serves as the braking force control unit for the front wheel, is disposed in a space surrounded by the cylinder 32 of the engine 17 at the front and the crankcase 30 of the engine 17 on the bottom. The rear wheel modulator 62 , which serves as the braking force control unit for the rear wheel, is disposed in a space surrounded by the crankcase 30 of the engine 17 at the front and the rear wheel 20 in the rear.
The front wheel modulator 61 is incorporated in a modulator box 63 of a rectangular box body. The front wheel modulator 61 has an internal mechanism (see FIG. 3 ) 64 built therein. The modulator box 63 is formed from a resin or the like having a heat insulation property. The modulator box 63 is screwed to a modulator fixing portion 52 formed on a left side portion of the main frame portions 26 via a bracket 65 that is assembled so as to surround an outside of the modulator box 63 . The bracket 65 is fixed in position using three bolts 66 .
The front wheel modulator 61 has an inlet side brake hose 67 and an outlet side brake hose 68 protruding outwardly therefrom. The inlet side brake hose 67 is connected in fluid communication to the front brake master cylinder 29 . The outlet side brake hose 68 is connected in fluid communication to the caliper cylinder 43 for the front wheel.
The rear wheel modulator 62 is incorporated in a modulator box 71 of a rectangular box body having an open rearward end. The rear wheel modulator 62 has an internal mechanism (see FIG. 4 ) 72 built therein. The modulator box 71 is formed from a resin or the like having a heat insulation property. The modulator box 71 is fixed to a modulator fixing portion 53 formed on a rear portion of the main frame portions 26 via a bracket 73 disposed rearwardly. The bracket 73 is fixed in position using three damper-less bolts 74 and three damper bolts 76 through which damper members 75 are passed.
The rear wheel modulator 62 has an inlet side brake hose 77 and an outlet side brake hose 78 protruding outwardly therefrom. The inlet side brake hose 77 is connected in fluid communication to the rear brake master cylinder 51 . The outlet side brake hose 78 is connected in fluid communication to the caliper cylinder 48 for the rear wheel.
The front wheel modulator 61 has a controller (not shown) built therein, in addition to the internal mechanism 64 . The front wheel controller incorporates electronic devices of various types and is electrically connected to a power source (not shown), the front wheel speed sensor 44 , the rear wheel speed sensor 49 , and the front wheel modulator 61 . Constantly monitoring a front wheel speed signal (electric signal) provided by the front wheel speed sensor 44 and a rear wheel speed signal (electric signal) provided by the rear wheel speed sensor 49 , the front wheel controller applies a drive signal to the front wheel modulator 61 . Being integrally built into the front wheel modulator 61 , the front wheel controller allows a wiring harness 70 to have a short routing length. A rear wheel controller is also built into the rear wheel modulator 62 . The front wheel controller and the rear wheel controller are electrically connected to each other.
In the motorcycle 10 , the front brake lever 28 , the front brake master cylinder 29 , the front wheel speed sensor 44 , the rear brake pedal 50 , the rear brake master cylinder 51 , the rear wheel speed sensor 49 , the front wheel modulator 61 , and the rear wheel modulator 62 constitute a brake apparatus for two-wheeled vehicles 100 .
Referring to FIG. 3 , the front wheel modulator 61 has the internal mechanism 64 , which is built into the modulator box 63 , assembled on a damper member 79 formed of an elastic rubber. Accordingly, despite the arrangement, in which the front wheel modulator 61 is fixed to the modulator fixing portion 52 on the main frame portions 26 using the three bolts 66 via the bracket 65 , the internal mechanism 64 is supported without being directly subject to vibration of the vehicle body. It goes without saying that the internal mechanism 64 is not directly subject to heat from the engine 17 , either, since the modulator box 63 has a heat insulation property. Further, the front wheel modulator 61 is fixed to the modulator fixing portion 52 that is surrounded by the cylinder 32 of the engine 17 at the front and the crankcase 30 of the engine 17 on the bottom, so that the front wheel modulator 61 is disposed at a position near a center of gravity of the motorcycle 10 .
Referring to FIG. 4 , the rear wheel modulator 62 has the internal mechanism 72 built into the modulator box 71 having an opening 80 in the rear. The rear wheel modulator 62 is fixed to the modulator fixing portion 53 at the rear portion of the center frame portion 27 via the bracket 73 . It is to be noted herein that the bracket 73 is fixed in position as detailed in the following. Specifically, the three damper-less bolts 74 are directly screwed into the modulator fixing portion 53 . Two of the three damper bolts 76 , through which the damper members 75 are passed, are screwed into a metal plate 81 fixed to the modulator box 71 . The remaining one damper bolt 76 is screwed into the modulator box 71 .
Accordingly, the arrangement, in which the rear wheel modulator 62 is fixed with the damper bolts 76 to the modulator fixing portion 53 of the center frame portion 27 via the bracket 73 , allows the internal mechanism 72 to be supported without being directly subject to the vibration of the vehicle body. It goes without saying that the internal mechanism 72 is not directly subject to heat from the engine 17 , since the modulator box 71 has a heat insulation property. Further, the rear wheel modulator 62 is fixed to the modulator fixing portion 53 that is surrounded by the crankcase 30 of the engine 17 at the front and the rear wheel in the rear, so that the rear wheel modulator 62 is disposed at a position near the center of gravity of the motorcycle 10 .
In the motorcycle 10 having the arrangements as described in the foregoing, the front brake lever 28 is gripped or the rear brake pedal 50 is depressed during ordinary braking. Then a pressurized brake oil is supplied to the caliper cylinder 43 on the side of the front wheel 15 from the front brake master cylinder 29 . Alternatively, a pressurized brake oil is supplied to the caliper cylinder 48 on the side of the rear wheel 20 from the rear brake master cylinder 51 . This applies a braking force to the front disc rotors 40 , or to the rear disc rotors 46 . At this time, neither the front wheel modulator 61 nor the rear wheel modulator 62 is energized.
Unlike the foregoing situation, when the front brake lever 28 is gripped in the same manner as above while the motorcycle 10 is running, the value of a front wheel speed signal given by the front wheel speed sensor 44 may become extremely small, resulting in the speed of the front wheel 15 decreasing excessively relative to the speed of the vehicle body. At this time, the front wheel controller, which constantly monitors the above electric signal, applies a drive signal to the internal mechanism 64 of the front wheel modulator 61 . This causes the front wheel modulator 61 to decrease the pressure of the brake oil in the outlet side brake hose 68 instantaneously and thereafter increase the pressure of the brake oil again. The front wheel modulator 61 executes this sequence of operations repeatedly, for example, a plurality of number of times per one second. This ensures that the front wheel 15 is braked while rotating without developing a wheel lockup.
Similarly, when the rear brake pedal 50 is depressed in the same manner as above while the motorcycle 10 is running, the value of a rear wheel speed signal given by the rear wheel speed sensor 49 may become extremely small, resulting in the speed of the rear wheel 20 decreasing excessively relative to the speed of the vehicle body. At this time, the rear wheel controller applies a drive signal to the internal mechanism 72 of the rear wheel modulator 62 . This causes the rear wheel modulator 62 to decrease the pressure of the brake oil in the outlet side brake hose 78 instantaneously and thereafter increase the pressure of the brake oil again. The rear wheel modulator 62 executes this sequence of operations repeatedly, for example, a plurality of number of times per 1 second. This ensures the rear wheel 20 is braked while rotating without developing a wheel lockup.
In accordance with the brake apparatus for two-wheeled vehicles 100 as described in the foregoing, the front wheel modulator 61 , which controls the braking force by increasing or decreasing the brake oil pressure, is disposed in the space surrounded by the cylinder 32 of the engine 17 at the front and the crankcase 30 of the engine 17 on the bottom. Specifically, the front wheel modulator 61 is disposed in a position near the center of gravity of the vehicle body surrounding the engine. Unlike the arrangement in the known art, therefore, the front wheel modulator 61 is not disposed far away from the center of gravity of the vehicle body. An inertia force that is generated during movement of the vehicle body is generated at a point with a small distance from the position of the center of gravity of the vehicle body. This enhances maneuverability.
In addition, in the brake apparatus for two-wheeled vehicles 100 , the rear wheel modulator 62 , which controls the braking force by increasing or decreasing the brake oil pressure, is disposed in the space surrounded by the crankcase 30 of the engine 17 at the front and the rear wheel 20 in the rear. Specifically, the rear wheel modulator 62 is disposed in a position near the center of gravity of the vehicle body surrounding the engine 17 . Unlike the arrangement in the known art, therefore, the rear wheel modulator 62 is not disposed far away from the center of gravity of the vehicle body. The inertia force that is generated during movement of the vehicle body is generated at a point with a small distance from the position of the center of gravity of the vehicle body. This enhances maneuverability.
In the brake apparatus for two-wheeled vehicles 100 according to the embodiment of the present invention, the front wheel modulator 61 and the rear wheel modulator 62 are accommodated in the modulator boxes 63 , 71 having the heat insulation property, respectively. The modulators 61 , 62 are not, therefore, susceptible to heat generated in the engine 17 . This eliminates the need for preparing a modulator offering high heat resistance, which contributes to a reduced cost. Further, performance can be ensured even if a modulator having low heat resistance is used.
In the brake apparatus for two-wheeled vehicles 100 according to the embodiment of the present invention, the front wheel modulator 61 controls the braking force of the caliper cylinder 43 included in the front wheel 15 . This allows the front wheel 15 to be braked while rotating without developing a wheel lockup when the vehicle body is braked.
In the brake apparatus for two-wheeled vehicles 100 according to the embodiment of the present invention, the rear wheel modulator 62 controls the braking force of the caliper cylinder 48 included in the rear wheel 20 . This allows the rear wheel 20 to be braked while rotating without developing a wheel lockup when the vehicle body is braked.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A brake apparatus for a two-wheeled vehicle includes a hydraulic brake, which receives a hydraulic force to thereby generate a braking force, and a braking force control unit, which controls the braking force by increasing or decreasing the hydraulic pressure. The two-wheeled vehicle includes an engine disposed between a front wheel and a rear wheel. The engine includes a crankcase disposed downward thereof and a cylinder extending upwardly from a front portion of the crankcase. The braking force control unit is disposed in a space surrounded by the cylinder at a position forward thereof and the crankcase at a position downward thereof, respectively. The brake apparatus for a two-wheeled vehicle is capable of promoting enhanced maneuverability, achieving sufficient durability performance, and improving electric connection performance. | 1 |
BACKGROUND OF THE INVENTION
This invention is related to the retardation of lubricant leaks in machinery and in particular to lubricant leaks in industrial sewing machines.
Oil leakage is a problem with machines which have inner oil containing cavities, and moving devices which extend from these cavities through the walls of the frame into the surrounding environment. Gasket junctures also present problems with lubricant leakage to various degrees.
To solve such problems, the prior art contains gaskets of many different shapes, forms, materials, etc. The same is true of seal devices. The problems are compounded by moving devices which extend through the walls of the frame, since very often because of unique configurations, specifically designed seals or gaskets are required. This being reflected back in the cost of the final product.
Accordingly, there is a need for a means which will effectively retard the leakage of lubricant to the exterior of the device regardless of its source.
SUMMARY OF THE INVENTION
The invention hereunder consideration involves machines that have a frame and at least one generally sealed inner cavity from which lubricant leakage occurs. The invention being: the lowering of the atmospheric pressure within the inner cavity below that of the atmosphere by any suitable means, such as a vacuum pump, until air from the environment is drawn into the cavity through the passages from which the lubricant is leaking. In so doing, the inflowing air, replaces the lubricant at all leakage points, thus retarding the outward passage thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a sewing machine incorporating the present invention;
FIG. 2 is a front view of a sewing machine partially broken away showing a pump means located within an inner cavity of the sewing machine;
FIG. 3 is a partial sectional view of the left portion of upper arm showing a device which passes from an inner lubricant containing cavity through the wall of the frame.
DETAILED DESCRIPTION OF THE INVENTION
First referring to FIG. 1 wherein is shown a sewing machine of the type manufactured by Union Special Corporation, 400 North Franklin Street, Chicago, Ill. and identified as Style XF511H100MF catalog no. 142M First Edition. It is understood that this is simply one embodiment of the invention which is applicable in general to machines having lubricant or oil containing inner cavities which suffer from leaks. Such leaks can take the form of any passage or permation through, around, across, etc. seals, bushings, gasket material, etc.
As stated, FIG. 1 shows the frame or body portion 1 of a sewing machine means 2 which includes: an upper arm means 4, a needle means 6 defining a sewing area or zone, a hand wheel 8, a frame wall means 10, a lower arm means 12, an oil sump means 14 containing oil and an inner cavity means 16. A drive shaft pulley means 18 cooperates with a belt and a motor (not shown) to transfer driving force to the sewing machine. In general, the inner cavity or cavities is/are sealed against lubricant leakage into the environment surrounding the machine. Referring to FIG. 3, such leakage can take place through or across gasket juncture means 20 which includes a gasket means 22 sandwiched between the removably arranged cover means 24 of the hollow or open front section 26 of the sewing machine frame 2. As is known in the prior art, the interior of a sewing machine frame may have a single inner cavity or may include a plurality of inner cavities such as 28, 30 and 32 in FIG. 3. These open cavities such as 28, 30 and 32 can contain various amounts of lubricant and are sealed against leakage of lubricant via cover means which cooperate with the machine frame to sandwich a gasket means. However, retarding the leakage of lubricant through said gasket junctures and around lubricated device means disposed substantially proximate the sewing zone, such as the needle bar 34 and bushing 36 which extend from the machine interior through and beyond the machine frame into the surrounding environment is not so simple. Gasket material is known to be semipermeable and lubricant leakage passages are known to exist around bushings, bearings, seals, etc. All of which leakage problems are evidenced by the presence of lubricant in the environment surrounding the machine frame. The various means or mode whereby the lubricant finds its way to the surrounding environment is beyond the scope of this invention and thus will only be speculated upon.
What we have discovered is that if the atmospheric pressure within the machine interior is reduced sufficiently below that of the surrounding environment, air will be inwardly drawn to the machine's interior through the means, mode, passages, etc. through which the lubricant was prior therefrom leaking to produce an air seal.
Any type of means for reducing the atmospheric pressure may be employed such as a vacuum pump 38 or a venturi means (not shown) etc. The means for reducing atmospheric pressure may be located exterior to the inner cavity such as pump 38 in FIG. 1 and FIG. 2 or it may be located within such as in cavity 30 in FIG. 3. The pump means 40 located in cavity 30 is sealed from the nonvented inner cavity (here cavity 28) in which the atmospheric pressure is being lowered. The pump means 40 may be a vacuum pump or a venturi means. Any suitable means is sufficient such as seal means 42 which is intimately arranged about the shaft. The atmospheric pressure in inner cavity 28 however must be reduced to the degree such that air flows in through any lubricant leakage means in the gasket means 22, between the vertically reciprocating needle bar 34 and bushing 36 or seal 42 etc. The air flow can be controlled, by controlling the pump means 40, to effectively block the desired amount of lubricant leakage from the machine's interior to the exterior of the frame. The more the atmospheric pressure is reduced, the greater will be air flow through whatever lubricant leakage means which may exist. A vent means 48 for cavity 30 allows air accumulating in the cavity 30 to return to the surrounding environment.
Thus, the method for reducing leakage of lubricant from a generally sealed machine which has at least one lubricant containing cavity includes the steps of: reducing the atmospheric pressure inside of said lubricant containing cavity sufficiently below that of the surrounding environment by removing therefrom lubricant, lubricant and air or generally just air; and drawing or flowing air from the environment into said lubricant containing cavities through the passages, holes, spaces, means in general through which lubricant leakage occurred thereby avoiding lubricant from being deposited on a workpiece passing through the sewing zone of the machine.
We have thus provided a method and apparatus for retarding the leakage of lubricant from a machine which includes a frame having an open lubricant containing cavity, a cover means removably secured to said frame such that it generally seals the cavity and a means for reducing the atmospheric pressure within the cavity to a degree such that air from the surrounding environment flows into the cavity through whatever means lubricant leakage was occurring.
Thus it is apparent that there has been provided in accordance with the invention, a Method and Apparatus For Retarding Lubricant Leakage In A Sewing Machine that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | The atmospheric pressure of lubricant containing cavities, from which leakage occurs, is lowered to a point below atmospheric pressure such that air from the environment is drawn thereinto. Since the air being drawn in occupies the passages through which lubricant leakage occurs, such leakage is effectively retarded. | 3 |
FIELD OF THE INVENTION AND RELATED ART
The present invention relates to a liquid ejection head for ejecting liquid and a manufacturing method of the liquid ejection head. Specifically, the present invention relates to an ink jet recording head for effecting recording by ejecting ink onto a recording material (medium) and a manufacturing method of the ink jet recording head.
As an example using the liquid ejection head for ejecting liquid, there is an ink jet recording head used in an ink jet recording method.
In an ink jet recording apparatus, image recording is effected by ejecting minute droplet-like ink from a plurality of ink ejection outlets arranged on an ink jet head.
A manufacturing method of the above-described liquid ejection head is disclosed in U.S. Pat. No. 4,657,631. In this manufacturing method, an ink jet head is manufactured through the steps of:
(1) forming, through patterning, a mold of an ink flow passage of a photosensitive material on a substrate on which a recording element is formed, (2) forming a coating resin material layer on the substrate by coating so as to coat the mold pattern, and then (3) removing the photosensitive material used for the mold after an ink ejection outlet communicating with the mold of the ink flow passage is formed on the coating resin material layer.
In the manufacturing method disclosed in U.S. Pat. No. 4,657,631, as the photosensitive material, a positive resist is used from the viewpoint of easiness of removal.
In the above-described manufacturing method, the ink flow passage, the ejection outlet, and the like are formed through lithography employed in semiconductor manufacturing, so that it is possible to perform fine processing with high accuracy. In this case, however, a change in shape in the neighborhood of the ink flow passage and the ejection outlet is basically restricted to a two-dimensional direction parallel to an element substrate. That is, the photosensitive material layer cannot be partially formed in a multiple layer because of use of the photosensitive material for the mold for the ink flow passage and the ejection outlet, so that the mold for the ink flow passage or the like cannot be changed in height (i.e., a shape of the mold with respect to a height direction of the element substrate is restricted to a uniform shape). As a result, ink flow passage design necessary to realize high-speed and stable ejection is restricted.
U.S. Patent Application Publication No. US2003/0011655 discloses a method for manufacturing an ink jet head having a three-dimensional liquid flow passage structure. In this manufacturing method, the ink jet head having the three-dimensional liquid flow passage structure is formed through the steps of:
(1) forming a first positive resist layer 7 on a substrate on which a heater is formed ( FIG. 4( a )), (2) forming a second positive resist layer 8 on the first positive resist layer 7 ( FIG. 4( b )), (3) forming a predetermined pattern by subjecting the upper second positive resist layer 8 to light exposure and development by using ionizing radiation in a wavelength range in which the second positive resist layer 7 causes decomposition reaction ( FIG. 4( c )), (4) forming a predetermined pattern by subjecting the lower first positive resist layer 7 to light exposure ( FIG. 4( d )) and development by using ionizing radiation in a wavelength range in which the first positive resist layer causes decomposition reaction ( FIG. 4( e )), (5) coating a coating resin material layer 9 of a negative resist on the resist patterns of the first and second positive resist layers ( FIG. 4( f )), (6) forming an ejection outlet pattern 10 on the coating resin material layer 9 ( FIG. 4( g )), and then (7) dissolving and removing the first and second positive resist patterns 7 and 8 ( FIG. 4( h )).
However, in order to suppress variations in an ejection amount, an ejection speed, and the like of small ink liquid droplets during advance of downsizing of a droplet size of ink with recent higher printing image quality, it is necessary to form bubble-generating chambers/ink flow passages with high accuracy. That is, with a smaller ink droplet, an ejection performance of the ink droplet depends on a dimension and a height of the bubble-generating chambers/ink flow passages, so that variations thereof can result in variations in ejection amount, ejection speed, and the like of the ink droplet.
For that reason, a processing method with higher accuracy is required but it has been difficult to achieve an objective bubble-generating chamber formation accuracy only by a conventional ink flow passage forming method.
As one of factors for causing the variation in shape dimension of the bubble-generating chambers, dissolution and deformation of the ink flow passage structure of the positive resist for providing the bubble-generating chambers by a solvent, gas, heat, and the like used in various steps can be considered.
For example, when the second positive resist is applied onto the first positive resist, solvents for these positive resists cause mutual dissolution or the second positive resist pattern causes a decrease in film thickness during development of the first positive resist.
In order to solve these problems, as a method of maintaining the shape dimension, the use of a positive resist having high resistance to the various steps can be considered. However, the positive resist is required to be removed after an ink flow passage wall is formed, so that the use of the positive resist having the high resistance can lead to a lowering in removal performance.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide a constitution of a highly reliable ink ejection outlet protecting film formed on a substrate.
Another object of the present invention is to provide a manufacturing method capable of facilitating provision of such a constitution.
According to an aspect of the present invention, there is provided a manufacturing method of a liquid ejection head including an ejection outlet forming member provided with an ejection outlet for ejecting liquid and including a flow passage communicating with the ejection outlet, the manufacturing method comprising:
preparing a substrate on which a first flow passage wall forming member for forming a part of a wall of the flow passage and a solid layer having a shape of a part of the flow passage contact each other, wherein the first flow passage wall forming member has a height, from a surface of the substrate, substantially equal to that of the solid layer;
providing a first layer formed of a negative photosensitive resin material;
exposing to light a portion of the first layer for constituting the ejection outlet forming member;
providing a second layer, on the first layer, formed of a negative photosensitive resin material;
exposing to light a portion of the second layer for constituting a second flow passage wall forming member for forming another part of the wall of the flow passage;
placing the exposed first layer and the exposed second layer on the solid layer and the first flow passage wall forming member so that a non-exposed portion of the second layer contacts the solid layer;
forming a part of the flow passage and the ejection outlet by removing a non-exposed portion of the first layer and the non-exposed portion of the second layer above the substrate; and
forming the flow passage by removing the solid layer.
According to the present invention, a first bubble-generating chamber and a flow passage therefor are formed of a negative photosensitive resin material through lithography and a second bubble-generating chamber and a flow passage therefor are formed by transfer of the second bubble-generating chamber and the flow passage therefor onto a first flow passage wall and a soluble resin material layer, so that the resultant bubble-generating chambers and ink flow passages are excellent in shape stability.
These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1( a ) to 1 ( j ) are schematic sectional views for illustrating an embodiment of the manufacturing method of a liquid ejection head according to the present invention.
FIGS. 2( a ) to 2 ( j ) are schematic sectional views for illustrating another embodiment of the manufacturing method of a liquid ejection head according to the present invention.
FIGS. 3( a ) to 3 ( j ) are schematic sectional views for illustrating another embodiment of the manufacturing method of a liquid ejection head according to the present invention.
FIGS. 4( a ) to 4 ( h ) are schematic sectional views for illustrating an embodiment of a conventional ink jet head manufacturing method.
FIG. 5 is a schematic perspective view for illustrating a recording head used in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinbelow, embodiments of the manufacturing method of a liquid ejection head according to the present invention will be described.
In the following description, with reference to the figures, constituent members having the same function are represented by the same reference numerals or symbols and are omitted from redundant explanation in some cases.
In the following description, an ink jet recording method will be described as an applied embodiment of the present invention. However, the present invention is not limited thereto but may also be applicable to biochip preparation, electronic circuit printing, etc.
The liquid ejection head is mountable to a printer, a copying machine, a facsimile machine including a communication system, a device such as a word processor including a printer portion, and industrial recording devices compositively combined with various processing devices. For example, the liquid ejection head can also be used for biochip preparation, electronic circuit printing, ejection of medication in the form of spray, etc. For example, by using this liquid ejection head for the purpose of recording, it is possible to carry out recording on various recording media (materials) such as paper, thread, fiber, fabric, leather, metal, plastic, glass, wood, and ceramics. Herein, “recording” means not only that a significant image such as a character image or a graphical image is provided to the recording medium but also that an insignificant image such as a pattern image is provided to the recording medium.
FIG. 5 is a schematic perspective view showing a recording head (liquid ejection head) according to an embodiment of the present invention.
The recording head in this embodiment includes a substrate 101 of Si on which energy generating elements 107 for generating energy utilized for ejecting ink as recording liquid are formed and arranged with a predetermined pitch. The substrate 101 is provided with a supply port 108 , formed by subjecting Si to anisotropic etching, which is opened between two arrays of the energy generating elements 107 . On the substrate 101 , ejection outlets 105 provided by a flow passage forming member 102 at positions opposite to the respective energy generating elements 107 and individual flow passages extending from the supply port 108 and communicating with associated ones of the ejection outlets 105 . Incidentally, the positions of the ejection outlets 105 are not limited to those opposite to the energy generating elements 107 .
In the case where the recording head is used as the ink jet recording head, a surface at which the ejection outlets 105 are formed is disposed so as to face a recording surface of a recording medium. The recording head causes energy generated by the energy generating elements 107 to act on ink filled on the flow passages through the supply port 108 , thus ejecting ink droplets from the ejection outlets 105 . Recording is effected by depositing these ink droplets on the recording medium. As the energy generating element, an electrothermal transducer or the like for thermal energy (so-called a heater) and a piezoelectric element or the like for mechanical energy may be used but the energy generating element is not limited to these elements.
(First Embodiment)
Hereinbelow, First Embodiment of the manufacturing method of an ink jet head (liquid ejection head) according to the present invention will be described with reference to schematic process sectional views of FIGS. 1( a ) to 1 ( j ). As a photosensitive resin material, a normal photoresist can be used.
First, on a substrate 1 on which a recording element 20 is formed, a negative photosensitive resin material layer 2 is formed ( FIG. 1( a )). As a material for the substrate 1 , single-crystal silicon, glass, ceramics, metal, or the like can be used. Of these, single-crystal silicon is a most preferable material from the viewpoint of formation and processing property of the recording element. As the recording element, an electrothermal transducer, a piezoelectric element, or the like such as a heater or a heat-generating resistor is used but the recording element is not limited to these elements. In the case where the electrothermal transducer is used as the recording element, a protecting film (not shown) is formed at a surface of the electrothermal transducer for the purpose of impact relaxation during bubble generation, alleviation of damage from the ink, and the like.
As the negative photosensitive resin material used, it is possible to use those utilizing cationic polymerization, radical polymerization, and the like but the negative photosensitive resin material is not limited to these resin materials. When the negative photosensitive resin material utilizing a cationic polymerization reaction is taken as an example, cations generated from a photo-cation polymerization initiator contained in the negative photosensitive resin material promote polymerization or crosslinking between molecules of cationically polymerizable monomers or polymer to cure the negative photosensitive resin material.
As the photo-cation polymerization initiator, it is possible to use aromatic iodonium salts, aromatic sulfonium salts, and the like. Specifically, e.g., photo-cation polymerization initiators (“ADEKA OPTOMER SP-170”, “ADEKA OPTOMER SP-150” (trade name)) are commercially available from ADEKA CORPORATION.
Such a negative photosensitive resin material is formed on the substrate 1 in the negative photosensitive resin material layer by a method such as a spin coating method, a direct coating method, or a lamination transfer method.
Next, the thus formed first negative photosensitive resin layer 2 is subjected to light exposure and development in a predetermined area to form a first flow passage wall 2 - 1 for forming a first bubble-generating chamber/flow passage ( FIG. 1( b )). In this step, a portion to be formed as the first bubble-generating chamber and the flow passage is light-blocked and an area other than the portion is irradiated with light to cure the negative photosensitive resin material in the light-irradiation area, thus forming a cured resin material layer. As developing liquid, it is possible to use methyl isobutyl ketone, a mixture solvent of methyl isobutyl ketone/xylene, and the like.
Incidentally, in this embodiment and also in the following Embodiments, in the case of the negative photosensitive resin material, the negative photosensitive resin material in the light-irradiation area is cured to form a cured resin material film (layer).
Next, on the above-formed first flow passage wall 2 - 1 , a soluble resin material layer 3 is formed ( FIG. 1( c )). The soluble resin material layer 3 is required to have a film thickness sufficiently larger than a height of the first flow passage wall 2 - 1 . As a forming method of the soluble resin material layer 3 , it is possible to use the spin coating method, the direct coating method, and the lamination transfer method but the forming method is not limited to these methods. As a material for the soluble resin material layer 3 , a photo-degradable positive photosensitive resin material may preferably be used. For example, a photosensitive resin material having a photosensitive wavelength range in the neighborhood of 290 nm, such as polymethyl isopropenyl ketone (PMIPK) or polyvinyl ketone or a photosensitive resin material having the photosensitive wavelength range in the neighborhood of 250 nm, such as a polymeric compound constituted by a methacrylate unit (e.g., polymethyl methacrylate (PMMA)) may be used but the material for the soluble resin material layer 3 is not limited to these materials.
Next, by abrading the formed soluble resin material layer 3 , a flattened surface is formed so that the soluble resin material layer 3 is flattened in an area surrounded by the ink flow passage wall 2 - 1 ( FIG. 1( d )).
As an abrading method, it is possible to use a CMP (chemical mechanical polish) technique, which is a chemical mechanical polishing method, by using slurry. In this case, the first flow passage wall 2 - 1 formed of the negative photosensitive resin material is sufficiently cross-linked by light exposure, thus providing a difference in hardness from the coated soluble resin material layer to sufficiently function as a polishing (abrasion) stop layer. As a result, it is possible to stably remove the soluble resin material layer by the abrasion until an upper pattern of the negative photosensitive resin material layer is exposed, so that the surface of the first flow passage wall 2 - 1 and the surface of the first positive photosensitive resin material layer 3 coincide with each other. Thus, the first flow passage wall 2 - 1 and the soluble resin material layer 3 have the substantially same height from the substrate 1 .
As another method of flattening the soluble resin material layer 3 and the first flow passage wall 2 - 1 , it is possible to use dry etching. Further, as particles for the abrasion, it is possible to use those of alumina, silica, and the like.
Separately, on a supporting substrate 6 , a negative photosensitive resin material layer 4 as a layer formed of a curable resin material is formed and thereafter against the negative photosensitive resin material layer 4 , a mold for transferring a flow passage wall 4 and an ejection outlet pattern 5 for providing a second bubble-generating chamber and a flow passage therefor is pressed ( FIG. 1( e )). Then, the negative photosensitive resin material layer 4 is irradiated with light to be cured, so that a pattern for providing a second flow passage 4 ′ and an ejection outlet 5 is transferred onto the negative photosensitive resin material layer 4 by separating the mold from the negative photosensitive resin material layer 4 ( FIG. 1( f )). The transfer can be carried out by using a nanoimprint method. The ejection outlet 5 may preferably have a diameter of 15 μm or less and the second flow passage 4 ′ may preferably have a diameter, larger than that of the ejection outlet 5 , of 20 μm or more.
As the supporting substrate 6 , it is possible to use quartz glass, single crystal silicon substrate, and the like.
Next, the substrate 1 and the supporting substrate 6 are disposed so that the negative photosensitive resin material layer 4 and the soluble resin material layer 3 are located opposite to each other ( FIG. 1( g )). Thereafter, the negative photosensitive resin material layer 4 is pressed against the soluble resin material layer 3 , so that the pattern of the second flow passage 4 ′ and the ejection outlet 5 provided to the negative photosensitive resin material layer 4 on the supporting substrate 6 is transferred onto the flattened substrate of the first flow passage wall 2 - 1 and the soluble resin material layer 3 ( FIG. 1( h )). The second flow passage 4 ′ is provided so as to be located on the soluble resin material layer 3 .
In this case, a condition including a transfer temperature, a transfer pressure, and a transfer time can be selected relatively freely since the lower layer is flattened but it is necessary to consider that both of the upper and lower layers caused no mutual dissolution and that the second flow passage wall 4 has sufficient adhesiveness to the previously formed first flow passage wall 2 of the negative photosensitive resin material. As a method of improving the adhesiveness, an adhesive layer of an adhesive may be formed between the upper and the lower layers or the ink flow passage wall 4 may be irradiated with light after the transfer.
Then, the supporting substrate 6 is separated ( FIG. 1( i )). In this case, in order to facilitate the separation between the supporting substrate 6 and the negative photosensitive resin material layer 4 , a release layer may be provided between the supporting substrate 6 and the negative photosensitive resin material layer 4 or the surface of the supporting substrate may be subjected to water-repellent treatment.
Then, the ink supply port (not shown) which penetrates through the substrate 1 is formed (not shown). As a method of forming the ink supply port, anisotropic etching or dry etching is generally used but the method is not limited to these etching methods. As an example thereof, an anisotropic etching method using a silicon substrate having a particular crystal orientation will be described. First, at a back surface of the silicon (Si) substrate 1 , an etching mask is formed in an entire area while leaving only a slit portion having a size of the ink supply port. Then, the substrate 1 is dipped into an alkaline etching liquid consisting of an aqueous solution of potassium hydroxide, sodium hydroxide, tetramethylammonium hydroxide, or the like while being warmed. As a result, only a portion exposed at the slit portion of the substrate 1 can be dissolved with anisotropy, so that the ink supply port can be formed. Next, the etching mask is removed as desired. Incidentally, in this case, for the purpose of protecting the negative photosensitive resin layer and the ink-repellent layer at the surface of the substrate from the etching liquid, a layer of resin material or the like having resistance to the etching liquid may be formed on the surface of the substrate as a protection layer.
Therefore, the soluble resin material layer 3 for forming a first ink flow passage pattern is dissolved and removed by using a removing liquid to form a first flow passage 3 ′ communicating with the ink ejection outlet ( FIG. 1( j )).
As the removing liquid, methyl isobutyl ketone (MIBK) or the like can be used.
In the case of using the positive photosensitive resin material for the soluble resin material layer, dissolubility of the resin material in the removing liquid is improved by irradiating the soluble resin material layer 3 for forming the flow passage pattern with ionizing radiation (light exposure) to cause decomposition reaction of the positive photosensitive resin material. In order to further improve the dissolubility, application of ultrasonic wave or temperature rise of the removing liquid is also effective. In this case, as the removing liquid, it is also possible to use MIBK.
(Second Embodiment)
Second Embodiment of the manufacturing method of an ink jet head according to the present invention will be described with reference to schematic process sectional views of FIGS. 2( a ) to 2 ( j ).
In the manufacturing method of the ink jet head in this embodiment, a photosensitive resin material layer, on which a latent image for a second flow passage wall and an ejection outlet pattern is formed, formed on a supporting substrate is transferred.
Manufacturing steps, shown in FIGS. 2( a ) to 2 ( d ), until the first ink flow passage wall and the sacrifice layer are formed to have a flattened surface are the same as those in First Embodiment shown in FIGS. 1( a ) to 1 ( d ), thus being omitted from detailed explanation.
On a supporting substrate 6 , a first negative photosensitive resin material layer 4 - 1 is formed and is subjected to light exposure through a mask having an ejection outlet pattern shape to form a latent image 5 ′ for an ejection outlet ( FIG. 2( e )). Then, on the first negative photosensitive resin material layer 4 , a second negative photosensitive resin material layer 4 - 2 is formed and exposed to light to form a latent image 4 ′, a second flow passage constituting a second bubble generating chamber and an ink flow passage wall ( FIG. 2( f )). A dimension of the latent image 5 ′ for the ejection outlet provided to the first negative photosensitive resin material layer 4 - 1 as a lower layer is smaller than that of the latent image 4 ″ for the second flow passage provided to the second negative photosensitive resin material layer 4 - 2 as an upper layer. For this reason, negative photosensitive resin materials to be exposed to light in the same wavelength can be used for the first negative photosensitive resin material layer 4 - 1 and the second negative photosensitive resin material layer 4 - 2 . That is, a portion at which the second negative photosensitive resin material layer 4 - 2 as the upper layer is exposed to light is within an area of a portion at which the first negative photosensitive resin material layer 4 - 1 as the lower layer is exposed to light. As a result, an unexposed portion of the lower layer 4 - 1 located under the upper layer 4 - 2 is not subjected to light exposure, so that there is no possibility that the lower layer 4 - 1 is adversely affected by the light exposure with respect to the upper layer 4 - 2 .
In this embodiment, a step of separately applying the first negative photosensitive resin material layer 4 - 1 for forming an orifice plate having the ejection outlet and the second negative photosensitive resin material layer 4 - 2 for forming a second flow passage 4 ′ is described but it is also possible to employ such a method that these layers are simultaneously formed in a thickness corresponding to the total thickness of the above layers 4 - 1 and 4 - 2 and then are subjected to light exposure through photomasks having different absorbances.
Next, the first and second negative photosensitive resin material layers 4 - 1 and 4 - 2 on which the latent images are formed, and the flattened first bubble-generating chamber and soluble resin material layer are disposed opposite to each other ( FIG. 2( g )). Then, the first and second negative photosensitive resin material layers 4 - 1 and 4 - 2 are applied to the flattened first flow passage wall 2 - 1 and soluble resin material layer 3 and thereafter the supporting substrate 6 is removed ( FIG. 2( h )).
Thereafter, the latent images which are non-exposed patterns are removed ( FIG. 2( i )) and then the soluble resin material layer 3 is removed by the same method as that in the step of FIG. 1( j ) ( FIG. 2( j )).
In this case, it is also possible to select a developing liquid capable of removing the latent image patterns and the soluble resin material layer 3 at the same time. As the developing liquid, an organic developing liquid, e.g., MIBK or the like, can be used.
(Third Embodiment)
Third Embodiment of the manufacturing method of the ink jet head according to the present invention will be described with reference to schematic process sectional views of FIGS. 3( a ) to 3 ( j ).
Manufacturing steps, shown in FIGS. 3( a ) to 3 ( d ), until the ink flow passage wall and the soluble resin material layer are flattened are the same as those in First Embodiment shown in FIGS. 1( a ) to 1 ( d ), thus being omitted from detailed explanation.
A dry film resist including a base film 7 and a first negative photosensitive resin material layer 4 - 1 formed on the base film 7 in a predetermined thickness is disposed so as to oppose a first flow passage wall 2 - 1 and a soluble resin material layer 3 ( FIG. 3( e )). Thereafter, the first negative photosensitive resin material layer 4 - 1 is pressed against the first flow passage wall 2 - 1 and the soluble resin material layer 3 to be provided on the first flow passage wall 2 - 1 and the soluble resin material layer 3 which have been flattened.
A condition including a transfer temperature, a transfer pressure, and a transfer time can be selected relatively freely since the lower layer is flattened but it is necessary to consider that no mutual dissolution with the sacrifice layer occurs and that the second flow passage wall 4 has sufficient adhesiveness to the previously formed first flow passage wall 2 of the negative photosensitive resin material. Further, in order to facilitate the transfer of the first negative photosensitive resin material layer 4 - 1 from the base film, fluorine-imparting treatment for the base film is also effective.
Then, the first negative photosensitive resin material layer 4 - 1 is subjected to light exposure through lithography ( FIG. 3( f )), so that a second flow passage wall 4 for constituting a second bubble-generating chamber and an ink flow passage therefor is formed in the first negative photosensitive resin material layer 4 - 1 ( FIG. 3( g )).
When the negative photosensitive resin material is selected, by using the negative photosensitive resin material having a sensitivity wavelength different from that of the soluble resin material layer 3 , it is possible to effect patterning without causing decomposition reaction of the soluble resin material layer 3 even when the soluble resin material layer 3 is exposed to light. Further, the developing liquid is required to be selected so as not to adversely affect the lower light. For this purpose, it is possible to use a mixture liquid such as a mixture of MIBK, xylene and isopropyl alcohol (IPA) or the like.
Then, by using a dry film resist including a second negative photosensitive resin material layer 4 - 2 constituting an orifice plate, the second negative photosensitive resin material layer 4 - 2 is transferred onto the first negative photosensitive resin material layer 4 - 1 ( FIG. 3( h )).
A transfer condition is required to be selected so that collapse does not occur at a hollow portion of the ink flow passage. For example, by suppressing the transfer temperature and the transfer pressure at low levels, it is possible to form a stable shape without adversely affecting the ink flow passage and the shape of the orifice plate.
Then, an ejection outlet 5 is provided to the second negative photosensitive resin material layer 4 - 2 by light exposure and development ( FIG. 3( i )). For patterning of the ejection outlet 5 , a mask is used in which light is blocked at a portion constituting the ink ejection outlet 5 and in an area other than the portion constituting the ink ejection outlet 5 , light exposure is permitted.
Then, by employing the same step as that of FIG. 1( j ), a liquid ejection head is manufactured ( FIG. 3( j )).
EXAMPLE 1
In this example, a liquid ejection head was prepared by using the manufacturing method of First Embodiment.
First, a single-crystal silicon substrate 1 on which a recording element, a driver circuit, and a logic circuit were formed was prepared. On the substrate 1 , a negative photosensitive resin material layer 2 was formed.
As a negative photosensitive resin material for forming the negative photosensitive resin material layer 2 , a photosensitive resin material solution having the following composition (1) was used.
(Composition (1))
EHPE-3150 (trade name, mfd. by DAICEL
100
wt. parts
CHEMICAL INDUSTRIES, LTD.)
HFAB (trade name, by Central Glass Co., Ltd.)
20
wt. parts
A-187 (trade name, mfd. by Nippon Unicar Co.,
5
wt. parts
Ltd.)
SP172 (trade name, mfd. by ADEKA
6
wt. parts
CORPORATION)
Xylene
80
wt. parts
Onto the substrate 1 , the above-constituted negative photosensitive resin material solution was applied by spin coating and then was pre-baked on a hot plate at 90° C. for 3 minutes, thus forming a 11 μm-thick negative photosensitive resin material layer 2 ( FIG. 1( a )).
Next, the negative photosensitive resin material layer was subjected to pattern exposure at an exposure amount of 500 mJ/cm 2 through a mask provided with a pattern of an ink flow passage wall by using a mask aligner (“MPA 600 Super” (trade name), mfd. by Canon Kabushiki Kaisha). Then, the negative photosensitive resin material layer 2 was subjected to PEB (post etching bake) at 90° C. for 180 sec, development using a mixture solution of methyl isobutyl ketone/xylene =2/3, and rinsing with xylene to form a first ink flow passage wall 2 - 1 ( FIG. 1( b )).
Next, this ink flow passage wall was coated with a soluble resin material layer 3 of a photodegradable positive photosensitive resin material.
As the photodegradable positive photosensitive resin material for forming a positive photosensitive resin material layer, polymethyl isopropenyl ketone (“ODUR-1010”, mfd. by TOKYO OHKA KOGYO CO., LTD.) was used. Specifically, the resin material was adjusted to provide a resin material concentration of 20 wt. % and was applied by spin coating. Thereafter, the resin material was subjected to pre-baking on a hot plate at 120° C. for 3 minutes to form a 18 μm-thick soluble resin material layer 3 ( FIG. 1( c )).
Next, the soluble resin material layer 3 was abraded by using the CMP method until the surface of the negative photosensitive resin material layer 2 - 1 is exposed ( FIG. 1( d )).
Separately, on a supporting layer 6 , a negative photosensitive resin material layer 4 having the above-described composition (1) was applied in a thickness of 10 μm through a release layer ( FIG. 1( e )). Then, a quartz-made mold having a projected shape corresponding to a shape of a second flow passage and an ejection outlet was subjected to fluorine-imparting treatment and thereafter was pressed against the negative photosensitive resin material layer 4 , followed by light exposure from the supporting substrate 6 side to cure the negative photosensitive resin material. Thereafter, the quartz-made mold was separated from the negative photosensitive resin material layer 4 ( FIG. 1( f )).
Then, the negative photosensitive resin material layer 4 provided with a second flow passage 4 ′ and an ejection outlet 5 and the first ink flow passage wall 2 - 1 and the soluble resin material layer 3 which were flattened were disposed opposite to each other ( FIG. 1( g )). At this time, these members are required to be positionally aligned so that the ejection outlet 5 and the recording element 20 formed on the substrate 1 are located opposite to each other.
This positional alignment can be performed by using an alignment pattern formed on the substrate 1 or the negative photosensitive resin material layer 2 formed on the substrate 1 and an alignment pattern formed on the supporting substrate 6 or the negative photosensitive resin material layer 4 in combination.
In this embodiment, the patterns formed on the substrate 1 and the supporting substrate 6 were used to perform the positional alignments.
Thereafter, the negative photosensitive resin material layer 4 which was formed on the supporting substrate 6 and was provided with the second flow passage 4 ′ and the ejection outlet 5 was transferred onto the first flow passage wall 2 - 1 and the soluble resin material layer 3 which were flattened ( FIG. 1( h )). In this case, between both the layers, a thin photocurable resin material layer as an adhesive layer was formed and exposed to light after the alignment to further enhance adhesiveness between the both layers.
Then, the supporting substrate 6 was removed ( FIG. 1( i )).
Next, onto an entire surface at which the ejection outlet 5 was formed, a protecting layer of “OBC” (trade name, mfd. by TOKYO OHKA KOGYO CO., LTD.) was applied. Then, at a back surface of the substrate, a slit-like etching mask was formed of a polyetheramide resin material (“HIMAL” (trade name), mfd. by Hitachi Chemical Co., Ltd.) and the substrate was immersed in a tetramethylammonium hydroxide aqueous solution at 80° C., so that anisotropic etching was performed with respect to the silicon substrate to form the ink ejection outlet at the back surface of the substrate 1 (not shown). The etching mask may also be formed in advance of the preparation of the substrate.
Next, the material (“OBC”) for the protecting layer was removed by xylene and thereafter the resultant structure was subjected to whole surface exposure at an exposure amount of 7000 mJ/cm 2 from the side where the ejection outlet was formed, so that the soluble resin material layer 3 for forming the ink flow passage pattern was solubilized. The structure was immersed in methyl lactate while applying thereto ultrasonic wave, thus removing the ink flow passage pattern to prepare an ink jet head as shown in FIG. 1( j ).
EXAMPLE 2
In this example, an ink jet head was manufactured by using the manufacturing method of Second Embodiment. Manufacturing steps shown in FIGS. 2( a ) to 2 ( d ) were performed by employing the same process as that in Example 1, thus being omitted from explanation.
In this embodiment, on the supporting substrate 6 , the negative photosensitive resin material having the composition (1) described above was applied by spin coating and then subjected to baking at 90° C. for 180 seconds to form a 5 μm-thick negative photosensitive resin material layer 4 .
Thereafter, the negative photosensitive resin material layer 4 was exposed to light at an exposure amount of 500 mJ/cm 2 through a photo-mask provided with a pattern for the ejection outlet 5 by using the mask aligner (“MPA600 Super”, mfd. by Canon Kabushiki Kaisha) to form a latent image 5 ″ for the ejection outlet in the negative photosensitive resin material layer 4 - 1 ( FIG. 2( e )). Thereafter, PEB at 90° C. for 180 seconds was performed.
Further, on the negative photosensitive resin material layer 4 - 1 , the negative photosensitive resin material having the above-described composition (1) was formed by spin coating, followed by baking at 90° C. for 180 seconds to form a 5 μm-thick negative photosensitive resin material layer 4 - 2 .
Next, the pattern for the second bubble-generating chamber and the ink flow passage is exposed to light by using the mask aligner (MPA600 Super), followed by PEB at 90° C. for 180 seconds to form a latent image 4 ″ for forming an ink flow passage wall 4 and an ink flow passage 4 ′ ( FIG. 2( f )).
Then, the negative photosensitive resin material provided with the latent image on the supporting substrate was positionally aligned with the first flow passage wall and the soluble resin material layer which are flattened. After both the members were brought into close contact with each other, the resultant structure was subjected to light exposure and then PEB at 90° C. for 180 seconds to transfer the pattern ( FIG. 2( g )). Thereafter, the supporting substrate 6 was removed ( FIG. 2( h )).
The positional alignment was performed by using the alignment patterns similarly as in Embodiment 1.
Further, in the same manner as in Embodiment 1, after the ink ejection outlet was formed on the substrate by wet etching, development of the latent image pattern of the negative photosensitive resin material layer was performed by using a mixture solution of MIBK/xylene ( FIG. 2( i )).
Finally, by using methyl lactate, the soluble resin material layer 3 was removed to prepare an ink jet head as shown in FIG. 2( j ).
EXAMPLE 3
In this example, an ink jet head was manufactured by using the manufacturing method of Third Embodiment. Manufacturing steps shown in FIGS. 3( a ) to 3 ( d ) were performed by employing the same process as that in Example 1, thus being omitted from explanation.
Onto the abraded surface of the soluble resin material layer 3 , a 6 μm-thick negative photosensitive resin material was transferred from a dry film resist including the negative photosensitive resin material to form a negative photosensitive resin material layer 4 - 1 ( FIG. 3( e )). In this step, a transfer condition including a transfer temperature of 60° C., a transfer pressure of 1 kgf/m 2 , and a transfer time of one minute was employed.
Then, the negative photosensitive resin material layer 4 - 1 was subjected to pattern exposure at an exposure amount of 300 mJ/cm 2 through a mask provided with a pattern for a bubble-generating chamber and an ink flow passage by using the mask aligner (MPA600 Super) ( FIG. 3( f )). Then, PEB was performed at 90° C. for 180 seconds and development was performed by using a mixture solution of MIBK/xylene (=2/3), followed by rinse treatment to form an ink flow passage wall 4 and an ink flow passage 4 ′ ( FIG. 3( g )).
Next, onto the ink flow passage wall 4 and the ink flow passage 4 ′, a 5 μm-thick negative photosensitive resin material having the above-described composition (1) was transferred from a dry film resist including the negative photosensitive resin material to form a negative photosensitive resin material layer 4 - 2 ( FIG. 3( h )). In this step, a transfer condition including a transfer temperature of 40° C., a transfer pressure of 1 kgf/cm 2 , and a transfer time of 1 minute was employed.
Then, the negative photosensitive resin material layer 4 - 2 was subjected to pattern exposure at an exposure amount of 300 mJ/cm 2 through a mask provided with a pattern for an ejection outlet by using the mask aligner (MPA600 Super). Then, PEB was performed at 90° C. for 180 seconds and development was performed by using a mixture solution of MIBK/xylene (=2/3), followed by rinse treatment to form an ejection outlet ( FIG. 3( i )).
Next, by using the same manufacturing step as that in Embodiment 1, an ink jet head was prepared ( FIG. 3( j )).
While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth and this application is intended to cover such modifications or changes as may come within the purpose of the improvements or the scope of the following claims.
This application claims priority from Japanese Patent Application No. 064139/2008 filed Mar. 13, 2008, which is hereby incorporated by reference. | A manufacturing method of a liquid ejection head includes forming on a substrate a first flow passage wall forming member contacting a solid layer of equal height, exposing a first layer of a negative photosensitive resin material to form an ejection outlet forming member; exposing a second layer, on the first layer, of a negative photosensitive resin material to form a second flow passage wall forming member for forming another part of the wall of the flow passage; placing the exposed first and second layers on the solid layer and the first flow passage wall forming member so that a non-exposed portion of the second layer contacts the solid layer; forming parts of the flow passage and the ejection outlet by removing non-exposed portions of the first and second layers above the substrate; and forming the flow passage by removing the solid layer. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to methods of modeling neuropsychological data and more particularly to methods of providing models, testing models and combining models.
BACKGROUND OF THE INVENTION
[0002] It is known in the field of neuropsychology that behavioral functions are based upon flow among various functional regions in the brain, involving specific spatiotemporal flow patterns. Likewise, behavioral pathologies are often indicated by a change in the patterns of flow. The specific spatiotemporal pattern underlying a certain behavioral function or pathology is composed of functional brain regions, which are often active for many tens of milliseconds and more. The flow of activity among those regions is often synchronization-based, even at the millisecond level and sometimes with specific time delays.
[0003] Models are commonly used in the field of neurology to gain understanding about the behavioral functions of the various regions of the brain and their interaction or flow, producing these spatiotemporal flow patterns. Understanding of the spatiotemporal pattern may be gained by using models. However, different models may be hypothesized for the same set of observations or data. Furthermore, there are a vast number of regions in the brain and potentially an equal amount of models to explain its function. Accordingly, to date it has been difficult to construct and test a unifying model able to explain observations relating to more than one specific region of the brain.
[0004] Currently, models are specific to an individual data set and cannot be extrapolated, related or correlated to other existing problems or data sets.
SUMMARY OF THE INVENTION
[0005] The background art does not teach or suggest a method for analyzing neurophysiological data using a unifying modeling platform. The background art does not teach or suggest a unifying modeling system and method. The background art also does not teach or suggest a unified modeling system that allows models to be integrated, related and tested against one another. The background art also does not teach or suggest a system that allows model abstraction, for testing observed data or hypotheses.
[0006] The present invention overcomes these drawbacks of the background art by providing a method to analyze neurophysiological data, and/or optionally behavioral and/or other types of neurological data, to construct one or more models that explain the observed data.
[0007] Neurophysiological data includes any type of signals obtained from the brain. Such signals may be measured through such tools as EEG is (electroencephalogram), which is produced using electroencephalography. Electroencephalography is the neurophysiologic measurement of the electrical activity of the brain (actually voltage differences between different parts of the brain), performed by recording from electrodes placed on the scalp or sometimes in or on brain tissue. As used herein, the term “neurophysiological data” also refers to brain imaging tools, including but not limited to CAT (computed tomography) scans, PET (positron emission tomography) scans, magnetic resonance imaging (MRI) and functional magnetic resonance imaging (fMRI), ultrasound and single photon emission computed tomography (SPECT).
[0008] Optionally and preferably, the model also features neuropsychological data, for example from a knowledgebase or any type of database. The information may optionally be obtained from literature and/or from previous studies, including studies performed according to one or more aspects of the present invention, for example as described herein and/or as described in PCT Application No. PCT/IL2007/000639, by the present inventors and owned in common with the present application.
[0009] The present invention also encompasses a system and method for unifying models based on neurophysiological data forming a comprehensive neural modeling platform. An embodiment of the present invention provides for a platform able to analyze, test and integrate different models. Optionally and preferably the comprehensive modeling platform of the present invention provides a neural model knowledgebase that may be defined and updated. Optionally and preferably the knowledgebase is based on published data and experimental data. Optionally and preferably the knowledgebase may be organized by function or location.
[0010] A further optional embodiment of the present invention provides a research tool that optionally allows researchers to model different areas of the brain. Optionally, individual areas of the brain may correspond to at least one or more models. An optional embodiment of the present invention provides researchers with an interface having a model knowledgebase to perform at least one or more tasks for example including but not limited to incorporating an existing model into the platform, building a model around their specific data, searching for an existing model(s) that fit their data, combining different models, relate known models to specific research articles or data in the field.
[0011] Optionally the models abstracted within the platform of the present invention may be used to model a plurality of data or an individual data set. For example, a plurality of data may be grouped and analyzed to perform group analysis, relating a model to the common features of the group. Alternatively, the model platform of the present invention may optionally produce a specific individualized model based on an individual data set, optionally corresponding to an individual, effectively producing a brain model fingerprint of the individual.
[0012] A further optional embodiment of the present invention provides for a neural modeling platform for modeling functional plasticity, disease state or normal state modeling. For example, it is possible to adjust the model for someone who is suffering from brain damage or disease. Also once recovery has started, as for example in a patient who had a stroke and initially could not speak, but then recovered the ability to speak, it is possible to map functional plasticity changes in the brain, preferably with regard to areas of the brain that are affected.
[0013] According to some embodiments of the present invention, the neurophysiological models are optionally abstracted based on data which comprises EEG data and/or source localization data. The EEG data is preferably decomposed to given format producing a common base from which the models may be abstracted, tested and integrated.
[0014] Although the present description centers around models constructed by using EEG data, it should be noted that this is for the purpose of illustration only and is not meant to be limiting in any way. Any type of brain imaging data may optionally be used, including but not limited to CAT (computed tomography) scans, PET (positron emission tomography) scans, magnetic resonance imaging (MRI) and functional magnetic resonance imaging (fMRI), ultrasound, MEG (magnetoencephalography) and single photon emission computed tomography (SPECT), or any other noninvasive or invasive method and/or combinations thereof. Optionally, a plurality of different types of data may be combined for determining one or more models as described herein.
[0015] According to some embodiments of the present invention, there is provided a method for constructing a neural model, comprising analyzing neurophysiological data to obtain the model. Optionally, the method further comprises modeling functional plasticity. Preferably, the modeling functional plasticity comprises modeling recovery from a disease state.
[0016] Optionally, the method further comprises modeling a disease state.
[0017] Optionally, the method further comprises modeling a normal state. Optionally and preferably, the method further comprises constructing a simulation of the neural model. More preferably, the constructing the simulation comprises determining expected data for the model. Most preferably, the constructing the simulation further comprises pruning the expected data to obtain a better fit to the model. Also most preferably, the constructing the simulation further comprises comparing the expected data to the neurophysiological data.
[0018] Optionally, the method further comprises observing a behavior; and constructing the model at least partially according to the behavior. Preferably, the behavior comprises performing an action or activity by a subject. More preferably, the constructing the model comprises constructing a plurality of models; and selecting a model from the plurality of models according to the neurophysiological data. Most preferably, the selecting the model comprises determining a likelihood of the neurophysiological data fitting the plurality of models; and determining the model having a greatest likelihood of the data fitting the model.
[0019] Also most preferably, the selecting the model further comprises performing at least one additional test to obtain additional neurophysiological data for comparison to the model.
[0020] Also most preferably, the determining the likelihood and the performing at least one additional test is performed more than once.
[0021] Preferably, the constructing the plurality of models further comprises arranging the plurality of models into a hierarchical structure according to specific areas of brain activity; and wherein the selecting the model further comprises selecting the model according to at least one specific area of brain activity.
[0022] According to any of the above embodiments, the neurophysiological data comprises one or more of EEG (electroencephalogram) signal data, CAT (computed tomography) scan data, PET (positron emission tomography) scan data, magnetic resonance imaging (MRI) data and functional magnetic resonance imaging (fMRI) data, ultrasound data, and single photon emission computed tomography (SPECT) data.
[0023] Preferably, the neurophysiological data comprises source localization data.
[0024] According to other embodiments, there is provided a system for establishing a knowledgebase of neuropsychological models, wherein the knowledgebase is constructed according to the above described method, further comprising an interface for accessing the knowledgebase, wherein the interface and the knowledgebase are operated through a computer or network of computers. Optionally, the knowledgebase is searchable. Preferably, the knowledgebase comprises a plurality of brain model fingerprints for a plurality of individuals.
[0025] 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 invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
[0026] Although the present invention is described in some embodiments with regard to a “computer” on a “computer network”, it should be noted that optionally any device featuring a data processor and/or the ability to execute one or more instructions may be described as a computer, including but not limited to a PC (personal computer), a server, a minicomputer, a cellular telephone, a smart phone, a PDA (personal data assistant), a pager, TV decoder, game console, digital music player, ATM (machine for dispensing cash), POS credit card terminal (point of sale), electronic cash register. Any two or more of such devices in communication with each other, and/or any computer in communication with any other computer, may optionally comprise a “computer network”.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above and further advantages of the present invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which:
[0028] FIG. 1A-C are illustrative diagrams of EEG signals and localization maps optionally used to abstract a neural model according to an optional embodiment of the present invention.
[0029] FIG. 1D is a block diagram illustration of the neural modeling system in accordance with an optional embodiments of the present invention; and
[0030] FIG. 2 is a block diagram illustration depicting the interaction between model processor and knowledgebase according to an optional system and method of the present invention; and
[0031] FIG. 3 is a block diagram illustration of the functions of the model processor according to an optional embodiment of the present invention; and
[0032] FIGS. 4A and 4B show exemplary user interfaces of the neural modeling platform research tool according to an optional embodiment of the present invention;
[0033] FIG. 5A is a flow chart of an exemplary depiction of the research tools according to an optional embodiment of the present invention;
[0034] FIG. 5B is an example of the functions of the research tool according to FIG. 5A ;
[0035] FIGS. 6A-6E are schematic illustrations of flow patterns showing connectivity between functional regions that may be modeled; And
[0036] FIG. 7 relates to an exemplary embodiment of a system according to the present invention.
[0037] It will be appreciated that for simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn accurately or to scale. For example, the dimensions of some of the elements to may be exaggerated relative to other elements for clarity or several physical components may be included in one functional block or element. Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. Moreover, some of the blocks depicted in the drawings may be combined into a single function.
DETAILED DESCRIPTION
[0038] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be understood by those of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components and structures may not have been described in detail so as not to obscure the present invention.
[0039] The present invention is directed to a system and method for neural modeling of neuropsychological processes. The principles and operation of methods according to the present invention may be better understood with reference to the drawings and accompanying descriptions.
[0040] Before explaining at least one embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0041] The present invention, in some embodiments, is directed to a platform that may be used for test groups or individual subjects, to analyze and identify models that explain observed brain activity or neuropsychological patterns, related to behavior. The present invention is further directed to a platform that correlates neural models with a particular pathological or non-pathological state. The instant invention further provides a research tool for testing, integrating, and abstracting neural models specific to raw neurophysiological data or processed data for example including but not limited to localization maps.
[0042] FIG. 1A-C depicts various views of neurophysiological data that may be utilized to abstract a neural model. FIG. 1A relates to an exemplary screenshot of software constructed according to some embodiments of the present invention. FIG. 1B depicts a graph of averaged EEG waveforms for signals obtained from three recording electrodes that are used to identify the localization maps of FIG. 1C showing the location of activity in a plurality of clusters in the brain. Neural modeling may optionally be used to determine the various sites identified by localization maps such as that depicted in FIG. 1C . Similarly, neural models may be optionally abstracted from the EEG electrode data as depicted in FIG. 1B .
[0043] Data analysis and processing of an EEG signal may lead to pattern and flow analysis that relate the activity of different regions of the brain to explain behavioral functions or pathologies or common sub-functions. Such information may optionally be compiled into a knowledgebase of data which preferably includes published neuropsychological literature. The analysis of published neuropsychological literature preferably includes a description of possible flow patterns among functional brain regions relating to specific behavioral functions, sub-functions or pathologies. Currently, such functional flow information is not generally available in the literature, which usually describes the participation of certain regions in a certain behavioral function or pathology, often without reference to their functional flow relations with other regions in the specific function or pathology or in alternative functions. The knowledge base, in turn, enables improved source localization and analysis of spatiotemporal patterns, by posing constraints regarding possible flow patterns among functional regions. Therefore the flow patterns may be used to abstract different models optionally using that described in the literature or from direct experimentation.
[0044] FIG. 1D depicts an exemplary, illustrative system 100 according to an optional embodiment of the present invention that may optionally incorporate data for example including but not limited to flow patterns, EEG raw data, localization maps or the like to abstract a neural model. System 100 preferably comprises a processor 104 , a knowledgebase 102 and a model processor 106 . Model processor 106 is preferably used to abstract models and process models. Optionally historical data available in the literature 108 is transcribed and incorporated into knowledgebase 102 of system 100 . Similarly, user(s) 110 for example a researcher or health care provider may optionally interact with system 100 to abstract a neural model based on new data 112 . New data 112 may optionally be used to abstract new models that may be used to expand and update knowledgebase 102 . New data 112 may for example come in the form of but is not limited to raw EEG data, flow patterns, localization maps or the like.
[0045] Model processor 106 and knowledgebase 102 of FIG. 1D are depicted in further details in FIG. 2 , in an exemplary embodiment. Model processor 106 optionally and preferably interacts with the knowledgebase 102 of FIG. 1D to create and update the models already incorporated into the knowledgebase. Model processor 106 optionally and preferably comprises integrating module 206 , testing and comparing module 208 , and modifying module 210 that are used to process various models allowing a user to actively modify a neural model. Knowledgebase 102 interacts with model processor 106 to update and upkeep the neural models stored in knowledgebase 102 . Preferably, knowledgebase 102 is compiled from literature based models 200 and newly created models 202 through its interaction with model processor 106 .
[0046] Reference is now made to FIG. 3 , which is a flow chart illustrating an optional embodiment of the stages to create a new neural model based on a data from multiple sources, for example including but not limited to literature data 302 and experimental data 304 or the like. This data may optionally be compiled from subjects from the different research groups. A research group is defined as a group of subjects with similar behaviors. The behaviors may be actions or activities which are performed in a specific way due to a pathological condition, or the behaviors may be non-pathological actions which the subjects are requested to perform, for example. A research group may also include a control group for comparison with a group having or suspected of having a certain pathological condition or a control group for comparison with a group performing the action. Activity data of subjects are grouped according to research groups for example, a target group and a control group.
[0047] The data is then used to create different models in stage 306 . Preferably, the model processor (not shown) of the present invention is able to abstract a number of models that are able to fit the data. Optionally and preferably, the different abstracted models are then scored in stage 308 optionally and preferably by a likelihood rating, reflecting the likelihood of the model fitting the data presented. Optionally and preferably a user may then alter and then test the abstracted models, ensuring that the best model has been chosen.
[0048] In stage 310 , optionally the user may create different combination sets of the models for further testing. In stage 312 , one or more models may optionally be altered to better fit the test data.
[0049] Interactive stages 310 and 312 may optionally be performed more than once to construct and refine the model that best suits the data. Once the interactive stages yield a satisfactory neural model, the user preferably chooses a specific model(s) in stage 314 which is then saved into the knowledgebase in step 316 .
[0050] FIG. 4A depicts an exemplary screen shot of user interface 400 of the system and method of the present invention, in which a suggested or abstracted model 404 , which is preferably based on actual collected data, is modified according to the method described in FIG. 3 to create model 406 that is believed to better suit the given data and flow. Each such corrected model 406 is preferably shown as a correction; optionally, a plurality of potential corrected models 406 may be displayed (not shown). User interface 400 further depicts the functional or spatial models 402 that may be optionally selected.
[0051] FIG. 4B shows another exemplary screen shot of user interface 400 of the system and method of the present invention, which relates to the operation of a simulator according to some embodiments of the present invention. The simulator may optionally be used to adjust the data for the model, for example by adding or removing data points that are incorporated in the model. Various methods which are known in the art may be optionally used for this process, including but not limited to minimum spanning trees, Steiner trees and the like. Next, optionally and preferably, the simulator may be used to “run” the data, by generating the real time patterns of data that would be expected if the model is correct. Such real time generation may also optionally be used to show if there are any aspects of the data that the new or corrected model does not fit or explain.
[0052] The simulator may optionally and preferably prune the data tree or other model of the data to remove points, but may also optionally add points from the data as being relevant. Such points may optionally relate to source localization and/or direct data (such as signals from an electrode for example); however, preferably the points relate to activity in particular regions of the brain. The process employed by the simulator enables a researcher or clinician to adjust the model without being an expert in model building.
[0053] Turning now to the area of interface 400 on the right, a graphical representation of the simulation 408 is displayed. Such a graphical representation is preferably accessible to the user once the model has been selected and the “run simulation” button is pressed or otherwise selected. Optionally and preferably, the data pattern is shown as well during the simulation, for example relating to any patterns found in the raw data, more preferably including EEG data (not shown).
[0054] To assist the user in selecting the correct model, the user preferably first selects a model type from a list 410 . The list 410 is preferably structured according to a hierarchical tree, with leaves of the tree representing specific areas of brain activity, as for example auditory activity as shown. Higher up within the hierarchy, preferably collections of brain activities are represented, as for example with regard to particular diagnoses and/or cognitive tasks as shown. The selected model also preferably relates to a relationship between areas of the brain.
[0055] Next, a list of brain areas for which relevant activity is expected from the model is shown as activity list 412 . The activity list preferably shows the network or brain area to which the activity belongs, as for example auditory activity (not shown). As previously described, the relationship between a first source area of activity and a second target area of activity is preferably also shown, more preferably according to the level of strength and delay (the latter refers to the length of time that elapses between location activities of source and target). Optionally one or more parameters may be added according to other data as well (such as physiological data for example; not shown). Also optionally the model may be refined according to one or more of data from the literature and multiple trials from a single patient and/or from multiple patients.
[0056] A script may optionally be constructed and/or adjusted and/or selected as shown in script window 414 . The script may optionally be constructed in a different software program, as for example the software program E-Prime as a non-limiting example. E-Prime is a software applications suite for conducting psychological and neuroscientific experiments, developed by Psychology Software Tools (PST). This software enables the user to construct experimental scripts, for example regarding which type of stimulus should be offered, when and for how long. The simulator preferably uses the same language for script construction and in fact is preferably symmetrical with the actual test to be performed. This enables the investigator to use the same terms and structure for the test and for the simulator.
[0057] The simulator may optionally comprise a library of literature models, which may then optionally and preferably be adjusted by the researcher.
[0058] FIG. 5A is an optional depiction of how a user may interact with the system and method of the present invention. In stage 502 data, for example optionally in the form of raw EEG data, flow diagrams, localization maps or the like is obtained from a user. Preferably, such data includes source localization data and patterns obtained from the application entitled “FUNCTIONAL ANALYSIS OF NEUROPHYSIOLOGICAL DATA” co-filed by the present inventors and owned in common with the present application, the contents of which are hereby incorporated by reference as if fully set forth herein. Such data preferably includes neurophysiological global parameters of representation and plasticity.
[0059] In stage 504 preferably a plurality of relevant models are abstracted from the knowledgebase. FIG. 5B below shows an example from the neuropsychological knowledgebase, marked as element 504 . The table contains the relations between pairs of regions (Source &Target regions) in specific functional network (Network ID). Each relation is characterized by effect of activation (Effect) and conduction delay (Delay).
[0060] The models abstracted at stage 504 are tested and a script is provided in stage 506 to identify relevant models in stage 508 .
[0061] FIG. 5B is a practical example of the stages described in FIG. 5A . As shown in box 502 , a plurality of different parameters is preferably provided in the model. For example, temporal representation is related to delay. The subsequent listed parameters are exemplary of temporal representation. ENT_DUR—entity duration; a spike of activity for the network of neurons, which may also be considered to be a pulse. This parameter relates to duration of the pulse. It is measured in milliseconds (for example 50). INACT_PER—inactivation period; it measures how long recovery takes after activation of the brain area. DEFAULT_DUR—provides an estimate of the duration. SYN_DELAY—synchronization delay. INTRA_DELAY—within an area. INTER_DELAY—delay period for interaction between areas.
[0062] Spatial representation relates to the number of entities or areas of the brain in the model. MOD_ENTS—number of entities (areas) in model. MOD_LIM—max limit of entities.
[0063] Long term plasticity may optionally have various parameters; it relates to long term changes in the brain. For example if two groups of neurons and/or brain areas are functioning together, then the connection between them is maintained. This process enables the brain to learn. NEG_TOL—negative tolerance—inhibition of working together. POS_TOL—positive tolerance—increased tendency to work together.
[0064] SOURCE_FACT—source and target for combination—relationship. This parameter relates to the strength of the connection between them (ie the extent to which each one operates individually as opposed to operating together).
[0065] Short term plasticity relates to the ability of the brain to adjust quickly but then to “forget” the learned activity or behavior. Cycling of activity relates to many short term bursts of activity, as for example seen in many short term bursts of sound. CYC-LEN—Cycle length (how long is the cycle); CYC-AMP—cycle strength to maintain plasticity.
[0066] Several examples of flow patterns showing connectivity between functional regions is shown in FIGS. 6A-6E and associated Table 1 which relates functional regions to the numbering on the figures. These diagrams were formed based on published literature that may optionally be used to create a neural model according to an optional embodiment of the present invention. It should be readily apparent that these are merely examples, and do not necessarily represent actual patterns. Moreover, many alternatives may be suggested based on theory and experimental findings.
[0067] FIG. 6A is a diagrammatic representation of global interrelationships between an action, perception, executive function and attention. FIGS. 6B-6E are more specific diagrammatic representations of perception, executive function, action and attention, showing relationships and interrelationships between different areas of the brain which are functional during these activities. Similar models may be created for particular tasks, behaviors or activities, as described with respect to the present invention.
[0000]
TABLE 1
Modules
Functional module
Hemi
BA
Neuroanatomy
1. Perception
1.1. Visual
1.1.1. Primary visual
X
17
1.1.2. Secondary visual
X
18
1.1.3. Tertiary visual
1.1.3.1. Objective oriented
Lt
19
1.1.3.2. Subjective oriented
Rt
-″-
1.2. Auditory
1.2.1. Primary auditory
Bi
41
1.2.2. Secondary auditory
Bi
42
1.2.3. Tertiary auditory
1.2.3.1. Objective oriented
Lt
21, 22
1.2.3.2. Subjective oriented
Rt
-″-
1.3. Somatosensory
1.3.1. Primary somatosensory
X
1, 2, 3
1.3.2. Secondary somatosensory
X
Parietal
operculum
1.4. Pain
1.4.1. Primary pain
X
Posterior Insula
1.4.2. Secondary pain
1.4.2.1. Objective oriented
Lt
Anterior Insula
1.4.2.2. Subjective oriented
Rt
-″-
1.5. Heteromodal content
(a) Objective oriented
Lt
(b) Subjective oriented
Rt
1.5.1. Visual-Auditory
37, 20
1.5.2. Visual-Somatic
39
1.5.3. Global
38
1.6. Heteromodal spatial
1.6.1. Body
X + Rt
Superior
parietal lobule
1.6.2. Milieu
X + Rt
Inferior parietal
lobule
1.7. Short term content direction
1.7.1. Objective oriented
Lt
Ventral
posterior
cingulum
1.7.2. Subjective oriented
Rt
-″-
1.8. Short term spatial direction
X
Dorsal posterior
cingulum
1.9. Association
1.9.1. Objective oriented
Lt
Hippocamus + pa
rahippocampal
1.9.2. Subjective oriented
Rt
-″-
2. Executive function
2.1. Significance evaluation
2.1.1. Objective oriented
Lt
Amygdala
2.1.2. Subjective oriented
Rt
-″-
2.2. Executive direction
(a) Content direction
LT
(b) Spatial direction
RT
2.2.1. Top level
9, 10
2.2.2. Basic level
46, 47
2.3. Outcome prediction
2.1.1. Objective oriented
Lt
Ventromesial
prefrontal
cortex
2.1.2. Subjective oriented
Rt
-″-
3. Action
3.1. Abstract action
3.1.1. Content action
Lt
44, 45
3.1.2. Spatial action
Rt
-″-
3.2. Implementation
X
Medial
cingulum
3.3. Complex action
3.3.1. Body
X
6
3.3.2. Eyes
X
8
3.4. Basic action
X
4
3.5. Action maintenance
II
Cerebellum
4. Attention
4.1. Process selection
4.1.1. Executive selection
4.1.1.1. Content selection
Lt
Ventral basal
ganglia
4.1.1.2. Spatial selection
Rt
-″-
4.1.2. Implementation selection
X
Dorsal basal
ganglia
4.2. Perceptual attention
U
Locus Ceruleus
4.3. Executive attention
U
Ventral
tegmental area
4.4. Action attention
U
Raphe nuclei
[0068] FIG. 7 relates to an exemplary embodiment of a system according to the present invention. As shown, a system 700 preferably features a user computer 702 . User computer 702 preferably enables on-line communication for the user (not shown) through a computer network 704 . By “online”, it is meant that communication is performed through an electronic communication medium, including but not limited to, telephone voice communication through the PSTN (public switched telephone network), cellular telephones or a combination thereof; exchanging information through Web pages according to HTTP (HyperText Transfer Protocol) or any other protocol for communication with and through mark-up language documents; exchanging messages through e-mail (electronic mail), messaging services such as ICQ® for example, and any other type of messaging service; any type of communication using a computational device as previously defined; as well as any other type of communication which incorporates an electronic medium for transmission.
[0069] User computer 702 preferably communicates with a model repository 706 . Models may optionally be accessed and more preferably simulated through model repository 706 . Optionally such data and interactions are performed through a web server 708 as shown.
[0070] A system such as the one described can potentially be used for many neurological and psychiatric conditions such as rehabilitation of brain injuries, treatment of neurocognitive dysfunctions and treatment of behavioral and emotional pathologies and problems. It should be noted that non-clinical applications are also ample, such as analysis of decision making, analysis of mood, analysis of personality and in general analysis of any behavioral function. Furthermore, the above system may also optionally be used for performing any of the above described methods, for example by having a computer perform the method to generate the model. Preferably, the result of the model is then displayed to a user, for example through the above described system.
[0071] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.
[0072] While certain features of the present invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those of ordinary skill in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present invention. | Systems and methods for constructing a neural model, wherein the system and method comprises analyzing neuropsychological data to obtain the model and modeling functional plasticity. | 6 |
BACKGROUND OF THE INVENTION
This invention concerns punch holders for turret type punch presses, and more particularly multiple tool holders of a type described in U.S. Pat. No. 4,998,958.
U.S. Pat. No. 4,998,958 describes a punch tool holder carrying a number of punches, any one of which may be selected to be individually driven by the press ram.
It has also been heretofore known to mount individual punching tools to enable rotation to any of various desired orientations of the punching tool.
See U.S. Pat. No. 4,412,469 for an example of such a prior design.
U.S. Pat. No. 5,048,385 describes a tool holder capable of holding a number of punching tools any of which may be driven by the press ram.
In addition, the holder described therein is capable of positioning each tool at a desired orientation when engaged by the press ram. This is done by including a separately rotatable striker and tool carrier in the holder. The striker and tool carrier are rotated together to select a particular tool orientation and the striker separately rotated to select a particular tool.
This approach inherently requires sequentially staged rotation of the striker alone and the striker and carrier together, increasing the cycle time.
Furthermore, the tool holder is itself made more complicated by adding a striker to the holder in order to provide the variable tool orientation capability. Since many tool holders may be required to equip a turret type press, the increased costs of the more complicated holders can be significant.
Accordingly, an object of the present invention is to provide an arrangement for enabling a variable orientation of each tool in a multiple tool holder, which does not necessarily increase the cycle time or the complexity of the tool holder.
The multiple tool holders of the type shown in the above-referenced U.S. patents are typically installed in punch presses which already have indexing drives for rotating single punch holders to enable setting of various orientations of punches mounted in the press turret.
A disadvantage of multiple tool holders requiring rotation of the tool holder is that most older and some newer machines are not equipped with rotary indexing drives, which is impractical to add to existing machines.
Another object of the present invention is to provide a multiple tool holder and ram arrangement which does not require rotation of the tool holder to execute tool selection.
SUMMARY OF THE INVENTION
The present invention comprises an arrangement of an indexing ram combined with a separately driven rotary multiple tool holder. The tool holder is rotated to orient the tools in any desired angular position, while the ram is indexed to select the particular tool in the holder. The press table controls compensate for the variability of the tool location.
The separate indexing ram and rotary tool holder drives enable simultaneous execution of both tool selection and the setting of tool orientation to minimize cycle time.
A standard multiple tool holder is employed to avoid increased tooling costs, and the arrangement is also compatible with single tool holders.
A rotary ram can be employed with stationery multiple tool carriers configured to carry out the tool selection process without the need to add indexing drives for the tool carriers.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary partially sectional elevational view of an arrangement according to the present invention together with adjacent press structure, and a diagrammatic representation of drive controls included in the arrangement.
FIG. 2 is a plan view of a tool holder incorporated in the arrangement of FIG. 1, with a diagrammatic representation of the associated drive and control.
FIG. 3 is a fragmentary partially sectional view of a rotary ram and stationary multiple tool holder installed in a press.
FIG. 4 is a fragmentary view of a portion of the rotary ram arrangement of FIG. 3 depicting an alternate ram drive connection.
FIG. 5 is a fragmentary partially sectional view of an alternate embodiment of the rotary ram stationary holder of FIG. 3.
FIG. 6 is a plan view of the tool pattern of the holder of FIG. 5.
DETAILED DESCRIPTION
In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.
Referring to FIG. 1, the arrangement according to the present invention includes a rotary ram 10 coupled to the press rod 12 by means of a ram connector 14 pinned to the end of the press actuator 12. The connector 14 is formed with a recess 16 retaining a flanged end 18 of the rotary ram 10 so as to allow rotation therein.
The rotary ram includes a main body portion 20 which is slidably received in a bore formed in a ram bushing 22. A key 24 and key way 26 prevent rotation of the rotary ram 10 in the ram bushing bore while accommodating the vertical sliding movement therein.
The ram indexing bushing 22 is itself received in a bushing 28 seated in a bore in a portion of the press frame 30.
A worm gear 32 is affixed or integral with the ram indexing bushing 22 and engaged with a worm 34 rotated by a drive motor 36 providing a control 38 with a position feedback signal.
The lower end of the rotary ram 10 is formed with an engagement feature 40 comprised of a radial protuberance which is variably positioned in indexed angular positions by operation of the drive motor 36. A proximity switch 42 or other suitable sensor provides a homing or zero position signal to the control 38.
The lower end of the rotary ram 10 is formed with a tee slot 44 adapted to receive a tee head 46 of a drive member 48 of each of a plurality of multiple tool holder 50 arranged in a circumferential array about the perimeter of an upper turret 52 of the press. Thus, as the upper turret 52 is rotated, each tee head 46 of each holder in the array successively passes into the tee slot 44 to in turn be coupled to the rotary ram 10.
The tool holder 50 comprises a multiple tool holder as described in U.S. Pat. No. 4,998,958 issued on Mar. 12, 1991, for a "Multi-tool Punch Holder," which is incorporated by reference herein. U.S. Pat. No. 4,929,276 shows a variation of such a design which is also suitable.
The tool holder 50 includes a cylindrical holder body 54 which carries a circular array of elongated punching tools, the stem ends 56 visible in FIG. 1 and 2. The holder body 54 is slidable vertically in a rotary holder bushing 58 but rotationally fixed by a key 60 and keyway 62.
A worm gear 64 is affixed or integral with a flange portion of the bushing 58, driven by a worm 66 and drive motor 68. The drive motor 68 is equipped with position feed back as indicated.
The bushing 58 is in turn rotatably supported in an outer bushing received in a bore in the press upper turret 52.
Further details of the tool holder 50 are set out in the above U.S. patents.
It shall be understood by those skilled in the art that the corresponding mating dies are mounted in a carrier cylinder rotatable bore in a lower turret of the press which carrier cylinder is rotated with a punch tool holder to keep each punch aligned and similarly oriented to a corresponding die. This can be done with a common drive or with suitable controls over independent drive means.
In operation, the orientation of the punch tools is set by rotating the tool holder 50 until the desired orientation is reached. In the meantime, the ram 10 is rotated to a spot where the desired tool is to be located, such that both selection processes can be accomplished simultaneously.
The controls 38 will operate the table controls to position the sheet material so as to take into account the actual variable X-Y position of the punch and die set to be used.
Referring to FIGS. 3-6, the rotating ram is shown combined with a nonrotational tool holder for a tool selection function only.
FIG. 3 shows a striking actuator 70 connected to be stroked by the press drive (not shown). A rotary ram 72 is mounted aligned beneath the actuator 70 with its upper end position to be engaged and downwardly advanced against the upward bias of the lifter spring 74 interposed between a gear 76 clamped to the rotary ram 72 with a clamping cone 73 and a flanged bushing 78 recessed into the machine frame 80.
The lower end 82 of the rotary ram 72 is formed with a tee slot 84 adapted to mate with a tee head 86 of an actuating plunger 88 of a rotationally stationary tool carrier 90.
The tool carrier 90 is slidably received in a bore 92 of the press upper turret 94, releasably held in a retracted or up position by a spring loaded plunger 96 having a ramp surface engaged with a ramp surface on the end of a key 98 attached to the outside diameter of the tool holder 90. The key 98 slides in a keyway 100 in the bore of the upper turret 94 receiving the tool carrier 90.
The tool carrier 90 is configured as described in U.S. Pat. No. 4,998,958, omitting the rotary index sleeve and bushing elements as shown in that patent. A circular array of punching tools is carried in the holder 90, the stems 102 thereof protruding to project upwardly. In this position, a selected one of the punches can be contacted with a radial feature 104 formed on the lower end 82 of the rotary ram 72.
When the actuator 70 is driven down, the tool carrier 90 is also driven down overcoming the restraint of the plunger 96 by the force exerted by the rotary ram 72 until the bottom face contacts the workpiece and is stopped. The plunger 88 continues down against the resistance of a stripper spring to enable the feature 104 to contact and drive the punch through the workpiece, as described in U.S. Pat. No. 4,998,958.
Tool selection is executed by a drive motor 106, having an output shaft fixed to a pinion 108 rotating gear 76 to rotate the feature 104 to a selected tool stem 102.
FIG. 4 shows an alternate engagement between the actuator 70A and the upper end of the rotary ram 72A comprised of a tee slot 110 in the actuator 70A and a tee head 112 on the rotary ram 72A, eliminating the need for the lifter spring 74.
FIG. 5 shows a modified rotary ram 72B and further modified tool carrier 90B which eliminates the tee coupling to substitute a push only engagement of the lower end 104B of the ram 72B and tool carrier 90B.
The tool carrier 90B is mounted for downward sliding movement in bore 92B against the force of compression springs 114 disposed in surrounding pockets in the turret 94B beneath respective ears 116.
A key 117 sliding in a mating keyway (not shown) prevents rotation.
FIG. 6 shows staggered rows of smaller and larger punches 118, 120, arranged in concentric circles with the radial feature 104B configured to engage only one at each position thereof as the rotary ram 72B is rotated.
The rotary ram 72B is relatively easily adapted to existing machines and thus provides the increased capacity multiple tool holders to older presses.
Conventional, multiple tool, and indexing multiple tool holders can be interchanged.
A simple rapid angular position and tool selection process and holder are provided. | A punch tool selection and orienting arrangement is disclosed in which a multiple tool holder and a rotary ram are separately driven to select and orient a single punch tool beneath the rotary ram for a punching operation. The rotary ram is also described as performing the tool selection process in disclosed embodiments in which a nonrotating tool carrier is used. | 8 |
This is a continuation of application Ser. No. 274,205, filed June 16, 1981, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an encapsulating case or box more particularly intended for hybrid circuits required to operate under high, uniform and hydrostatic pressures.
In the case of low level measurements it is known that amplification electronics must be located as close as possible to the sensor or transducer so as to be able to transmit an amplified signal, which is less disturbed by noise or local interference. Although this is easy to bring about at pressures close to atmospheric pressure it becomes difficult when the pressure of the medium in which the circuit has to operate is high and exceeds, for example, 100 bars.
Thus, the components of hybrid circuits are not normally intended to operate under high pressures and the pellets of integrated circuits or semiconductors, the capacitors and resistors connected to a hybrid circuit substrate break at pressures above a few bars, as does the actual substrate.
Non-limitative examples of circuits operating under high pressures are those submerged at a depth of two or three thousand meters or circuits introduced into pressurized industrial installations, e.g. for measuring flows or pressures.
The generally adopted solution consists of enclosing the electronic circuit in a metal case, which is often round or cylindrical, intended to resist the external pressure. One example is constituted by a "glove finger" which penetrates an industrial installation, but which is not applicable to a circuit submerged under several thousand meters of water. In this case the connection by cable requires the metal case to be provided with so-called "glass/metal" passages, i.e. metal connections sealed in the case by glass beads. However, this type of seal and these passages are very fragile.
BRIEF SUMMARY OF THE INVENTION
The invention provides a solution for this double problem of the operation of a hybrid circuit under a high pressure and to its electrical connections with the outside, by proposing a hermetic case constituted by a thin, planar substrate, the hybrid circuit being formed on one or both faces and to which are connected two convex enveloping covers without sharp angles and which face one another so as to grip the substrate. Furthermore the substrate projects beyond the perimeter of the covers making it possible to fix thereto external connecting pins, which are electrically connected to the hybrid within the case by metal tracks of limited thickness deposited on the said substrate and which pass between the latter and the cover in the thickness of the sealing joint. The two covers are sealed with the substrate by any known means, excellent results being obtained with an epoxy glue on an alumina member.
The present invention more specifically relates to an encapsulating case which is able to resist high external pressures for a hybrid circuit made on a planar substrate formed from a ceramic material, wherein it is firstly constituted by two identical half-shells made from an electrically insulating, rigid material and having a convex shape with no sharp angles and having an internal concavity of dimensions adapted to the circuit to be protected, said half-shells being arranged symmetically on the two faces of the substrate of the hybrid circuit, thus creating within the case an unpressurized area with a zero deformation and secondly the electrical connections between the hybrid circuit and the external connecting pins are provided by flat, thin metal conductors deposited on at least one face of the substrate and which traverse the encapsulating case in the plane of the sealing joint of one half-shell on the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein show:
FIG. 1 a ceramic hybrid circuit case for resisting an external pressure.
FIG. 2 a metal hybrid circuit case.
FIG. 3 a view in space of a further embodiment of the hybrid circuit case according to the invention provided with its pressure resistant covers.
FIG. 4 an exploded view of a hybrid circuit according to the invention shown in FIG. 3 with its two covers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a hybrid circuit case, viewed in space, with its adaptation for resisting an external pressure. The actual hybrid circuit is deposited on a substrate plate 1 and is protected by a first cover 2 from one side of the substrate plate and by a second cover 3 from the other side of the substrate plate, the said covers 2 and 3 facing one another. The external connections are formed by a known type of pin 4. The most commonly encountered hybrid circuits are square or rectangular and as a result the covers 2 and 3 are themselves square or rectangular and adapted to the hybrid circuit.
Although this type of microbox or external protection is suitable for low pressures, it does not provide an adequate resistance when the pressures rise and reach e.g. 100 bars, because there is then an accumulation of stresses in the sharp angles 5 of the covers, which are disconnected and crushed by the pressure.
FIG. 2 shows another hybrid circuit case, which attempts to solve the problems due to high pressures. This type of case is based on the metal cases used for power transistors and comprises two metal half-shells 6, 7 offering a good resistance and e.g. of stainless steel or titanium, said half-shells being peripherally welded. One of the half-shells, 6 in FIG. 2, corresponds to the base of a power transistor. The hybrid circuit, which is hidden in the drawing because it is located within the case, is welded to the central part 8 thereof. The other half-shell, 7 in FIG. 2, corresponds to the power transistor case cover. The electrical connections with the outside are provided by means of output terminals, which are electrically insulated and sealed in the half-shell 6 by means of glass beads.
This represents an adaptation of hybrid cases in a known encapsulation, which causes no problems for the hybrid circuits when operating at atmospheric pressure, but which must e.g. be protected from corrosion by a tightly sealed case. However, in the case of high pressures, e.g. 200 to 400 bars, problems are encountered in connection with the resistance of the glass/metal passages or the glass beads 9.
Moreover, this adaptation of a known case has the industrial disadvantage of necessitating a machining of the half-shells, a polishing of the contacting surfaces for welding and the use of costly materials and processes, which in many cases lead to prohibitive costs.
FIG. 3 is a view in space of the hybrid circuit encapsulating case according to the invention. The hybrid circuit, which is intended to operate at high pressures, is produced on a substrate plate 10 according to the prior art. The actual hybrid circuit connectors are joined to outer connecting pins 11 by means which will be developed subsequently and which involve the use of metal strips deposited on substrate 10. The encapsulating case according to the invention consists inter alia of joining to the two main faces of substrate 10 two half-shells or covers 13 and 14, which are identical, convex and free from sharp angles. These covers are fixed on either side of the substrate in such a way that the pressure exerted on the latter, level with the joint, by one of the covers is cancelled out by the pressure exerted on the other cover. Thus, the central part of the substrate is within the case and outside the high pressure area.
The circular shape of each of the covers 13 and 14 is best adapted to the pressure resistance, because all the forces are equally distributed perpendicular to the cover wall. Moreover, the radius of curvature of each of the covers is matched to the pressure to be withstood. This convex curvature can be relatively limited for pressures e.g. of approximately 50 bars, whilst it can reach a hemispherical shape for much higher pressures.
As the substrate of a hybrid circuit is conventionally made from alumina or a ceramic material, the two covers 13 and 14 are also advantageously made from alumina or a ceramic material like that of the substrate in such a way that the mechanical and thermal characteristics are identical.
The thickness of each of the two members serving as covers is adapted to the pressure to be withstood. In all cases it is sufficient on the edge of the covers coming into contact with the substrate 10 to permit a seal, either directly by means of glue, or via a seal provided by welding, which then requires insulating joints to prevent the weld from causing short-circuiting between the connecting tracks 12.
The round shape of each of the covers calls for the substrate to be square. In actual fact the square shape although possible is not advantageous, because the substrate then has four curvilinear triangles which are fragile. An octagonal shape has proved to be particularly advantageous because on the one hand it makes it possible to fix the output pins 11 to between one and eight sides if necessary, said pins then being aligned on each of the sides, which corresponds to the traditional positioning of the pins. On the other hand the octagonal shape makes it possible to construct the substrates more easily in that they are cut either by laser or by scratching in a square shape from an alumina plate and whose four corners are then cut again to give octagons. This octagonal shape is consequently more advantageous from the industrial standpoint than a square or circular shape which is difficult to produce. Within its size the octagon inscribes in a very satisfactory manner the circular shape of the covers.
FIG. 4 is an exploded view of the same hybrid circuit as in FIG. 3 located in its high pressure resistant case.
This drawing better shows the substrate 10 to which the hybrid circuit pellet 15 is welded in the conventional known manner for hybrid circuits with external connecting pins 11 by using thin, flat metal strips 12 by means of connecting wires 16. The metal strips 12 are shown in rectilinear form, but their design can differ and can be adapted to the connection requirements of hybrid circuit 15. In the same way hybrid circuit 15 can be joined to pins 11 and to the metal terminals 12 by a collective welding system of the TAB type, i.e. by a collective weld using a film for an automatic transfer to a strip.
FIG. 4 also shows, on the basis of a half-shell 13, the shape of the half-shells used as the upper and lower cover for the high pressure resistant case according to the invention.
It is firstly possible to see the internal concavity of half-shell 13 corresponding to the volume of the hybrid circuit which is to be protected against the pressure, whilst it is also possible to see the thickness of the edge of said half-shell. According to the invention the thickness of each half-shell 13, 14 has a double function. Firstly the sealing of half-shells 13, 14 to substrate 10 is effected by the edge thereof and is ensured by means of a joint with a glue surface necessary for ensuring that the glue can resist the effect of the external pressure. Furthermore the two half-shells work in force opposition on either side of the substrate and if they were too thin it could happen that as a result e.g. of poor glueing of the two not precisely facing half-shells that the substrate would shear and break. Moreover, if the half-shells were thin the glue film by which they adhere to the substrate would not be adequate to resist the external pressure exerted on the glue joint. However, as the metal conductive strips 12 are thin a very limited glue thickness is adequate to ensure the sealing and glueing of the half-shells to the substrate. A thickness of a few dozen microns is very adequate and provides an adequate resistance during pressure tests.
The outer connecting terminals 11 shown in FIGS. 3 and 4 are metal pins of a type frequently encountered in hybrid circuits. However, they do not form part of the actual invention and can be replaced by any other system suitable for the particular use of the hybrid circuit, such as a connection by a wire directly welded to the metal strips 12 or by a multiple connector connection.
FIG. 4 only shows a hybrid circuit mounted on one face of the substrate 10. However, if the number of outer connections permits it and if this is necessary, two hybrid circuits can be mounted respectively on each of the substrate faces and the outer pins are divided up between those which are joined to a first hybrid circuit on a first face of the substrate via a certain number of metal strips 12 on said substrate face and those which are joined to a second hybrid circuit on the second substrate face by means of other metal strips 12 located on the other substrate face.
The invention is not limited to the embodiments described and represented hereinbefore and various modifications can be made thereto without passing beyond the scope of the invention. | An encapsulating case or box for hybrid circuits, able to operate in highly pressurized atmosphere, the components of the hybrid circuit being not subject to the action of pressure. For this purpose, said circuit is enclosed in a case taking the plane of the hybrid circuit substrate as the plane of symmetry, two half-shells made from an electrically insulating rigid material being arranged in symmetrical manner on the two faces of the substrate for creating a zero deformation area within the case. The electrical connections between the hybrid circuit and the connecting pins, outside the case and supported by the substrate are provided by flat metal conductors passing in the gluing plane to the substrate of a half-shell. | 7 |
This application is a continuation of application Ser. No. 665,884, filed Oct. 29, 1984 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a control for a vehicle power transmission and more particularly to a control for a steplessly variable vehicle power transmission.
2. Description of the Prior Art
It has been known to control the speed ratio of asteplessly variable vehicle power transmission in accordance with vehicle operating conditions. For example, the U.S. Pat. No. 4,161,894 discloses a vehicle transmission including a belt-pulley type steplessly variable transmission mechanism provided with a hydraulic actuator for adjusting the speed ratio of the transmission mechanism. A speed ratio control valve is provided for adjusting the hydraulic pressure applied to the actuator in accordance with the vehicle operating conditions so that a desired speed ratio can be obtained. For the purpose, that control valve has a valve spool, the position of which is determined by the engine intake pressure and a pressure representing the speed ratio of the transmission mechanism. The known transmission further includes a selector valve for modifying the pressure applied to the actuator in accordance with the position of an engine control foot pedal so that the speed ratio adjusting characteristics can be changed depending on the engine output.
It should, however, be noted that the above-described transmission system cannot satisfy demands in automatic transmissions for modern passenger cars. For example, the control system as proposed by that U.S. patent cannot provide adequate acceleration under partial throttle valve opening.
OBJECT OF THE INVENTION
It is an object of the present invention to provide a control system for a steplessly variable transmission in which the speed ratio changing characteristics can be selectively changed depending on a desire of an operator.
Another object of the present invention is to provide a steplessly variable vehicle transmission having a control system which makes it possible to manually determine the speed ratio changing characteristics.
A further object of the present invention is to provide a control system for a steplessly variable transmission having power mode and economy mode speed ratio changing characteristics, which can be alternately selected as desired.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, the above and other objects can be accomplished by a steplessly variable power transmission device for motor vehicles comprising a steplessly variable transmission mechanism of which the speed ratio can be changed steplessly, hydraulic actuator means for determining the speed ratio of the transmission mechanism, and valve means for controlling the supply of hydraulic pressure to said hydraulic actuator means. Speed ratio control are provided for producing a valve control signal in accordance with vehicle operating conditions and for applying the control signal to said valve means so that the speed ratio of the transmission mechanism is controlled in accordance with the vehicle operating conditions, said speed ratio control means including control mode changing means having at least two patterns of control mode for controlling the speed ratio in accordance with the vehicle operating conditions, and manual select means for selecting one of said patterns of control mode. According to a preferable aspect of the present invention, the speed ratio control means includes control signal pressure generating means for producing the valve control signal in the form of a hydraulic pressure. The control signal generating means may be valve means for producing the control signal pressure in accordance with a governor pressure representing the vehicle speed and a throttle or engine load pressure representing the engine load. The control mode changing means may include modulating means capable of producing at least two different hydraulic pressures, preferably at least two different throttle or engine load pressures, and the manual select means may include select valve means for selectively passing one of the hydraulic pressures to the control signal pressure generating means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a steplessly variable vehicle transmission and its control system in accordance with one embodiment of the present invention;
FIG. 2 is a circuit diagram showing the details of the control circuit included in the control system in FIG. 1;
FIG. 2A is a sectional view of the control valve included in the circuit shown in FIG. 2;
FIG. 2B is a sectional view of the switching valve;
FIG. 3 is a sectional view showing details of the pressure modulating valves and the switching valve;
FIG. 4 is a diagram showing speed ratio control lines under different engine throttle valve openings;
FIG. 5A is a diagram showing the relationship between the speed ratio pressure and the speed ratio of the transmission;
FIG. 5B is a diagram showing the relationship between the throttle pressure and the speed ratio; and,
FIG. 5C is a diagram showing the relationship between the governor pressure and the vehicle speed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, particularly to FIG. 1, there is shown a belt-pulley type steplessly variable transmission 6 including a primary pulley assembly 1, a secondary pulley assembly 3 and an endless belt 5 extending between the pulley assemblies 1 and 3. The primary pulley assembly 1 comprises a stationary flange 1a integrally formed with an input shaft 2 which is adapted to be connected with an engine output shaft (not shown). On the input shaft 2, there is mounted a movable flange 1b which is slidable in the axial direction with respect to the stationary flange 1a and the input shaft 2. The flanges 1a and 1b have frustoconical side surfaces which are opposed to each other to form a circumferential groove of V-shaped cross-section. The movable flange 1b is formed at the outer side with a cylinder 7a which slidably receives a piston 7b secured to the input shaft 2. The cylinder 7a and the piston 7b form an actuator 7 for the primary pulley assembly 1.
The secondary pulley assembly 3 comprises a stationary flange 3a formed integrally with an output shaft 4 and a movable flange 3b mounted on the output shaft 4 for axially slidable movement with respect to the stationary flange 3a and the output shaft 4. The flanges 3a and 3b have frustoconical side surfaces which are opposed to each other to form a circumferential groove of V-shaped cross-section. On the outer side of the movable flange 3b, there is formed a cylinder 8a which axially slidably receives a piston 8b secured to the output shaft 4 to form an actuator 8 for the secondary pulley assembly 3. The endless belt 5 is passed around the primary and secondary pulley assemblies 1 and 3 and engaged with the circumferential grooves of the pulley assemblies. By controlling the hydraulic pressure applied to the actuator 7, it is possible to adjust the effective diameter of the primary pulley assembly 1 and therefore the speed ratio of the transmission 6. Hydraulic pressure applied to the actuator 8 on the secondary pulley assembly 3 functions to maintain the tension in the belt 5.
In FIG. 1, there is further shown a hydraulic circuit for controlling the speed ratio of the transmission 6. The hydraulic circuit includes a hydraulic pump 9 having an outlet port connected with a pressure line 9a which is in turn connected with the actuator 8 for the secondary pulley assembly 3. In the pressure line 9a, there is provided a pressure regulating valve 11 which functions to produce a regulated pressure in accordance with a governor pressure representing the vehicle speed and a throttle pressure which represents the position of the engine throttle valve (not shown). The pressure regulating valve 11 has a valve body 11a formed with a valve bore 11b in which a valve spool 11c is axially slidably received. The valve spool 11c has a pair of axially spaced lands 11d and 11e and the valve body 11a is formed with a pressure port 11f located between the lands 11d and 11e. The valve body 11a is further formed with an exhaust port 11g which is adapted to be controlled by the land 11d of the spool 11c. The spool 11c is biased by a spring 11h toward left as seen in FIG. 1. At the left side of the land 11e, the valve body is formed with a chamber 11i which is connected with the pressure line 9a. Further, at the ends of the spool 11c, the valve body 11a is formed with a left chamber 11j and a right chamber 11k.
An engine throttle valve position sensing valve 12 is provided for producing a hydraulic pressure which is referred to as the throttle pressure PT and corresponds to the position of the engine throttle valve (not shown). The throttle pressure PT from the valve 12 is introduced into the right chamber 11k. Further, a governor valve 17 is provided for producing a hydraulic pressure which is referred to as the governor pressure PG and corresponds to the vehicle speed as shown in FIG. 5c. The governor valve 17 may be of any conventional type which is widely used in vehicle automatic transmissions. The governor pressure PG is applied to the chamber 11j. It will therefore be understood that the position of the valve spool 11c is determined by the throttle pressure PT and the force of the spring 11h, which function to force the spool 11c toward the left, and the line pressure in the chamber 11i and the governor pressure PG, which functions to force the spool 11c to the right to control the opening of the exhaust port 11g.
The hydraulic circuit further includes a second pressure regulating valve 13 which has a valve body 13a formed with a valve bore 13b and a valve spool 13c axially slidably received in the valve bore 13b. The spool 13c has a pair of axially spaced lands 13d and 13e, and the valve body 13a is formed with an inlet port 13f and outlet port 13g which are located between the lands 13d and 13e. The valve body 13a is further formed with a drain port 13h connected with a reservoir R and adapted to be controlled by the land 13e. At the right side of the land 13e, the valve body 13a is formed with a chamber 13i in which a spring 13j is provided to force the spool 13c toward the left, to thereby decrease the opening of the drain port 13h. At the left side of the land 13d, the valve body 13a is formed with a chamber 13k which is connected with the outlet port 13g. The inlet port 13f is connected with the exhaust port of the first pressure regulating valve 11. The outlet port 13g is connected with the actuator 7 of the primary pulley assembly 1.
There is provided a control valve 14 which produces a speed ratio control pressure signal as will be described in detail. The pressure signal is applied to the chamber 13i of the pressure regulating valve 13 so that the pressure in the outlet port 13q of the valve 13 increases as the pressure signal increases to thereby increase the effective diameter of the primary pulley assembly 1. This will result in a decrease in the speed ratio of the transmission 6. It will be noted that the pressure in the exhaust port 11g of the first pressure regulating valve 11 is substantially the same as that in the outlet port 13g of the second pressure regulating valve 13. Thus, the pressure in the pressure line 9a is adjusted to a value which is dependent on the governor pressure, the throttle pressure and the pressure applied to the actuator 7 of the primary pulley assembly 1.
Referring to FIG. 2, there is shown in detail a control circuit for controlling the control valve 14. As shown in FIG. 2A, the control valve 14 includes a valve body 14a formed with a valve bore 14b in which a spool 14c is axially slidably received. The spool 14c has a pair of axially spaced lands 14d and 14e and the valve body 14a is formed with an inlet port 14f which is adapted to be controlled by the right land 14e. The valve body 14a is further formed with an outlet port 14g located between the lands 14d and 14e. At an axial end of the spool 14c adjacent to the land 14e, there is provided a spool shifting plunger 14h which is also received in the valve bore 14b. The plunger 14h has three axially spaced lands 14i, 14j and 14k, which are arranged in this order from an end adjacent to the spool 14c. The land 14i has the largest diameter, the land 14j a medium diameter and the land 14k the smallest diameter. A spring 14l is provided to force the plunger 14h toward the left so that the spool 14c is shifted leftward to a position wherein the land 14e blocks the inlet port 14f. Between the lands 14i and 14j, there is formed a chamber 14m. Similarly, a chamber 14n is formed between the lands 14j and 14k. At the right side of the land 14k, there is formed a chamber 14p.
Adjacent to the other axial end of the spool 14c, there is provided a second spool shifting plunger 14q, which is also received in the valve bore 14b. The plunger 14q has a pair of axially spaced lands 14r and 14s, the land 14s being located adjacent to the spool 14c and larger in diameter than the land 14r. Between the lands 14r and 14s, there is formed a chamber 14t and, at the left side of the land 14r, there is a chamber 14u. A spring 14w is provided in a chamber 14x adjacent to the right end of the spool 14c to force the plunger 14q leftward. Hydraulic pressure applied to any one of the chambers 14t and 14u serves to force the plunger 14q and therefore the spool 14c, toward the right to thereby open the inlet port 14f to the space between the lands 14d and 14e. Hydraulic pressure applied to any one of the chambers 14m, 14n and 14p serves to counteract the pressure in the chambers 14t and 14u. The inlet port 14f is connected with the hydraulic pump 9, whereas the outlet port 14q is connected with the chamber 13i of the second pressure regulating valve 13.
Referring to FIG. 2, the governor pressure PG from the governor valve 17 is applied on one hand directly, and on the other hand through an anti-overrun valve 28, to the control valve 14. More specifically, the governor pressure PG is directly applied to the chamber 14t between the lands 14r and 14s and through the anti-overrun valve 28 to the chamber 14u on the left side of the land 14r. The anti-overrun valve 28 includes a valve body 28a formed with a valve bore 28b which receives a valve spool 28c for axial slidable movement. The spool 28c has three axially spaced lands 28d, 28e and 28f, and the valve body 28a is formed with an inlet port 28g and a drain port 28h, which are adapted to be controlled by the intermediate land 28e. When the spool 28c is shifted toward the right, the inlet port 28g is opened to the space between the left land 28d and the intermediate land 28e. When the spool 28c is shifted toward the left, the drain port 28h is opened to the space between the lands 28e and 28f. The valve body 28a is further formed with an outlet port 28i opened to the space between the lands 28d and 28e, and an exhaust port 28j opened to the space between the lands 28e and 28f. The inlet port 28g is connected with the governor valve 17, whereas the ports 28a and 28j are connected with the chamber 14u of the control valve 14. The valve 28 is provided at the right end of the spool 28c with a spring 28k, which functions to force the spool 28c toward the left to open the drain port 28h to the space between the lands 28e and 28f. At the left end of the spool 28c, there is provided a chamber 28l connected with a second governor valve 17a, which produces an engine speed pressure PE corresponding to the engine speed. It will therefore be understood that when the engine speed increases beyond a predetermined limit speed, the pressure PE functions to shift the spool 28c toward the right to connect the inlet port 28g with the outlet port 28i, to thereby direct the governor pressure PG to the chamber 14u for increasing the rightward biasing force to the spool 14c in the control valve 14.
The engine throttle valve position sensing valve 12 includes a valve body 12a formed with a valve bore 12b in which an axially slidable spool 12c is received. The spool 12c has a pair of axially spaced lands 12d and 12e. The valve body 12a is formed with an inlet port 12f adapted to be cntrolled by the left hand land 12d and a drain port 12g adapted to be controlled by the right hand land 12e. An outlet port 12h is also formed in the valve body 12a to open to a space between the lands 12d and 12e. The inlet port 12f is connected with the hydraulic pump 9, whereas the drain port 12g is connected to the reservoir R. The land 12d is formed at the left portion thereof with a large diameter land 12i to provide a shoulder with the land 12d. The valve body 12a is formed with a chamber 12j facing the shoulder between the lands 12d and 12i, and the chamber 12j is connected with the outlet port 12h. A spring 12k is provided to force the spool 12c toward the right so that the inlet port 12f is blocked by the land 12d.
The valve 12 is associated with a kick-down valve 27, which includes a spool 27a located rightward of the spool 12c and axially slidable in the valve bore 12b. The spool 27a has a pair of axially spaced lands 27b and 27c, and the valve body 12a is formed with an inlet port 27d adapted to be controlled by the land 27b, and a main port 27e adapted to be controlled by the land 27c. Further, the valve body 12a is formed with an outlet port 27f opened to a space between the land 27b and 27c. Between the spools 12c and 27a, there is a compression spring 27g. The right hand end of the spool 27a is engaged with a lever 27h which is interconnected with an engine throttle lever actuating mechanism (not shown). It will therefore be understood that the spool 12c is subjected to a leftward biasing force which is applied through the kick-down spool 27a and the spring 27g from the engine throttle lever actuating mechanism in a direction wherein the opening of the inlet port 12f to the outlet port 12h is increased in response to an increase in the engine throttle valve opening. Thus, there is produced in the outlet port 12h the aforementioned throttle pressure PT which corresponds to the engine throttle valve opening. Where the engine is of a type that has no throttle valve, the lever 27a may be connected with an engine output power control mechanism. The ports 27d, 27e and 27f of the kick-down valve 27 are located so that the port 27f is normally opened to the drain port 27e, but it is connected with the inlet port 27d when the engine throttle valve is fully opened. The inlet port 27d is connected with the outlet port 12h of the valve 12 and the outlet port 27f is connected with the chamber 14n so that the throttle pressure PT is introduced into the chamber 14n under full engine throttle valve position.
As shown in FIG. 2, the control circuit 15 includes a manual select valve 22 having a valve body 22a formed with a valve bore 22b in which a manually operated spool 22c is axially slidably received. The spool 22c has three axially spaced lands 22d, 22e and 22k, and the valve body 22a is formed with inlet ports 22f and 22l. The valve body 22a is further formed with a first outlet port 22g, a second outlet port 22h, and drain ports 22i and 22j. The spool 22c is movable either from an extreme right position, which is referred as the L-position, to an intermediate position, which is referred to as the D 1 -position, and to an extreme left position, which is referred to as the D 2 -position. The ports of the valve 22 are located so that, in the L-position of the spool 22c, the outlet ports 22g and 22h are opened to the drain ports 22 i and 22j, respectively. In the D 1 -position of the spool 22c, the first outlet port 22g is connected with the inlet port 22f and the second outlet port 22h is opened to the drain ports 22. In the D 2 -position, the inlet port 22f is opened to the first outlet port 22h and the inlet port 22l is opened to the second outlet port 22h. The inlet ports 22f and 22l of the manual select valve 22 are connected with the hydraulic pump 9.
There is provided a mode changing device 20 in the control circuit 15. The device 20 is constituted by a manual select device 23, and a pair of pressure modulating valves 16 and 17. Referring to FIG. 3, the manual select drive 23 is constituted by a switching valve 21, which has a valve body 21a formed with a valve bore 21b in which a spool 21c is axially slidably received. The spool 21c has three axially spaced lands 21d, 21e and 21f. The valve body 21a is formed with an inlet port 21g which is adapted to be controlled by the intermediate land 21e, and a pair of drain ports 21h and 21i which are located at the opposite sides of the inlet port 21g and adapted to be controlled, respectively, by the lands 21d and 21f. Further, the valve body 21a is formed with a first outlet port 21j opening to a space between the lands 21d and 21e, and a second outlet port 21k opening to a space between the lands 21e and 21f. At the right end of the spool 21c, there is provided a spring 21l which functions to force the spool 21c leftward. At the left end of the spool 21c, the valve body 21a is formed with a chamber 21m, which is connected with a second outlet port 22h of the manual select valve 22 so that the line pressure is applied to the chamber 22m in the D 2 -position of the select valve 22. The inlet port 21g of the switching valve 21 is connected with the outlet port 12j of the valve 12 so that the throttle pressure PT is drawn to the inlet port 21g. The inlet port 21g is located so that, when the spool 21c is shifted toward the left under the influence of the spring 21e, the port 21g is connected with the second outlet port 21k, but when the spool 21c is shifted toward the right under the line pressure applied to the chamber 21m, the port 21g is connected with the first outlet port 21j.
The first outlet port 21j is connected with the second modulating valve 17 whereas the second outlet port 21k is connected with the first modulating valve 16. As shown in FIG. 2, the control circuit 15 includes a speed ratio detecting valve 19, which includes a valve body 19a formed with a valve bore 19b in which a spool 19c is slidably received. The spool 19c has a pair of axially spaced lands 19d and 19e, and the valve body 19a is formed with an inlet port 19f adapted to be controlled by the left hand land 19d and a drain port 19g adapted to be controlled by the right hand land 19e. The valve body 19a is further formed with an outlet port 19h which is opened to a space between the lands 19d and 19e. Adjacent to the left hand end of the spool 19c, there is provided a shifting plunger 19i which is engaged by a lever 19 j responsive to the axial position of the movable flange 1b of the primary pulley assembly 1, so that the shifting plunger 19a is subjected to a biasing force corresponding to the speed ratio of the transmission 6. Between the spool 19c and the plunger 19i, there is a compression spring 19k. At the right hand end of the spool 19c, there is a chamber 19l which is connected with the outlet port 19h. The inlet port 19f is connected with the hydraulic pump 9. The ports 19f and 19g are located so that the inlet port 19f is connected to the outlet port 19h when the spool 19c is shifted toward the left under the pressure applied to the chamber 19l, but the outlet port 19h is opened to the drain port 19g when the spool 19c is shifted toward the right under a force applied from the lever 19j. It will therefore be understood that there is produced in the outlet port 19h a hydraulic pressure which decreases in response to a decrease in the speed ratio of the transmission, as shown in FIG. 5A. This pressure will hereinafter be referred to as the speed ratio pressure PR.
Referring again to FIG. 3, the first modulating valve 16 includes a valve body 16a formed with a valve bore 16b in which a spool 16c is axially slidably received. The spool 16c has three axially spaced lands 16d, 16e and 16f of the same diameter, and the valve body 16a is formed with an inlet port 16g adapted to be controlled by the left hand land 16d and a drain port 16h adapted to be controlled by the intermediate land 16e. The valve body 16a is further formed with an outlet port 16i which opens to a space between the lands 16d and 16e. At the right hand end of the spool 16c, there is a chamber 16j in which a spring 16k is located to force the spool 16c leftward. At the left hand end of the spool 16c, there is formed a chamber 16l which is connected with the outlet port 16i. The inlet port 16g is connected with the second outlet port 21k of the switching valve 21 and the chamber 16j is connected with the outlet port 19h of the speed ratio detecting valve 19 so that the speed ratio pressure PR is introduced therein. The spool 16c is shifted leftward under the influence of the spring 16k and the speed ratio pressure PR in the chamber 16j. When the spool 16c is shifted rightward under the pressure in the chamber 16l, the inlet port 16g is connected with the outlet port 16i. It will therefore be understood that the throttle pressure PT which has passed through the switching valve 21 is modified by the speed ratio pressure PR and a first modulated pressure PT' is produced in the outlet port 16i.
The second modulating valve 17 has a structure similar to that of the valve 16 so that corresponding parts are designated by the reference numeral 17 with the same letter. In the valve 17, the right hand land 17f is larger in diameter than the other lands 17d and 17e so that the spool 17c receives a larger leftward force by the speed ratio pressure PR than in the valve 16. The inlet port 17g is connected with the first outlet port 21j of the switching valve 21. It will therefore be understood that the valve 17 produces a second modulated pressure PT" which is larger than the first pressure PT'.
The outlet ports 16i and 17i of the modulating valves 16 and 17, respectively, are connected with a shuttle valve 18 which has an outlet connected with the chamber 14p of the control valve 14. It will therefore be understood that when the manual select valve 22 is in either of the L or D 1 -positions, the throttle pressure PT is applied to the first modulating valve 16 and the first modulated pressure PT' is applied to the control valve 14. If, however the manual select valve 22 is in the D 2 -position, the throttle pressure PT is applied to the second modulating valve 17 so that the second modulated pressure PT" is applied to the control valve 14. The modulated pressures PT' and PT" are shown in FIG. 5B.
The first outlet port 22g of the manual select valve 22 is connected with a high ratio control valve 26. The valve 26 includes a valve body 26a formed with a valve bore 26b in which a spool 26c is axially slidably received. The spool 26c has a pair of axially spaced lands 26d and 26e and is biased by a spring 26f toward left. The valve body 26a has an inlet port 26g adapted to be controlled by the left land 26d, an outlet port 26h opened to a space between the lands 26d and 26e, and a drain port 26j controlled by the right land 26e. At the left side of the spool 26c, there is provided a chamber 26i which is connected with the first outlet port 22g of the manual select valve 22. The inlet port 22g is connected with the hydraulic pump 9. In the L-position of the manual valve 22, wherein the port 22g is drained, the spool 26c is shifted toward the left so that the inlet port 26g is opened to the outlet port 26h. Thus, the line pressure is applied to the outlet port 26h. This pressure may be referred to as the maximum throttle pressure PT max. In either of the D 1 and D 2 -positions, the line presure is applied to the chamber 26i and the spool 26c is shifted toward the right to open the outlet port 26h to the drain port 26h.
The outlet port 26h of the valve 26 is connected to one inlet port of a shuttle valve 127 which has another inlet port connected with the outlet port 12j of the throttle valve position sensing valve 27. When the pressure PT max is not produced in the port 26h, the throttle pressure PT is passed through the shuttle valve 127. However, when the pressure PT max is produced in the port 26h, this pressure PT max is passed through the shuttle valve 127. The outlet port of the shuttle valve 127 is connected with the chamber 14x of the control valve 14.
The control circuit 15 further includes a switching valve 25 which includes, as shown in FIG. 2B, a valve body 25a formed with a valve bore 25b in which spool 25c is axially slidably received. The spool 25c has a pair of axially spaced lands 25d and 25e and is biased by a spring 25j toward the left. The valve body 25a is formed with an inlet port 25f adapted to be controlled by the left land 25d and a drain port 25g adapted to be controlled by the right land 25e. The valve body 25a is further formed with an outlet port 25h which is opened to a space between the lands 25d and 25e. At the left side of the spool 25c, there is provided a chamber 25i. The inlet port 25f is connected with the governor valve 17 to receive the governor pressure PG. The chamber 25i is connected with the outlet port 12j of the valve 12. The spring 25j of the valve 25 is adjusted so that the spool 25c is normally shifted toward the right under the throttle pressure PT applied to the chamber 25i to open the outlet port 25h to the drain port 25g but is shifted toward the left when the engine throttle valve is closed, to connect the inlet port 25f to the outlet port 25h. The outlet port 25h of the valve 25 is connected with the chamber 14m of the control valve 14.
In operation, as far as the engine throttle valve is opened, the switching valve 25 is closed so that the chamber 14m in the control valve 14 is drained. Unless the engine is overrunning, the anti-overrun valve 28 is also closed so that the chamber 14u is also drained. In the D 1 -position of the manual select valve 22, the port 22h is drained so that the port 21g of the switching valve 21 is opened to the port 21k, and the first or lower modulating pressure PT' is applied to the chamber 14p. Further, the shuttle valve 127 passes the throttle pressure PT to the chamber 14x. When the vehicle is not in the kick-down condition, the chamber 14n is drained.
The spool 14c of the valve 14 is therefore biased leftward by the first modulated pressure PT' and the throttle pressure PT applied respectively, to the chambers 14p and 14x, and is biased rightward by the governor pressure PG applied to the chamber 14t. The pressure in the outlet port 14g decreases as the engine throttle valve opening increases, but that pressure increases as the vehicle speed increases. The pressure in the outlet port 14g is applied to the chamber 13i of the valve 13 so that an increase in the outlet pressure of the valve 14 causes and increase in the outlet pressure of the valve 13 to thereby increase the effective diameter of the primary pulley assembly 1. This will result in a decrease of the speed ratio. FIG. 4 shows the speed ratio change in accordance with the vehicle speed under different throttle valve positions.
It should be clear from FIG. 4 that the pressure signal produced by the modulating means formed by valves 16 and 17 is determined in such a manner that the difference in the values of the signals between the two control modes is increased as the speed ratio is increased. It should further be clear from FIG. 4 that the speed ratio at the full throttle condition is changed between a first engine speed and a maximum engine speed higher than the first engine speed and a maximum speed in the other of the control modes.
In the D 1 -position of the manual select valve 22, the engine speed changes in response to a change in the vehicle speed as shown by dotted lines. The inclination angle of each line represents the speed ratio. Engine overrun is prevented by the valve 28 which directs the governor pressure PG to the chamber 14u when the engine speed reaches a predetermined value to thereby increase the outlet pressure of the valve 14. This will cause a decrease in the speed ratio resulting in a decrease in the engine speed. The D 1 -position of the manual select valve 22 may be called an economy mode because the vehicle acceleration is relatively moderate as seen in FIG. 4.
In the D 2 -position of the valve 22, the second or higher modulated pressure PT" is applied to the chamber 14p of the valve 14. This will cause a decrease in the outlet pressure of the control valve 14. Thus, the outlet pressure of the valve 13, is correspondingly decreased and a higher speed ratio is maintained. In this condition, the vehicle is accelerated as shown by solid lines in FIG. 4. This condition may be referred as the power mode because a powerful acceleration is performed.
In the L-position, the line pressure is applied to the chamber 14x so that the leftward biasing force on the spool 14c is further increased. This will cause a decrease in the outlet pressure of the control valve 14 and therefore a decrease in the outlet pressure of valve 13. Therefore, a higher speed ratio is maintained.
In the illustrated embodiment, the switching valve 25 functions to apply the governor pressure PG to the chamber 14m when the engine throttle valve is closed for deceleration so that the leftward biasing force on the spool 14c is further increased. Thus, the speed ratio of the transmission 6 is maintained at a higher level so that a stronger engine brake function is developed. It should further be noted that, since the governor pressure increases in response to an increase in the vehicle speed, the speed ratio is increased as the vehicle speed increases. This will mean that the engine brake effect becomes stronger as the vehicle speed increases. Since the governor pressure PG changes as shown in FIG. 5c, the speed ratio is returned to a normal value under a predetermined vehicle speed V 1 .
The invention has thus been shown and described with reference to a specific embodiment, however, it should be noted that the invention is in no way limited to the details of the illustrated arrangements, but changes and modifications may be made without departing from the scope of the appended claims. | A control system for controlling a steplessly variable power transmission device for a motor vehicle. The speed ratio of the transmission mechanism is based upon vehicle operating conditions, and particularly upon the vehicle speed and the engine load, either in terms of throttle setting or engine load pressure. Manual selector means are provided to select one of two control mode patterns for either economical operation or for power operation, and each of the control modes provides a different ratio of transmission input speed to output speed. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing an IC (Integrated Circuit) package, and more particularly to a method of manufacturing a stacked package having a PoP (Package on Package) structure.
2. Description of the Related Art
A semiconductor industry generally has an increasing trend of lightening, miniaturization, multifunction, and high performance in addition to cheap production. One critical technique required to meet such a trend is IC packaging.
IC packaging involves protecting semiconductor chips such as a single device and an IC formed by stacking a variety of electronic circuits and wirings from various external environments such as dust, moisture, and electric and mechanical loads, forming the semiconductor chips with signal input/output terminals to/from a main board using a lead frame, a PCB (Printed Circuit Board), or the like to optimize and maximize electric performance of the semiconductor chips, and molding the semiconductor chips using an encapsulant.
Meanwhile, as products to which an IC package is mounted recently have a light, thin, short, and small structure and require many functions, a method such as a SIP (System in Package) method or a PoP (Package on Package) method by which a plurality of semiconductor chips is mounted in the IC package is applied as the IC packaging technique.
Moreover, a PCB on which high-integrated and ultrathin components are mounted should also be thin. This enables increased freedom in circuit design of the board, and thus various techniques such as a micro via process and a build-up process are adopted to solve the issue.
In particular, a micro via-hole is receiving attention as a method for satisfying high integration and fine wiring pitch demand as a degree of integration of a semiconductor device is currently increased.
In particular, an MLB (multi layer board) is configured only by a through-hole passing through all layers. However, a blind via-hole through which interlayer conduction may be selectively performed is in the limelight since a build-up PCB further requires high-density wirings.
A mechanical drilling process, a plasma etching process, a laser drilling process, or the like is generally known as a method of forming the blind via-hole of the PCB.
In particular, the laser process is currently the most widely used method to form the blind via-hole of the PCB and includes processes using excimer, Nd:YAG, and CO 2 laser drills.
FIGS. 1A to 1C are views illustrating a process of forming via-holes by a conventional laser drilling process. First, a semiconductor chip 20 is stacked on a PCB 10 and then a molding portion 30 is formed, as shown in FIG. 1A . Next, laser drilling positions 40 are determined on parts of the molding portion 30 to be formed with via-holes by the coordinate and then the parts are drilled using a laser, as shown in FIG. 1B . Consequently, TMVs (Through Mold Vias) 50 are formed as shown in FIG. 1C .
However, the laser drilling process has a limit to realize a fine pitch equal to or less than 0.3 mm. Since a laser drilling position is determined on an upper surface of a mold with no mark by the coordinate after an EMC molding process in the laser drilling process, a via-hole may be formed at an inaccurate position, thereby causing an error.
Moreover, process equipment such as a plasma cleaner, a reflow M/C, a flux cleaner, and an off-loader may be additionally required in order to remove residues generated during the laser drilling process. Since the laser equipment is expensive, equipment investment may be costly.
[Patent Document 0001] Korean Patent Publication No. 10-0674316 (Jan. 18, 2007)
SUMMARY OF THE INVENTION
Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a method of manufacturing a stacked package, capable of substantially compensating for many defects of the related art.
It is another object of the present invention to provide a method of manufacturing a stacked package, capable of processing a fine pitch equal to or less than 0.3 mm at low cost.
In accordance with one aspect of the present invention, a method of manufacturing a stacked package includes a first process of stacking a semiconductor chip on an upper surface of a PCB having a wiring pattern and a via-hole pad, a second process of forming a photoresist (PR) layer on the upper surface of the PCB having the semiconductor chip and the via-hole pad, a third process of removing the photoresist layer of a remaining region except for an upper portion of the via-hole pad so that a photoresist layer of a via-hole region remains only at the upper portion of the via-hole pad, a fourth process of forming a molding layer by molding the upper surface of the PCB having the semiconductor chip so as to expose an upper surface of the photoresist layer of the via-hole region, and a fifth process of removing the photoresist layer of the via-hole region to form a via-hole on the via-hole pad.
In the method of manufacturing a stacked package according to one aspect of the present invention, the third process may be performed by a photolithographic process using a photomask.
In the method of manufacturing a stacked package according to one aspect of the present invention, the semiconductor chip may be stacked by flip-chip bonding or wire bonding.
In accordance with another aspect of the present invention, a method of manufacturing a stacked package includes a first process of forming a photoresist (PR) layer on an upper surface of a PCB having a wiring pattern and a via-hole pad, a second process of removing the photoresist layer of a remaining region except for an upper portion of the via-hole pad so as to form a photoresist layer of a via-hole region at the upper portion of the via-hole pad, a third process of stacking a semiconductor chip on the upper surface of the PCB, a fourth process of forming a molding layer by molding the upper surface of the PCB having the semiconductor chip so as to expose an upper surface of the photoresist layer of the via-hole region, and a fifth process of removing the photoresist layer of the via-hole region to form a via-hole on the via-hole pad.
In the method of manufacturing a stacked package according to another aspect of the present invention, the second process may be performed by a photolithographic process using a photomask.
In the method of manufacturing a stacked package according to another aspect of the present invention, the semiconductor chip may be stacked by flip-chip bonding or wire bonding.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIGS. 1A to 1C are cross-sectional views illustrating a method of manufacturing a stacked package according to the related art;
FIGS. 2A to 2F are views illustrating a method of manufacturing a stacked package according to an embodiment of the present invention; and
FIGS. 3A to 3G are views illustrating a method of manufacturing a stacked package according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
In a case in which it is determined that a detailed description of known relevant technologies or configurations may unnecessarily obscure the gist of the present invention in the description thereof, the detailed description thereof will be omitted. In addition, terms used herein are defined in consideration of functions of the present invention, and these may vary with the intention or practice of a user. Therefore, unless otherwise defined, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure.
FIGS. 2A to 2F are views illustrating a method of manufacturing a stacked package according to an embodiment of the present invention.
First, as shown in FIG. 2A , a structure of attaching a semiconductor chip 110 on a PCB 100 is prepared. In FIG. 2A , while the semiconductor chip 110 has a flip-chip attach structure 112 which is electrically connected to the PCB, the semiconductor chip 110 may also have a structure which is connected to the PCB by wire bonding.
Wiring patterns 101 and 102 and via-hole pads 104 are formed on the PCB 100 . Although not shown, the PCB 100 has via contacts for electrically connecting the wiring patterns 101 and 102 on upper and lower surfaces of the PCB to each other.
In addition, the PCB 100 is provided, on a lower surface thereof, with solder balls 120 .
Next, as shown in FIG. 2B , photoresist (PR) is applied (coated) to the whole surface of the PCB 100 on which the semiconductor chip 110 is attached. In this case, the formed photoresist layer 130 has a thickness which is set to be slightly thicker in consideration of a height of a via-hole to be formed later. The photoresist refers to a material in which a portion receiving light and the other portion may be selectively removed during a subsequent developing process using properties by which solubility in developer is changed when the material receives light having a specific wavelength.
In order to remove an organic solvent remaining on the photoresist after coating, soft bake is carried out at a low temperature. The soft bake enables exposure equipment and mask contamination due to residual solvent to be prevented and photoresist reaction characteristics to be uniformly maintained. In the soft bake, the solvent is typically removed by being heated at a temperature of approximately 90° C. to 110° C., thereby allowing photoresist density to be increased so as to reduce sensitivity to environmental change.
Next, as shown in FIG. 2C , a photomask 140 is aligned on the photoresist layer 130 and then an exposure process is performed by irradiating UV light onto the photomask 140 . In this case, the photomask 140 has patterns formed at via-hole regions so as not to irradiate UV light onto the lower photoresist layer 130 . In addition, the photomask has a mask image which is projected at a 1:1 ratio and a mask image which is decreased and projected at a certain ratio. The 1:1 ratio is utilized when the pattern has a size equal to or more than 1 μm or the shape of the pattern is completed at an overall exposed area. In this case, UV light is irradiated onto the mask in a state in which the mask comes into contact with the PR. In a case in which the pattern size is equal to or less than 1 μm or the same pattern shape is continuously repeated, after the pattern size is magnified in integer multiples (typically four multiples) of a desired pattern size in the mask, UV light is irradiated onto the upper and lower surfaces of the mask using a reduced optical system (lens) in a state in which the mask and the PR are maintained to be spaced apart from the coated wafer by a proper distance.
After exposure is completed, bake is carried out once again. The PEB (post exposure bake) process is a process of forming a pattern through diffusion of photoresist. In ArF photoresist using a 193 nm wavelength, a chemical amplified resist is frequently used. In this case, since a chemical amplified reaction is generated through the PEB process, the temperature of the PEB affects sensitivity of photoresist.
Next, as shown in FIG. 2D , the remaining photoresist layer 130 is removed except for photoresist layers 130 ′ of the via-hole regions via a developing process. The photoresist developer may be a water-soluble alkaline solution and uses KOH and TMAH (TetraMethyl-Ammonium-Hydroxide) aqueous solutions as main materials.
After developing is completed, the developer is removed and hard bake may be performed as occasion demands.
Next, as shown in FIG. 2E , the overall upper surface of the PCB 100 including the photoresist layers 130 ′ of the via-hole regions and the semiconductor chip 110 is molded via a molding process so as to form a molding layer 150 .
Next, as shown in FIG. 2F , the photoresist layers 130 ′ of the via-hole regions are removed via a photoresist strip process so as to form via-holes 160 .
As described above, since the via-holes are formed in the PCB by the photolithographic process according to the embodiment, it may be possible to realize a fine pitch equal to or less than 0.3 mm and improve position accuracy of the via-holes.
In addition, it may be possible to prevent EMC residues from being generated when the via-holes are formed by the conventional laser drilling process.
FIGS. 3A to 3G are views illustrating a method of manufacturing a stacked package according to another embodiment of the present invention.
First, as shown in FIG. 3A , a PCB 200 provided with wiring patterns 201 and 202 and via-hole pads 204 is prepared. The PCB 200 has via contacts (not shown) for electrically connecting the wiring patterns 201 and 202 on upper and lower surfaces of the PCB to each other. The lower surface of the PCB 200 is provided with solder balls 220 .
Next, as shown in FIG. 3B , photoresist (PR) is applied (coated) to the whole surface of the PCB 200 on which a semiconductor chip is attached. In this case, the formed photoresist layer 230 has a thickness which is set to be slightly thicker in consideration of a height of a via-hole to be formed later. The photoresist refers to a material in which a portion receiving light and the other portion may be selectively removed during a subsequent developing process using properties by which solubility in developer is changed when the material receives light having a specific wavelength.
In order to remove an organic solvent remaining on the photoresist after coating, soft bake is carried out at a low temperature. The soft bake enables exposure equipment and mask contamination due to residual solvent to be prevented and photoresist reaction characteristics to be uniformly maintained. In the soft bake, the solvent is typically removed by being heated at a temperature of approximately 90° C. to 110° C., thereby allowing photoresist density to be increased so as to reduce sensitivity to environmental change.
Next, as shown in FIG. 3C , a photomask 240 is aligned on the photoresist layer 230 and then an exposure process is performed by irradiating UV light onto the photomask 240 . In this case, the photomask 240 has patterns formed at via-hole regions so as not to irradiate UV light onto the lower photoresist layer 230 .
After exposure is completed, bake is carried out once again. The PEB (post exposure bake) process is a process of forming a pattern through diffusion of photoresist. In ArF photoresist using a 193 nm wavelength, a chemical amplified resist is frequently used. In this case, since a chemical amplified reaction is generated through the PEB process, the temperature of the PEB affects sensitivity of photoresist.
Next, as shown in FIG. 3D , the photoresist layer 230 formed at the remaining portion except for the via-hole regions is removed via a developing process. The photoresist developer may be a water-soluble alkaline solution and uses KOH and TMAH (TetraMethyl-Ammonium-Hydroxide) aqueous solutions as main materials. After developing is completed, the developer is removed and hard bake may be performed as occasion demands.
Next, as shown in FIG. 3E , a semiconductor chop 210 is attached on the PCB 200 . In FIG. 3E , while the semiconductor chip 210 has a flip-chip attach structure 212 which is electrically connected to the PCB 200 , the semiconductor chip 210 may also have a structure which is connected to the PCB by wire bonding.
Next, as shown in FIG. 3F , the overall upper surface of the PCB 100 including the photoresist layers 230 ′ of the via-hole regions and the semiconductor chip 210 is molded via a molding process so as to form a molding portion 250 .
Next, as shown in FIG. 3G , the photoresist layers 230 ′ of the via-hole regions are removed via a photoresist strip process so as to form via-holes 260 .
As described above, since the via-holes are formed in the PCB by the photolithographic process according to the embodiment, it may be possible to realize a fine pitch equal to or less than 0.3 mm and improve position accuracy of the via-holes.
In addition, it may be possible to prevent EMC residues from being generated when the via-holes are formed by the conventional laser drilling process.
As is apparent from the above description, in accordance with a method of manufacturing a stacked package according to the present invention, it may be possible to reduce an economic burden of investment in expensive laser equipment because a lithographic patterning technique using photoresist is utilized.
In addition, it may be possible to improve position accuracy by directly forming a photoresist pattern on a via-hole pad of a PCB.
Moreover, it may be possible to prevent generation of misalignment, ball bridge, missing ball, and the like by a laser drilling process.
Furthermore, an additional process for removing EMC residues generated by the laser drilling process may be omitted.
Although the preferred embodiments of the present 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. Accordingly, it is to be understood that differences relevant to the variations and modifications fall within the spirit and scope of the present disclosure defined in the appended claims. | A method of manufacturing a stacked package includes a first process of stacking a semiconductor chip on an upper surface of a PCB having a wiring pattern and a via-hole pad, a second process of forming a photoresist (PR) layer on the upper surface of the PCB having the semiconductor chip and the via-hole pad, a third process of removing the photoresist layer of a remaining region except for an upper portion of the via-hole pad so that a photoresist layer of a via-hole region remains only at the upper portion of the via-hole pad, a fourth process of forming a molding layer by molding the upper surface of the PCB having the semiconductor chip to expose an upper surface of the photoresist layer of the via-hole region, and a fifth process of removing the photoresist layer of the via-hole region to form a via-hole on the via-hole pad. | 7 |
FIELD
[0001] The present invention relates to frames for pictures and artwork, and more particularly to the method of hanging/mounting picture frames on walls or other non-ferrous surfaces, which comprise a multi-piece magnetic system to mount and adjust the frame when it is hung/mounted.
BACKGROUND
[0002] There have been numerous attempts to improve picture frames. For example, U.S. Pat. No. 6,354,030 B1 discloses a magnetic picture frame for use in hanging a picture on a refrigerator. This example uses magnets as a picture frame to secure pictures to a refrigerator. While it uses magnetic force to secure the frame, its use is limited to ferrous surfaces and is not based on a complete magnetic mounting device system.
[0003] U.S. Pat. No. 7,762,517 B1 discloses an adjustable picture frame that includes a mounting base that is secured to the wall using screws or other similar fasteners. There are movable inner and outer carriages on the bracket allowing the frame to be positioned on the wall through up/down and left/right directional adjustments. While this device allows for small adjustments like the magnetic multi-directionally adjustable picture frame, the attachment mechanism is different, the adjustment mechanism is different and it requires the user to use screws to secure the apparatus to the wall.
[0004] U.S. Pat. No. 3,1187,449 “Magnetic Picture Frame and Sign” discloses a picture frame with magnets used to affix the frame to an automobile dashboard. While it uses magnetic force to secure the frame, its use is limited to ferrous surfaces and is not based on a complete magnetic mounting device system.
[0005] U.S. Pat. No. 4,785,562 “Magnetic Display Holder” discloses an adjustable display device (frame) that secures and displays items of various sizes to ferrous surfaces. While it uses magnetic force to secure the frame, its use is limited to ferrous surfaces and is not based on a complete magnetic mounting device system.
[0006] U.S. Pat. No. US 2012/0233898 A1—“Adjustable Framed Picture Hanger Back” discloses a device for hanging a framed picture that allows for vertical and or horizontal adjustment on the wall as well as rotation of the framed picture. The mechanism for affixing the frame to the wall, and its subsequent adjustment is significantly different from the Magnetic multi-directionally adjustable picture frame mount and associated magnetic mounting method; specifically it does not use magnetic force and uses a different friction based attachment mechanism.
[0007] Accordingly, there is a continuing need to provide an improved picture frame mounting and adjustment mechanism and method.
SUMMARY
[0008] An objective of the invention is to provide a mounting device system which allows a picture frame to be quickly hung or mounted to a wall or non-ferrous mounting surface, leveled, adjusted and or aligned without removing the frame from the wall, or putting holes in a wall or other mounting surface.
[0009] A magnetic mounting device system according to certain embodiment of the invention secures a picture frame to a wall that allows adjustment up, down, left or right without removing the frame or mounting device system from the wall and does not require tools to make wall position adjustments within the limited range of the mounting plated. The magnetic mounting device includes magnets that are secured to the picture frame through a mounting bracket, adhesive or combination of mounting bracket and adhesive, using magnetic force the frame is then connected to the ferrous mounting plate that is adhered to the wall. After the frame is mounted to the wall or mounting surface, the frame can be adjusted in any direction provided the magnets maintain contact with the mounting plate; the adjustment range is limited by the size of the mounting plate. The picture frame may include one or more magnetic mounting device assemblies depending on the size and weight of the frame and the degree of desired wall adhesion.
[0010] In certain embodiments, the steel or magnetic mounting base or bases are attached to the wall using an adhesive agent (e.g. double sided tape, glue or adhesive strip, such as 3M COMMAND brand adhesive strips). The magnet or magnets can be attached to the picture frame assembly using an adhesive, mounting bracket or mechanical fastener.
[0011] The above summary is not intended to limit the scope of the invention, or describe each embodiment, aspect, implementation, feature or advantage of the invention. The detailed technology and preferred embodiments for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a side exploded view of a magnetic picture frame mounting system device according to certain embodiments of the invention.
[0013] FIG. 2 is a side view of a magnetic picture frame mounting system device according to certain embodiments of the invention attached to a wall.
[0014] FIG. 3 is a rear view of a magnetic picture frame mounting system device according to certain embodiments of the invention.
[0015] FIG. 4 is a front view of a magnetic picture frame mounting system according to certain embodiments of the invention indicating possible directions of movement.
[0016] FIG. 5 is a side view of a magnetic picture frame mounting system according to certain embodiments of the invention indicating possible directions of movement.
[0017] FIG. 6 is a perspective view of a magnetic picture frame mounting system according to certain embodiments of the invention.
[0018] FIG. 7 is a perspective view of a magnetic picture frame mounting system according to certain embodiments of the invention.
[0019] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0020] In the following descriptions, the present invention will be explained with reference to various example embodiments; nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention. The various features or aspects discussed herein can also be combined in additional combinations and embodiments, whether or not explicitly discussed herein, without departing from the scope of the invention,
[0021] Referring to FIGS. 1-3 , the various components of the system according to one embodiment are depicted. The number and location of the mounting assemblies on a given frame will vary based on picture frame size, shape and weight.
[0022] As can be seen in FIG. 1 , the mounting assembly depicted comprises picture frame (A), magnet attachment mechanism (B), permanent magnet(s) (C), steel sheet metal or other ferromagnetic material (D) and wall adhesive (E) as assembled onto the back of a picture frame in the order listed.
[0023] FIG. 2 shows the components noted above as they would be arranged when in use for securing the picture frame to a wall. The wall adhesive (E) is attached directly to the wall or surface securing the sheet of steel or other ferromagnetic material (D) to the wall. The permanent magnet(s) (C) connect the picture frame to the steel magnetically and allow the picture frame to be easily removed and reattached to the sheet of steel mounting plate (D). The magnets (C) are attached to the rear of the picture frame by adhesive or mechanical means, such as a fastener.
[0024] FIG. 3 illustrates of some of the many potential locations for providing the magnetic mounting assemblies to a picture frame. In the illustrated example embodiment, there is one assembly at each of the top left and right corners, and one assembly spanning horizontally along the bottom region of the frame. This arrangement balances out the weight of the frame as indicated by line (F). Of course, the number, size and locations of the magnetic mounting assemblies can be varied depending on the weight of the frame, size of the frame and strength of desired wall adhesion.
[0025] The magnets are permanently secured to the rear of the picture frame when in use and do not move. With the magnets secured to the frame, the frame can be easily re-positioned anywhere on the surface of the steel plate that is affixed to the wall, while maintaining secured to the wall. Thus, the user can easily adjust the picture frame left to right, up and down, diagonally, etc. in the two-dimensional plane of the wall to achieve a user's desired placement and rotational orientation of the picture frame. The arrows provided to FIGS. 4-5 illustrate examples of the possible adjustment of the picture frame permitted by the present invention.
[0026] The frame can also easily be leveled by moving one of the right or left sides upward or downward with respect to the other.
[0027] FIGS. 6-7 show additional embodiments of the invention. Here, there are four separate magnet assemblies, one adjacent each corner of the frame. The assemblies are set inward from the outer edges of the frame so that the steel plates are not visible when the frame is secured to the wall.
[0028] Note that in both of FIGS. 6-7 , one of the magnet assemblies is shown with its components in an exploded depiction to aid in understanding the invention.
[0029] In use, the magnets are secured to the rear of the picture frame. Then the steel plates are disposed on the magnets, preferably so that the magnets are approximately centered on the respective plates. The wall adhesive is applied to the wall-facing side of the steel plates either before or after disposing the plates on the magnets. If necessary, the wall adhesive is exposed. Then the frame is pressed against the wall or other surface in a desired location. The adhesive is permitted to set, if necessary. Then the user can slide the magnets along their respective plates to reposition and orient the frame as desired by applying force to the edges of the frame. Pulling the frame in a direction normal to the wall severs the magnetic securement from the steel plates fastened to the wall.
[0030] The “wall” as described herein is not limited to merely a wall. The “wall” can be any generally flat surface or other surface conforming to the contour of the frame.
[0031] While the invention has been described in connection with what is presently considered to be the most practical and preferred example embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed example embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.
[0032] For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim. | A magnetic mounting device secures a picture frame to a wall that allows adjustment up, down, left or right without removing the frame from the wall or using tools. The magnetic mounting device includes magnets to secure the picture frame to the mounting plate that is adhered to the wall. The picture frame may include one or more magnetic mounting device assemblies depending on the weight of the frame and the degree of desired wall adhesion. | 0 |
BACKGROUND
1. Field of the Invention
This invention pertains generally to trenching machines. Specifically, this invention pertains to an improvement to such a machine, whereby boulders which are excavated intact are crushed prior to being deposited onto the refuse conveyor belt.
2. Prior Art
The device with which the present invention will find primary utility is the large trenching machine. These machines are used to dig the trenches in the ground into which pipe, power line, cables and other apparatus are laid. Often, these machines are used to dig trenches spanning distances up to hundreds and even thousands of miles, with the resultant trenches being up to 10 ft. or more deep and 6 ft. or more wide. The earthen material to be trenched can range from soft dirt to rock harder than concrete. Regardless of the hardness of the material being trenched, a particular problem is presented by rocks and boulders which are often encountered and dislodged intact by the machine.
When such a large rock or boulder is encountered, one of three things typically happens. If the boulder is so large, so hard and so firmly embedded that the trenching machine cannot break or remove it, the trenching operation slows considerably as the trenching machine digs its way through the large boulder. This slows the operation, but is not a problem otherwise. Or, the boulder may be broken into several small pieces when hit by the trenching machine, in which case the smaller pieces are removed by the machine from the trench in the normal course and the progress of the machine proceeds unimpeded. Lastly, however, and this is often the case, the entire boulder is dislodged intact, and is then excavated from the trench by the machine and transported to the conveyer belt where it is literally dropped onto the conveyer belt along with the surrounding earth and matter.
Several problems may be encountered when this occurs. First, the conveyer belt or its underpinnings may be damaged when the large, heavy boulder is dropped upon it. Second, even if the conveyer belt is not damaged, the boulder may be too large to fit through the "window" in the frame of the trencher through which the dirt is expelled. In that case, the boulder becomes wedged in the window in the frame, requiring that the trenching operation be stopped completely while the rock is removed. Even if the rock or boulder is small enough to exit the trencher, it cannot be used for back filling the trench after the pipe or other apparatus is laid. Accordingly, that boulder either remains at the site or, as is most often the case, must be transported elsewhere.
The trenching machines with which this invention is primarily used have been in existence for several years. These devices typically comprise a large track-laying motorized vehicle, which is used both to move the trencher forward and to provide a power take-off source for the trenching component of the device. Various types of trenching components are known and used. One is a rotating trenching wheel having buckets which cut the trench and excavate the dislodged earthen material from the trench; another is referred to as a "chain-saw" type trenching component, which resembles a large chain-saw blade attached to and powered by the track-laying vehicle. The "chain-saw" portion typically comprises a large elongated boom around the periphery of which travels a digging belt having a combination of digging teeth which simultaneously cut the earthen material to be extracted and then carry it out of the trench into the body of the trenching component, where it is deposited on a transversely-running conveyor belt which moves the dirt and other material extracted to the side of the trench. After the pipe (or other apparatus) is laid in the trench, the extracted dirt is used to refill the trench. This invention is intended for use with this boom-type trenching machine.
None of the existing prior art trenching machines deal effectively with the problems posed by these dislodged boulders. One attempted solution was to make the "window" in the frame larger, but the problems of damage to the conveyor system and of having the boulders at the trench-site remained. Therefore, a need exists in the field of largescale trenching machines for an improved trencher which will overcome these deficiencies of the prior art.
SUMMARY OF INVENTION
This invention provides such an improved trenching machine by incorporating a device which crushes most of the boulders removed before they reach the interior of the trencher and the conveyer belt, the invention comprising a preferably rotating bar-like element attached to the frame of the machine in close proximity to the digging belt and the ground such that dislodged boulders are prevented from entering the machine until broken up or ground down to a manageable size.
One embodiment of this invention is shown in the attached drawings, wherein the bar-like element comprises a crusher drum attached to the frame of the machine in close proximity to the digging belt. In operation, any boulders that are dislodged by the digging belt are moved up and out of the hole and come against the crusher drum which impedes its progress. At this point, the combined forces of the crusher drum, the digging belt and the ground may force the boulder to crumble. If not, the boulder remains lodged in that location while the digging belt continues to travel over it, abrading it until it is reduced to a size that can travel through the space between the crusher drum and the digging belt.
It is, therefore, the object of this invention to provide an improved trenching machine.
DESCRIPTION OF THE FIGURES
FIG. 1 is a side view depiction of a typical boom-type tractor trencher of the type with which this invention will find primary utility. The boom is depicted in the lowered or digging position.
FIG. 2 is a side view in isolation, of that portion of the trenching machine wherein the bar-like crusher element is located. The boom is shown in the up or elevated position, and is shown in shadow in the down or lowered position.
FIG. 3 is a cross sectional isolation end view of the boom apparatus (in the elevated position) showing the crusher drum in greater detail and, for clarity, omitting depiction of a digging belt.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred trencher will have a central frame (not shown), attached to which are an engine compartment 10, an enclosed cab 12, a track system 14, and a hydraulically adjustable boom assembly 16, rotatably attached to the central frame by means of boom frame 18. The boom assembly 16 generally comprises a boom 19, and a digging belt 20 which is attached to two chains 21 which travel within a track around the periphery of the boom 19.
The digging belt 20, as seen in cross-section in FIG. 3, comprises a number of plates 22 to which are attached a plurality of digging teeth 24 and scraping plates 25. The digging belt 20 is caused to rotate continuously around the periphery of the boom 19 by a typical power take-off mechanism 26 attached to the boom frame 18 of the trencher. In the preferred embodiment, this mechanism comprises a conventional belt drive system.
The power plant (not shown) housed within the engine compartment 10 should be of sufficient power output to turn the track system 14 and the digging belt 20, and to provide hydraulic power to raise and lower the boom assembly 16 and to power the conveyor belt system 40. Appropriate and typical clutch means (not shown) are provided so that power to the digging belt 20 can be engaged or disengaged at will.
The boom assembly 16 is raised or lower by means of two hydraulic arms 28 attached at one end by typical rotatable means 30 to the boom frame 18 of the trenching machine, and at the other end by similar attachment means 32 to the boom 19. As will be seen in FIG. 2, as the hydraulic arms 28 are extended, the boom 19 is moved up and out of the hole, and as the hydraulic arms 28 are retracted, the boom 19 is lowered into contact with the ground. As best seen in FIG. 1, the weight of the boom 19 and the forward motion of the track system 14 provide for sufficient friction between the digging belt 20 and the ground so that trenching occurs.
In operation, the trencher is positioned so that its tracks straddle the location in the ground where the trench is to be dug, with the boom 19 in a completely elevated position, out of the ground.
To begin the trenching operation, power is supplied to the boom assembly 16 such that the digging belt 20 is caused to rotate around the periphery of the boom 19. The operator of the trencher then releases the hydraulic pressure to the arms 28, allowing the boom assembly 16 to lower against the ground. The digging teeth 24 on the digging belt 20 dislodge the dirt and the scraping plates 25 pull material up and out of the ground, creating a trench. Once the boom 19 has reached the desired depth in the ground, the track system 14 is engaged and the trencher moves forward bringing the submerged portion of the boom assembly 16 and the digging teeth 24 on the digging belt 20 into contact with new ground, thereby extending the length of the trench.
The material that is loosened from the ground is urged upward into a chute 34 formed integrally into the boom frame 18 on the trenching machine. The chute 34 directs the excavated material through the interior of the frame 18, where it empties onto the conveyer belt system 40, consisting of a flexible conveyor belt 41 looped around interior rollers 42 and a drive mechanism at either end of the belt (not shown). The conveyor belt 41 extends out from the side of the trenching device a safe distance away from the trench being cut, where the refuse material is dumped, to be later used for back-filling the hole after the pipe or other appliance has been placed in the trench. Because of the tremendous volume of material that large trenchers can remove from the ground, the conveyer belt typically moves at 1000 ft. per minute, and is approximately 3 ft. wide. It too is powered by the power plant in the engine compartment 10.
A window 43 is created in the frame 18 through which the conveyor belt 41 extends. The size of the window 43 is made as large as possible given the surrounding structure, so as not to unduly impede the movement of the refuse material exteriorly of the trencher. In most trencher designs, however, there is a upper limit to the size of window 43. Accordingly, in operation, it was not unusual for the trencher to dislodge a boulder that would not fit through the window 43. The digging belt 20 would transport the boulder into the chute 34 and onto the conveyer belt system 40. If the boulder were sufficiently large, the conveyer belt system 40 may be damaged simply from the weight and rough exterior of the boulder when it is dropped on the moving conveyer belt 41. Also, because the conveyer belt 41 is moving at such a high rate of speed, and the boulder may be too heavy and have too much inertia to be made immediately to move at the rate of speed of the conveyer. In that not uncommon circumstance, the boulder begins to roll in place. This can further damage the conveyer belt assembly, or create an obstacle which prevents the free flow and removal of the other refuse material. If the boulder does move and is too large to fit through the window 43, the high speed of the conveyer belt 41 causes the boulder to become securely wedged in the window 43.
When this happens, the trenching operation must completely stop so that the boulder can be removed. Often, the ground being trenched will include some amount of water in the soil, such that the dirt has a consistency of mud, making the removal process not only time-consuming and inconvenient, but also extremely dirty. Sometimes, because of the size of the boulder, it must be chained and lifted out of the boom frame 18 by another apparatus.
This problem is effectively corrected by the addition of a crusher drum 50 which is rotatably attached to and between flanges 52, which are in turn securely attached one to either side of the boom frame 18. The crusher drum 50 is perpendicular to and extends the entire distance of and beyond the digging belt 20. The crusher drum 50 is fitted with a plurality of teeth 54, which are angled toward the teeth 24 on the digger belt 20. A clearance between the teeth 54 and the teeth 24 of approximately eight (8) inches has been found to be workable. This distance, however, can be varied according to the size of the trenching machine and the size of the material being encountered. Any of the commercially available long-wearing, hard-faced digging, drilling or trenching teeth should provide acceptable performance. The preferred teeth, however, are obtained from Kenametal Corp.
A stop plate 56 is attached to the bottom portion of boom frame 18. When the boom 19 is in its lowered positions, the stop plate 56 resides immediately behind the crusher drum 50 to protect it from back wash of refuse material down the chute 34.
In operation, if a boulder is dislodged from the material being trenched, it is carried up and out of the trench by the digging belt 20. Whereas in the prior art machines, the boulder would be lifted into the chute 34 and hence onto the conveyor belt system 40, and maybe or maybe not, through the window 43, with this invention that boulder in this device, if the boulders cannot fit through the space between the crusher drum 50 and the digging belt 20, it becomes lodged against the crusher drum 50, held in place there by the crusher drum 50 on one side, the ground on another side, and the belt 20 on the third side. If the boulder is not broken apart by the resultant forces, it remains in that position while the belt continues to abrade it until reduced to a sufficiently small size to be safely expelled.
Described above is the preferred embodiment of this invention. The scope of the invention, however, is not so limited, but is of the full breadth of the following claims. | In a machine for digging a trench, in which the digging apparatus comprises an elongated boom having a movable chain around its periphery and which is lowered into the ground, the problem of dislodged boulders which heretofore would be excavated into the machine where they often damaged the conveyor belt system or became stuck, is prevented by an elongate bar or drum which is attached to the frame of the machine in close proximity to the operating chain and immediately before the boulder would otherwise enter the machine. The boulder is held there until it either breaks apart or its abraded by further action of the chain to a sufficiently small size that it can safely navigate through the machine and be expelled in the normal course. | 4 |
The present application is a continuation-in-part of U.S. application Ser. No. 07/440,898, filed Nov. 22, 1989, now U.S. Pat. No. 5,194,654.
BACKGROUND OF THE INVENTION
The present invention relates generally to the treatment of viral infections using lipid derivatives of antiviral compounds. More particularly, the present invention relates to lipid derivatives of antiviral phosphonoacids and their use. The lipid derived compounds can be integrated into the structure of liposomes, thereby forming a more stable liposomal complex which can deliver greater amounts of these compounds to target cells with less toxicity.
The publications and other reference materials referred to herein are hereby incorporated by reference, and are listed for convenience in the bibliography appended at the end of this specification.
There has been a great deal of interest in recent years in developing agents to treat viral infections. In the past the most significant viral diseases were those caused by viruses of the herpes and influenza groups of viruses as well as those viruses causing hepatitis. In the past decade, infections with human immunodeficiency retrovirus (HIV) have become a major public health problem. Effective antiviral agents are those that interfere with the replication or transcription of viral genetic information while not inhibiting the normal functions of the host cell.
Phosphonoacetic acid (PAA) and phosphonoformic acid (PFA or Foscarnet), having the following structures: ##STR1## have been shown to have good antiviral activity against herpes simplex viruses types 1 and 2 (1), as well as against influenza viruses, hepatitis virus B, and retrovirus infections (2).
Acquired immunodeficiency syndrome (AIDS) is caused by the human immunodeficiency virus (HIV). HIV is a retrovirus which infects cells bearing the CD4 (T4) surface antigen, such as CD4+ helper lymphocytes, CD4+ monocytes and macrophages and certain other CD4+ cell types. The HIV infection of CD4+ lymphocytes results in cytolysis and cell death which contributes to the immunodeficiency of AIDS; however, CD4+ monocytes and macrophages may not be greatly harmed by the virus. Viral replication in these cells appears to be more prolonged and less cytotoxic than in lymphocytes, and as a result, monocytes and macrophages represent important reservoirs of HIV infection. It has recently been discovered that macrophages may serve as reservoirs of HIV infection even in certain AIDS patients who test negative for the presence of HIV antibodies. No effective cure is available for AIDS, although nucleosides analogues, particularly the dideoxynucleosides have been shown to prolong life and to reduce the incidence of certain fatal infections associated with AIDS.
Dideoxynucleoside analogues are the most potent agents currently known for treating AIDS, but these therapies are not entirely satisfactory. In a recent human clinical trial using AZT, serious toxicity was noted, evidenced by anemia (24%) and granulocytopenia (16%) (3,4). Certain monocyte-derived macrophages, when infected with some strains of HIV, have been found to be resistant to treatment with dideoxycytidine, azidothymidine, and other dideoxynucleosides in vitro as shown by Richman, et al. (5). The resistance may be due in part to the low levels of dideoxynucleoside kinase which result in a reduced ability to phosphorylate AZT, ddC or ddA.
Phosphonoformate (PFA) may provide an effective alternative therapy to nucleoside analogues. PFA inhibits a broad range of DNA polymerases as well as the RNA polymerase of influenza virus. PFA also inhibits the reverse transcriptase (RT) of HIV and other retroviruses at concentrations below 1 μM. Since the DNA polymerases are much less sensitive to PFA than the reverse transcriptases, the possibility exists that this drug may have a good therapeutic ratio for use in HIV infection. The phosphonoacids PFA and PAA may also supplement therapy using antiviral nucleosides. Lambert (6) has found that when PFA or PAA are coupled with certain antiviral nucleosides, particularly 5-bromo-2'-deoxyuridine (BUdR), the antiviral activity of the coupled nucleoside against herpes simplex viruses is greater than that of the parent nucleoside.
Efforts to increase the effectiveness of both antiviral nucleosides analogs and the phosphonoacids include association of these agents with lipids.
Attempts have been made to improve the therapeutic effectiveness of nucleoside analogues, such as arabinofuranosylcytosine (ara-C) and arabinofuranosyladenine (ara-A) as chemotherapeutic agents in the treatment of various types of cancer, by chemically linking them to phospholipids in order to enhance their catabolic stability (7). These phospholipid-derived agents showed a decreased toxicity and increased stability over the nucleoside analogues alone. However, they also exhibited poor cellular uptake (6) and poor drug absorption (8).
Another approach to increase the effectiveness of antiviral agents comprises encapsulation within liposomes to facilitate their delivery to cells. Liposomes are lipid vesicles which can be formed according to the method of Alex Bangham. Bangham and coworkers discovered in 1965 that dried films of phosphatidylcholine spontaneously formed closed bimolecular leaflet vesicles upon hydration (9). One of the most effective applications of liposomes in medicine is as a carrier to deliver therapeutic agents to target organs. The agents are encapsulated during the process of liposome formation and released in vivo after liposomes are taken up by cells. Liposomes thereby provide a means of delivering higher concentrations of therapeutic agents to target organs. Further, since liposomal delivery focuses therapy at the site of liposome uptake, it reduces toxic side effects.
Liposomal incorporation has been shown to provide a more effective way of delivering antiparasitic compounds which not only increases the potency of the dose but prolongs its efficacy and decreases its toxicity. For example, liposomal antimonial drugs are several hundred-fold more effective than the free drug in treating leishmaniasis as shown independently by Black and Watson (10) and Alving, et al. (11). Liposome-entrapped amphotericin B appears to be more effective than the free drug in treating immunosuppressed patients with systemic fungal disease (12). Other uses for liposome encapsulation include restriction of doxorubicin toxicity (13) and diminution of aminoglycoside toxicity (14).
PFA has been found to inhibit HIV-1 replication in several in vitro systems at concentrations which are attainable in patients. However, the low degree to which PFA enters cells causes much higher levels to be required than that found to be effective in cell free systems with HIV RT (15). Also, PFA has toxic side effects and is known to accumulate in bone because of its similarity to pyrophosphate. Phosphonoacetic acid (PAA), which has antiviral activity similar to that of PFA, appears to have an affinity for bone that may preclude its use in humans (6).
Attempts have been made to increase the intracellular antiviral efficacy of the phosphonoacids by encapsulating them into liposomes. Szoka, F. and Chu, C. (16) found that liposomal delivery enhanced the cellular uptake and viral inhibitory activity of both PFA and PAA. Liposomal encapsulation also decreased the cytopathic effect of PFA; however, the cytopathic effect of liposomal PAA as compared to the free drug appeared to be increased.
As previously mentioned, it is now thought that macrophages are an important reservoir of HIV infection (17, 18). Macrophages are also a primary site of liposome uptake (19, 20). Accordingly, it would be desirable to utilize liposomes to enhance the effectiveness of antiviral phosphonoacid and antiviral phosphonoacid esters of antiviral nucleosides in treating AIDS and other viral infections. Clearly, it would be useful to have more effective ways of delivering large amounts of effective antiviral phosphonoformate compounds to macrophages infected with HIV or other viruses and to other cells having viral infections.
Co-pending applications, U.S. Ser. Nos. 216,412 and 319,485 (21, 22) disclose lipid derivatives of nucleoside analogues which are capable of being incorporated into the structure of liposomes so as to further improve therapy comprising liposomal delivery of these agents.
In order to use phosphonoacid antivirals more effectively, it is desirable to synthesize lipid prodrugs of the agents. It is therefore an object of the invention to provide methods for producing phosphonoacid lipid derivatives which can be incorporated into stable liposomal form.
The methods disclosed here apply not only to the use of lipid derivatives of phosphonoacids in the treatment of AIDS and other retroviral diseases, but also to their use in the treatment of diseases caused by other viruses, such as influenza, herpes simplex virus (HSV), human herpes virus 6, cytomegalovirus (CMV), hepatitis B virus, Epstein-Barr virus (EBV), and varicella zoster virus (VZV).
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 demonstrates the effect of a composition of the present invention on plaque formation in HIV-infected cells.
SUMMARY OF THE INVENTION
The invention provides a composition having antiviral properties, comprising an antiviral phosphonoacid having a lipid moiety linked thereto. In a preferred embodiment, the phosphonoacid is phosphonoformic acid, and in another embodiment, the phosphonoacid is phosphonoacetic acid. The phosphonoacid can be attached to the lipid group through either a phosphate ester or carboxyester linkage. The invention also includes phosphonoacids linked to lipids through diphosphate groups.
According to one embodiment of the invention, the lipid moiety attached to the phosphonoacid is a diacyl- or dialkylglycerol or a 1-acyl-2-O-alkyl glycerol, or a 1-O-alkyl-2-acylglycerol; in other embodiments, the lipid moiety is a monoacyl- or monoalkylglycerol or a fatty acid, a phospholipid, or a more complex lipid moiety, such as, for example, a sphingosine, a ceramide, cardiolipin, or bis(diacylglycero)phosphate. The lipid moiety may comprise from 1 to 4 long chain aliphatic groups, each comprising from 2 to 24 carbon atoms, which may be unsaturated, containing from 1 to 6 double bonds. The aliphatic groups of glycerols may be attached to the constituent glycerol unit by ester, ether, or vinyl ether bonds. The aliphatic groups of lipids having more than one such group may be the same or different in structure.
Preferred phosphonoacid lipid derivatives are 1-O-alkyl-sn-glycero-3-phosphonoacids. 1-O-hexadecyl-sn-glycero-3-phosphonoacids are particularly preferred. Other preferred embodiments are 1-O-alkyl-sn-glycero-3-oxycarbonylphosphonoacids.
According to another aspect of the invention there are provided lipid-rich derivatives of phosphonoacids of the general formula (VI) and including bisdiacylglycerol phosphate phosphonoacids and diphosphatidylglycerol derivatives of phosphonoacids.
The invention further comprises a liposome formed at least in part from any of the compositions of the invention.
Another aspect of the present invention is a method for preparing a suspension of liposomes for use in treating viral infections in a mammal, comprising providing an lipophilic antiviral agent selected from the group consisting of a phosphonoacid linked to a lipid moiety; combining the lipophilic antiviral agent and a pharmacologically acceptable aqueous solvent to form a mixture; and forming liposomes from the lipophilic antiviral agent.
The invention further comprises methods for treating viral infection in a mammal, comprising administering an effective amount of any one of the compositions of the invention. In a preferred embodiment, the mammal is a human, and the virus is the retrovirus HIV. In particularly preferred embodiments, a method of the invention is used in combination with the administration of AZT or other antiretroviral analogues. The methods may include avoiding or overcoming resistance to AZT or other antiviral analogues by administering the analogues in the form of one of the compositions of the invention.
The lipophilic nature of these compounds provides advantages over the use of the phosphonoacids alone, by prolonging their persistence in vivo following administration. The lipid-phosphonoacids can also be incorporated into the lamellar structure of liposomes when combined with similar lipophilic molecules. In the form of liposomes, these antiviral molecules are preferentially taken up by macrophages and monocytes, cells that have been found to harbor the target human immunodeficiency virus (HIV). Additional site specificity can be incorporated into the liposomes by the inclusion of ligands, such as monoclonal antibodies or other peptides or proteins that bind to viral proteins. These prodrugs have been found to prevent viral replication in HIV infections that have become resistant to therapy with conventional forms of the antiretroviral agents.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides synthesized lipid derivatives of phosphonoacids which can be incorporated into the lipid bilayer of liposomes. These derivatives are converted into antiviral phosphonoacids by constituent metabolic processes, and they accordingly have antiviral effects in vivo and in vitro. A phosphonoacid has the general structure ##STR2##
In preferred embodiments of the invention, n is 0 to 1, and the phosphonoacid is phosphonoformic acid or phosphonoacetic acid.
Lipid Derivatives of the Invention
Any lipid derivative of a phosphonoacid which possesses antiviral activity is within the scope of the invention. Compositions which will be most effective will have a lipid portion sufficient to be able to incorporate the material in a stable way into a liposomal bilayer, cell membrane, lipid bilayer, or other macromolecular array. Lipid groups attached to the phosphonoacids can be, for example, glycolipids, sphingolipids, phospholipids, glycerolipids, or fatty acids.
The phosphonoacid can be conveniently linked to an available hydroxyl group of a lipid either through a carboxyester link or through a phosphoester link. Some preferred lipid derivatives of phosphonoacids are members of the following general classes:
Antiviral diacylglycerol phosphonoacids
One species of this class of antiviral lipid compounds has the structure: ##STR3## wherein n is 0 or 1; an aliphatic acid, either formic or acetic, is joined to P through a phosphonate bond to form the phosphonoacid; and R 1 and R 2 are aliphatic groups, defined below.
Another species of this class of compounds is 1, 2,-diacylglycerol oxycarbonyl phosphonoacids. having the structure: ##STR4## wherein n=0 or 1, and R 1 and R 2 are C 2- aliphatic groups having 0 to 6 double bonds, and are linked to the C1 and C2 of a glycerol group through an ester linkage.
1-O-alkyl glycerol derivatives of phosphonoacids:
One species of this class are those lipid derivatives having the general structure: ##STR5## wherein n is 0 or 1; an aliphatic acid, either formic or acetic, is joined to P through a phosphonate bond; and R 1 is an aliphatic group defined below.
Another species of this class of compounds has the structure ##STR6## wherein a phosphonoacid, either phosphonoformic, (n=0), or phosphonoacetic (n=1), is linked to the glycerol moiety by means of a carboxyester bond.
Diacylglycerol phosphate phosphonoacids
This class of antiviral phosphonoacid lipids has the general structure: ##STR7## wherein n is 0 or 1; an aliphatic acid group, either formate or acetate, is joined to P through a phosphonate bond; and R 1 and R 2 are aliphatic groups, defined below.
Ceramide antiviral phosphonoacids:
Antiviral phosphonoacids can also be generated in cells after liposomal delivery of ceramide derivatives thereof having the general structure shown below: ##STR8## where n is 0 or 1 and CER is an N-acylsphingosine having the structure: ##STR9## wherein R is an aliphatic group as defined below, or an equivalent lipid-substituted derivative of sphingosine. This class of compounds is useful in liposomal formulation in the therapy of AIDS and other viral diseases because it can be acted upon by sphingomyelinase or phosphodiesterases in cells giving rise to the antiviral phosphonoacid. In addition to the compound shown above, ceramide diphosphate phosphonoacids can also be synthesized, which may be degraded by cellular pyrophosphatases to give a phosphonoacid and ceramide phosphate.
Lipid-Rich Derivatives of Antiviral Phosphonoacids
One approach to achieving even greater stability of lipid derivatives of phosphonoacids within liposomes is by increasing lipid-lipid interaction between the lipid-phosphonoacid structure and the lipid bilayer. Accordingly, in preferred embodiments, lipid derivatives of phosphonoacids having up to four lipophilic groups may be synthesized. Specific compositions are provided having the formula:
(L).sub.m --(V).sub.n --W--T [VI]
wherein W is ##STR10## T is (CH 2 ) p --C(O)--O--, wherein p=0 or 1; V is phosphate; n=0 to 2; L is a lipid moiety; m=1 to 3; and wherein each L is linked directly to V in a phosphoester linkage and T is linked to W through a phosphonate bond.
In another embodiment, compositions are provided having the formula: ##STR11## wherein W is ##STR12## V is phosphate; n=0 or 1; T is (CH 2 ) p --C(O)--O; p is 0 or 1; L is a lipid moiety; L 1 is (CH 2 --CHOH--CH 2 ); and wherein L and L 1 are each linked to V through a phosphoester bond and T is joined to W through a phosphonate bond.
One class of these comprises diphosphatidylglycerol derivatives, having the general structure: ##STR13## wherein n is 0 or 1, and R 1-4 are two, three or four aliphatic groups which are independently R as defined below, said groups being in acyl ester, ether, or vinyl ether linkages. In this class, phosphonoacids are attached to one or both phosphates by a diphosphate bond. There may be one or two phosphonoacids attached to each molecule. Another class of phosphonoacid derivatives having increased lipid components comprises bis(diacylglycero)phosphate phosphonoacids, having the general structure: ##STR14## where n is 0 or 1, and R 1 -R 4 are as defined previously. This compound will be metabolized to a phosphonoacid in the cells by endogenous pyrophosphatases or other esterases. These two types of compounds may provide superior metabolic and physical properties.
Lipid Structures
Substituent R groups R 1 and R 2 , as well as R 3-4 for the bis(diacylglycero) species) may be the same or different, and are C 2 to C 24 aliphatic groups, having from 0 to 6 sites of unsaturation, and preferably having the structure
CH.sub.3 --(CH.sub.2).sub.a --(CH═CH--CH.sub.2).sub.b --(CH.sub.2).sub.c --Y
wherein the sum of a and c is from 0 to 22; and b is 0 to 6; and wherein Y is C(O)O - , C--O - , C═C--O - , C(O)S--, C--S--, C═C--S--; forming acyl ester, ether or vinyl ether bonds, respectively, between the aliphatic groups and the glycerol moiety.
These aliphatic groups in acyl ester linkage therefore comprise naturally occurring saturated fatty acids, such as lauric, myristic, palmitic, stearic, arachidic and lignoceric, and the naturally occurring unsaturated fatty acids palmitoleic, oleic, linoleic, linolenic and arachidonic. Preferred embodiments comprise a monoester or diester, or a 1-ether, 2-acyl ester phosphatidyl derivative. In other embodiments, the aliphatic groups can be branched chains of the same carbon number, and comprise primary or secondary alkanol or alkoxy groups, cyclopropane groups, and internal ether linkages.
The glycero-phospho bonds may be racemic or sn-1 or sn-3 ester bonds; alternatively, the phosphate group may be joined at the 2-position of the glycerol moiety. There may be 1 or 2, (as well as 3, or 4 for the bis(diacylglycero) species) acyl ester groups, or alkyl ether or vinyl ether groups, as required.
In any of the above embodiments, L is independently selected from the group consisting of R; ##STR15## wherein R, R 1 and R 2 are independently C 2 to C24 aliphatic groups in ester, ether, or vinyl ether linkage. In any of the specific compositions described, R, R 1 and R 2 independently have from 0 to 6 sites of unsaturation, and have the structure:
CH.sub.3 --(CH.sub.2).sub.a --(CH═CH--CH.sub.2).sub.b --(CH.sub.2).sub.c --Y
wherein the sum of a and c is from 0 to 22; and b is 0 to 6; and wherein Y is C(O)O--, C--O--, C═C--O--, C(O)S, C--S, or C═C--S.
Synthesis of Lipid Derivatives of Phosphonoacids
This class of lipid derivatives of phosphonoacids wherein the lipid is joined through a phosphate ester link with the phosphate of the phosphonoacid, for example, the compounds of formula IIa, IIIa, IV, V, VI, VII, VIII, and IX, can be prepared as described in Examples 1, 2, and 5. Diacylglycerophosphonoformates of formula IIa, for example, can be synthesized from the reaction of a diacylglycerol and phosphonoformic acid using triisopropylbenzenesulfonyl chloride in pyridine as described for the preparation of 1,2-dimyristoyl-glycero-3-phosphophonoformate in Example 1, or 1,2-dipalmitoyl-glycero-3-phosphophonoformate in Example 2. 1-O-alkyl-sn-glycero-3-phosphonoacids, of the general formula IIIa, or 2-O-alkyl-sn-glycero-3-phosphonoacids, can be prepared according to Example 5, in a similar procedure.
Lipid derivatives of phosphonoacids wherein the phosphonoacid is linked to the lipid group through a carboxyester bond with the carbonyl group of the phosphonoacid, of the formulas IIb and IIIb, can be prepared according to the method set forth in Examples 3 and 4. The unesterified glycerol hydroxyl groups having protective groups, such as benzyl.
Other analogs, comprising 1-acyl-2-O-alkylglycerols, 1-O-alkyl-2-acylglycerols, dialkylglycerols, 1-acylglycerols, 2-acylglycerols, 2-O-alkylglycerols can be synthesized by the same methods, using similar protective groups as necessary.
The diacylglycerol phosphate phosphonoacid class of compounds of formula IV may also be synthesized by preparing the morpholidate derivative of the phosphonoacid and coupling to phosphatidic acid in dry pyridine as described for cytidine diphosphate diglyceride by Agranoff and Suomi (23). Alternatively, the morpholidate of phosphatidic acid may likewise be coupled to the phosphonoacid directly.
Ceramide phosphonoacids of formula V may be prepared in a method similar to the method for preparing antiviral phosphonoacid diphosphate diglycerides, with appropriate changes to the starting materials.
The bis(diacylglycero)phosphate phosphonoacid compounds of formula IX may be synthesized by joining a phosphonomorpholidate to the phosphoester residue of bis(diacylglycero)phosphate by the condensation methods presented in the Examples.
Other suitable lipid derivatives of phosphonoacids may be synthesized using the same methods and using appropriate novel lipids as starting materials. It is desirable, for example, to synthesize phospholipid derivatives of antiviral and antiretroviral phosphonoacids which will give rise to potent antiviral agents upon alternate paths of metabolism by the target cells which take up the lipid formulation.
Liposome Preparation
After synthesis and purification, the lipid derivative of the phosphonoacid is incorporated into liposomes, or other suitable carrier. The incorporation can be carried out according to well known liposome preparation procedures, such as sonication and extrusion. Suitable conventional methods of liposome preparation include, but are not limited to, those disclosed by Bangham, et al. (9) Olson, et al. (24), Szoka and Papahadjapoulos (25), Mayhew, et al. (26), Kim, et al. (27), and Mayer, et al. (28).
The liposomes may be made from the lipid derivatives of phosphonoacids alone or in combination with any of the conventional synthetic or natural phospholipid liposome materials including phospholipids from natural sources such as egg, plant or animal sources such as phosphatidylcholine, phosphatidylethanolamine, phosphatidylglycerol, sphingomyelin, phosphatidylserine, or phosphatidylinositol. Synthetic phospholipids that may also be used, include, but are not limited to: dimyristoylphosphatidylcholine, dioleoylphosphatidyl-choline,dipalmitoylphosphatidylcholine and distearoylphosphatidycholine, and the corresponding synthetic phosphatidylethanolamines and phosphatidylglycerols. Other additives such as cholesterol or other sterols, cholesterol hemisuccinate, glycolipids, cerebrosides, fatty acids, gangliosides, sphingolipids, 1,2-bis(oleoyloxy)-3-(trimethyl ammonio)propane (DOTAP), N-[1-(2,3-dioleoyl) propyl]-N,N,N-trimethylammonium chloride (DOTMA), DL-2,3-distearoyloxypropyl(dimethyl)-β-hydroxyethylammonium (29), or psychosine can also be added, as is conventionally known. The relative amounts of phospholipid and additives used in the liposomes may be varied if desired. The preferred ranges are from about 80 to 95 mole percent phospholipid (including the lipid phosphonoacid) and 5 to 20 mole percent psychosine or other additive. Cholesterol, cholesterol hemisuccinate, fatty acids or DOTAP may be used in amounts ranging from 0 to 50 mole percent. The amounts of antiviral phosphonoacids and nucleoside analogue incorporated into the lipid layer of liposomes can be varied with the concentration of their lipids ranging from about 0.01 to about 100 mole percent.
Using conventional methods, approximately 20 to 30% of the phosphonoacid present in solution can be entrapped in liposomes; thus, approximately 70 to 80% of the active compound is wasted. In contrast, where the lipid phosphonoacid is incorporated into liposomes, virtually all of the antiviral compound is incorporated into the liposome, and essentially none of the active compound is wasted.
The liposomes with the above formulations may be made still more specific for their intended targets with the incorporation of monoclonal antibodies or other ligands specific for a target. For example, monoclonal antibodies to the CD4 (T4) receptor may be incorporated into the liposome by linkage to phosphatidylethanolamine (PE) incorporated into the liposome by the method of Leserman, et al. (30).
Therapy of Vital Diseases
The lipid derivatives of the present invention or liposomes comprising these antiviral agents and containing 0.1 to 100% of a lipid derivative such as batyl alcohol phosphonoformic acid or phosphatidylphosphonoformic acid (phosphatidyl-PFA) or phosphatidylphosphonoacetate (phosphatidyl-PAA) or antiviral analogues of this class of compounds may be administered by parenteral routes to persons infected with HIV or cytomegalovirus (CMV). These liposomes can be given to AIDS or CMV patients by parenteral administration, enhancing delivery of the compound to macrophages and monocytes, an important reservoir of viral infections. This will allow for the efficacious use of lower doses of the modified phosphonoacids, reducing toxicity of the compound. These antiviral agents may be used alone or in combination with other antiviral nucleosides of this general class as given conventionally. In addition, it is important to note that liponucleotides of AZT, ddC, ddA, ddI, d4T and ddT as disclosed in a copending application (22) may also be incorporated into the phosphatidyl-PFA liposomes singly or in combination to produce pPFA/dideoxynucleoside combination therapies. Alternatively, phosphate esters of the dideoxynucleosides may be encapsulated in the interior of the pPFA liposome as previously described (16) to produce a combination therapy for HIV infections.
These combination therapies with AZT and phosphatidyl-PFA may be especially important in order to treat more effectively the AZT-resistant (or nucleoside-resistant) strains which have been seen to develop during single drug therapy (31). The use of combination therapy as outlined may greatly reduce the tendency for drug resistant HIV mutant strains to appear and would therefore increase the likelihood of stopping the progression of HIV infection. The same argument would hold equally well in treating cytomegalovirns or herpes virus infections with regard to the likelihood of developing resistant strains.
The liposome-incorporated lipid-phosphonoacid conjugate is administered to patients by any of the known procedures utilized for administering liposomes. The liposomes can be administered intravenously, intraperitoneally, intramuscularly, intravitreally or subcutaneously as a buffered aqueous solution. Any pharmaceutically acceptable aqueous buffer or other vehicle may be utilized so long as it does not destroy the liposome structure or the activity of the lipid phosphonoacid analogue. One suitable aqueous buffer is 150 mM NaCl containing 5 mM sodium phosphate with a pH of about 7.4 or other physiological buffered salt solutions.
The dosage for a mammal, including a human, may vary depending upon the extent and severity of the infection and the activity of the administered compound. Dosage levels for the phosphonoacids are well established (2,6,16). Dosage levels of liposomal lipid analogs of phosphonoacids will be about the same as for the phosphonoacid itself, but in general, should be such that about 0.1 mg/kilogram to 1000 mg/kilogram is administered to the patient on a daily basis and more preferably from about 1 mg/kilogram to about 100 mg/kilogram.
The present invention utilizes the antiviral phosphonoformate derivatives noted above incorporated in liposomes in order to direct these compounds to macrophages, monocytes and any other cells which take up the liposomal composition. Ligands may also be incorporated to further focus the specificity of the liposomes. The derivatives described have several unique and novel advantages over the liposomal water soluble phosphonoformates. First, they can be formulated in liposomes to much higher ratios of drug to lipid because they are incorporated into the wall of the liposome instead of being located in the aqueous core compartment. Secondly, the liposomes containing the lipophilic phosphonoformate derivatives noted above do not leak during storage, providing improved product stability. Furthermore, these compositions may be lyophilized, stored dry at room temperature, and reconstituted for use, providing improved shelf life. They also permit efficient incorporation of antiviral compounds into liposomal formulations without significant waste of active compound. A further advantage is that the compositions used in vivo treatment cause a larger percentage of the administered antiviral lipid-phosphonoacid conjugate to reach the intended target. At the same time the use of the compositions reduces the amount being taken up by cells in general, thereby decreasing the toxic side effects of the nucleosides. The toxic side effects of the phosphonoformates may be further reduced by targeting the liposomes in which they are contained to actual or potential sites of infection by incorporating ligands into the liposomes.
Lipid derivatives of antiviral agents have a prolonged antiviral effect as compared to the lipid-free agents; therefore they provide therapeutic advantages as medicaments even when not incorporated into liposomes. Non-liposomal lipid derivatives of antiviral phosphonoacids may be applied to the skin or mucosa or into the interior of the body, for example orally, intratracheally or otherwise by the pulmonary route, enterally, rectally, nasally, vaginally, lingually, intravenously, intra-arterially, intramuscularly, intraperitoneally, intradermally, or subcutaneously. The present pharmaceutical preparations can contain the active agent alone, or can contain further pharmaceutically valuable substances. They can further comprise a pharmaceutically acceptable carrier.
Pharmaceutical preparations containing lipid derivatives of antiviral phosphonoacids are produced by conventional dissolving and lyophilizing processes to contain from approximately 0.1% to 100%, preferably from approximately 1% to 50% of the active ingredient. They can be prepared as ointments, salves, tablets, capsules, powders or sprays, together with effective excipients, vehicles, diluents, fragrances or flavor to make palatable or pleasing to use.
Formulations for oral ingestion are in the form of tablets, capsules, pills, ampoules of powdered active agent, or oily or aqueous suspensions or solutions. Tablets or other non-liquid oral compositions may contain acceptable excipients, known to the art for the manufacture of pharmaceutical compositions, comprising diluents, such as lactose or calcium carbonate; binding agents such as gelatin or starch; and one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring or preserving agents to provide a palatable preparation. Moreover, such oral preparations may be coated by known techniques to further delay disintegration and absorption in the intestinal tract.
Aqueous suspensions may contain the active ingredient in admixture with pharmacologically acceptable excipients, comprising suspending agents, such as methyl cellulose; and wetting agents, such as lecithin or long-chain fatty alcohols. The said aqueous suspensions may also contain preservatives, coloring agents, flavoring agents and sweetening agents in accordance with industry standards.
Preparations for topical and local application comprise aerosol sprays, lotions, gels and ointments in pharmaceutically appropriate vehicles which may comprise lower aliphatic alcohols, polyglycols such as glycerol, polyethylene glycol, esters of fatty acids, oils and fats, and silicones. The preparations may further comprise antioxidants, such as ascorbic acid or tocopherol, and preservatives, such as p-hydroxybenzoic acid esters.
Parenteral preparations comprise particularly sterile or sterilized products. Injectable compositions may be provided containing the active compound and any of the well known injectable carriers. These may contain salts for regulating the osmotic pressure.
The therapeutically effective amount of the lipid derivatives is determined by reference to the recommended dosages of the active antiviral phosphonoacid, bearing in mind that, in selecting the appropriate dosage in any specific case, consideration must be given to the patient's weight, general health, metabolism, age and other factors which influence response to the drug. The parenteral dosage will be appropriately an order of magnitude lower than the oral dose.
A more complete understanding of the invention can be obtained by referring to the following illustrative examples, which are not intended, however, to unduly limit the invention.
EXAMPLE 1
Synthesis of 1,2 -dimyristoyl-glycero-3-phosphonoformate.
To a three necked reaction flask was added 0.620 grams of phosphonoformate (PFA; Sigma Chemical Co., St. Louis, Mo.) dissolved in 4 ml of dry pyridine (Aldrich, Milwaukee, Wis.) and 1.28 grams of triisopropylbenzenesulfonyl chloride (Aldrich). 40 ml of 1,2 dimyristoylglycerol (10 mg/ml; Avanti Polar Lipids, Pelham, Ala.) was evaporated and redissolved in 10 ml of freshly distilled dry chloroform and added dropwise to the reaction mixture over a period of 30 minutes. The reaction mixture was stirred overnight at room temperature. After 24 hours, the reaction was stopped by the addition of 50 ml of cold 0.1N HCL. The organic phase was separated, dried over P 2 O 5 and evaporated under vacuum. The product was crystallized from chloroform and acetone at 20° C. Thin-layer chromatography of the crystallized product, developed in a basic system of chloroform, methanol, ammonia and water (70/30/1/1 by volume) gave three phosphorus-containing products. Further purification of the required compound was obtained by column chromatography. The product, in 50 ml of chloroform, was loaded onto 40 gms of silica gel G, 70-200 mesh, in a glass column measuring 1×14 inches and sequentially eluted with 200 ml of chloroform, 200 ml of chloroform/methanol (1:5), 200 ml of chloroform/methanol (1:10), and finally 300 ml of chloroform/methanol (1:1). Pure 1,2-dimyristoyl-3-phosphonoformate was recovered in the chloroform/methanol (1:1) fraction.
The purity of the compound was checked using two solvent systems, chloroform, methanol, ammonia, and water (70/30/1/1) and chloroform, methanol, ammonia, and water (65/35/4). The pure compound has an Rf value of 0.54 in the former basic system.
EXAMPLE 2
Synthesis of 1,2 -dipalmitoyl-glycero-3 -phosphonoformate
1 gram of phosphonoformic acid (PFA), trisodium salt (Fluka, Ronkonkoma, N.Y.) was dissolved in 50 ml of distilled water and passed through a 1.4×10 cm column of Dowex 50-X8 (H+), 200-400 mesh. The PFA-H+ was eluted with water, lyophilized overnight, and dried for 48 hours over P 2 O 5 in a vacuum oven at room temperature. To a 50 ml round bottom flask containing 15 ml of dry pyridine (Aldrich, Milwaukee, Wis.) was added 120 mg 1,2-dipalmitoylglycerol (Sigma, St. Louis, Mo.) and 230 mg of PFA-H+ and 527 mg of triisopropylbenzenesulfonyl chloride (TPS, Aldrich Milwaukee, Wis.). The vessel was sealed with a rubber serum stopper and flushed with argon. The reaction was stirred overnight under argon and after 24 hours, 15 ml of chloroform/methanol (1:2) was added and the product was precipitated by the addition of 15 ml of acetone at -20° C. The precipitate was collected and recrystallized from chloroform/acetone to obtain 1,2-dipalmitoylglycero-sn-3-phosphonoformate in yield of about 70%.
The product was taken up in a small volume of chloroform/methanol (1:2) and a small aliquot was applied to silica gel G plates (Uniplate, Analtech) and developed with either chloroform/methanol/conc. ammonia/water (70/30/1/1 by volume) or chloroform/methanol/water (65/35/6). The product was present as a phosphorus-positive spot with Rf values of 0.69 or 0.80, respectively. The purity of the compound was estimated to be 0% by visual inspection after charring with concentrated sulfuric acid.
Further purification was achieved by subjecting a portion of the crude product to preparative thin layer chromatography using 20×20 cm plates of silica gel G (silica thickness 0.5 mm, Analtech) developed with chloroform/methanol/conc. ammonia/water (70/30/1). The compound was located by spraying reference guide spots on the outside edges of the plate with phosphorus spray, taking care to cover the surface of the remainder with a clean glass plate. The spot representing the product was scraped and extracted with chloroforom/methanol/water (1/2/0.8). The chloroform phase was separated by the addition of chloroform/water (1/1) so that the final ratio of solvents is 1/1/0.9 as described by Bligh and Dyer (32). The chloroform phase was separated and the solvent was evaporated in vacuo and the product was dried by lyophilization from cyclohexane. The purified product gave single spots upon thin layer chromatography in the two systems noted above.
EXAMPLE 3
Synthesis of 1-O-octadecyl,2-O-benzyl-sn-glycero-3-oxycarbonylphosphonate (C-batylPFA)
A solution of 1-O-octadecyl, 2-O-benzyl-sn-glycerol (OBG) (Bachem Bioscience, Philadelphia, Pa.) (0.68 g) in tetrahydrofuran was added over a period of 1.5 h to a solution of phosgene (1.5 eg) in triethylamine (5 ml) while maintaining the temperature at 0° C. After the addition was completed the reaction mixture was stirred at 0° C. for 4 h. At the end of which time trimethylphosphite (4 equiv) was added at 0° C. and the reaction mixture was gradually warmed to room temperature overnight. The intermediate bis (methoxy) phosphonate was demethylated and the crude product was purified by chromatography to afford the title compound in 40% yield.
EXAMPLE 4
Synthesis of 1-O-octadecyl, 2-O-benzyl-sn-glycero-3-oxycarbonylphosphoacetic acid (C-batylPAA)
A solution of OBG alcohol (0.68 g) in tetrahydrofuran was added over a period of 1 h to a cooled (-50° to -55° C.) solution of (dichlorophosphinyl) acetyl chloride (0.6 g) and the mixture was stirred for 1 h at -30° C. and gradually warmed to 0° C. The solvent was evaporated and the residue treated with methanol (5 ml) and the mixture allowed to stir at room temperature for 4 h, At the end of which time the solvent was removed under reduced pressure and the solid was filtered and the solid was washed with ice cold methanol to afford the desired product in 50% yield.
EXAMPLE 5
Synthesis of Batyl-Phosphonoformate
A quantity of 0.9 grams of racemic batyl alcohol (1-O-octadecyl-2, 3-glycerol, Sigma Chemical, St. Louis, Mo.), 2.6 grams of triisopropylbenzenesulfonyl chloride (TPS, Aldrich, Milwaukee, Wis.) and 0.16 grams of phosphonoformate, acid form, were reacted in 15 ml of dry pyridine at room temperature under nitrogen. The reaction was monitored at half hour intervals by thin layer chromatography as in Example 3 and was judged to be complete at about 24 hours. The reaction was stopped by the addition of 10 ml of chloroform/methanol/water (1/2/0.8 by volume). The organic (lower) phase was separated by further addition of 2 ml of chloroform and 2 ml of water. The organic phase was removed and evaporated in vacuo and the product was obtained as a white powder. The crude product was dissolved in a small volume of chloroform/methanol (1/1 by volume) and subjected to preparative thin layer chromatography using 0.5 mm layer of silica gel G plates (Analtech, Newark, Del.) developed with chloroform/methanol/concentrated ammonia/water (70/30/1/1). Two PFA-containing spots were visualized, scraped and extracted with chloroform/methanol/water as described earlier in Example 3. The two compounds are referred to as batyl-PFA, top and bottom, respectively.
EXAMPLE 6
Liposome Formation with Phosphatidyl-PFA
To a sterile 2.0 ml sonication vessel were added (in chloroform solution) 7.5 μmoles of dioleoylphosphatidyl choline, 4.5 μmoles of cholesterol, and 3 μmoles of pPFA. The solvent was removed in vacuo, forming a thin film of the lipid mixture. The lipid film was hydrated with 0.3 ml of sterile 10 mM sodium acetate buffer (pH 5.0) containing isotonic dextrose. The mixture was vortexed intermittently for 10 minutes followed by sonication for 90 to 120 min using the cup horn of a Heat Systems Ultrasonics sonicator (Model 431B) at output control setting #9, which treatment resulted in clarification of the sample. This sample was diluted with sterile RPMI tissue culture medium and used in HIV experiments at the contractions indicated.
EXAMPLE 7
Demonstration of Anti-HIV Activity in HT4-6C Cells
HT4-6C cells were grown in RPMI 1640 medium containing 100 U/ml penicillin G, 100 ug/ml streptomycin, 2mM glutamine and 10% fetal bovine serum (Hyclone Laboratories, Logan, Utah). Cells were infected with HIV-1 (LAV-1 strain, L. Montagnier, Paris, France) at a multiplicity of infection sufficient to give 100-300 plaques per well in the no drug controls. Virus was allowed to adsorb at 37° C. for one hour. Liposomes containing the two batyl-PFAs were prepared as described in Example 3. The sonicated preparation was diluted with sterile RPMI buffer and added to the tissue culture wells at the indicated concentrations. After a 3-day incubation at 37° C., the cell monolayers were fixed with 10% formaldehyde and stained with 0.25% crystal violet to visualize plaques. The straining procedure showed individual dense foci of multinucleated giant cells which were counted and used to assess antiretroviral drug activity.
The results of the experiment are shown in FIG. 1. Both preparations of batyl-PFA (top spot and bottom spot) were active in this experiment. The amount of drug require to produce 50% inhibition (I.C. 50 ) can be estimated from the FIGURE as follows: PFA 200 uM; batyl-PFA (top) 110 uM and batyl-PFA (bottom) 180 uM.
EXAMPLE 8
Inhibition of human cytomegalovirus-specific DNA by phosphonoformate and phosphonoacetate lipid prodrugs
Assay Method:
MCR-5 (human lung fibroblast) cells (about 5×10 4 cells per well of a 24 well plate) are plated in DME media with 10% fetal bovine serum one to two days before drug addition. The drugs in dimethylsulfoxide (DMSO) were added to the medium in a final DMSO concentration of 1%. In some cases where the compound was not readily soluble in water or DMSO, liposomes were prepared by sonication containing 10 mole % drug/50 mole % dioleoylphosphatidylcholine/30 mole % cholesterol and 10 mole % dioleoylphosphatidylglycerol. Control liposomes were also prepared without the added drug and incubated at matched lipid concentrations as controls. This media is then aspirated and changed to the drug dilutions made in 2% FBS media and incubated for 24 hours. The drug-containing media is transferred to sterile tubes and a 1:50 dilution (about 20,000 PFUs) of the AD-169 human CMV virus pool is added to the wells at 0.2 ml per well and incubated at 37 C for 60 min. The inoculum is made in DME plus 2% FBS media. After the incubation, the inoculum is aspirated from the wells and the drug dilutions are added back. Cells are incubated for five to six days when they should show a 50-100% cytopathic effect.
At the end of the 5 to 6 day incubation period, the quantification of the CMV DNA present is done by nucleic acid hybridization using a CMV antiviral susceptibility test kit from Diagnostic Hybrids (Athens, Ohio). The media from each well is aspirated completely and two drops of lysis solution (DNA wicking agent) is added to each well. After about five seconds the Hybriwix filter pairs are placed in the wells in numerical order and the solution is absorb onto the filters for about 30 minutes or until the wells are dry. Using forceps, the Hybriwix are removed and placed on a paper towel. Each pair of Hybriwix are cut vertically from the shared bridge of the filter. The Hybriwix are transferred to vials containing I 125 labelled CMV Probe Hybridization Agent (a maximum of 24 Hybriwix per vial) along with three negative control Hybriwix and two positive control Hybriwix per vial.
The vials are placed in a 60° C. gently shaking water bath for a minimum of two hours to overnight. After the hybridization, the solution is aspirated from the vials and collected into a radioactive waste container. 4 ml of distilled water is added to each vial to rinse, capped, swirled and then aspirated. 6 ml of Wash Reagent is added to the Wash Container and the Hybriwix are transferred to this and gently swirled. 114 ml of distilled water that has been pre-heated to 73° C. is added to the Wash Container and this is placed in a 73° C. water bath for 30 minutes. The wash solution is then removed to a radioactive waste container and the Hybriwix are placed in numerical order on a paper towel and then are transferred to gamma counting tubes and counted for two minutes.
Results:
After subtraction of the blank value, results are expressed as the percentage of the no drug control. The concentration dependence of the CMV-DNA production was plotted and the amount of the respective drugs required to reduce the control level by 50% (IC 50 ) was determined and the results are shown in the following table.
EXAMPLE 9
Effect of Phosphonoformate, Phosphonoacetate and Various Lipid Analogs on Production of hcmv-specific DNA by mrc-5 Human Lung Fibroblasts in vitro
______________________________________COMPOUND IC.sub.50______________________________________PFA 55; 60DMG-PFA 178; 112BATYL, BENZYL-PFABATYL, BENZYL 1.7*; <3.16*PAA 31; 26DMG-PAA 19; 5DMP-PAA 49; 40LIPOSOME CONTROL 125*______________________________________ *Liposome formulation. All other data obtained with compounds dissolved directly in 1% DMSO in Dulbecco's modifiedEagle's medium. Abbreviations: PFA, phosphonoformic acid; PAA, phosphonoacetic acid; DMGPFA, 1,2dimyristoyl-sn-glycero-3-phosphonoformic acid; Batyl, benzylPFA, 10-octadecyl, 2benzyl-sn-glycero-3-phosphonoformic acid DMGPAA, 1,2dimyristoyl-sn-glycero-3-phosphonoacetic acid; DMPPAA, 1,2dimyristoyl-sn-glycero-3-phospho-phosphonoacetic acid.
As demonstrated in the preceding table, all lipid analogs of PFA and PAA exhibited activity in reducing the production of human CMV-specific DNA without apparent toxicity as determined by visual inspection of the cell monolayers. Liposome controls reduced CMV-specific DNA production at very high lipid doses but the activity of liposomal batyl, benzyl-PFA was 74 times more active than matched liposome controls without the lipid drug.
It should be apparent from the foregoing that other phosphonoacid compounds and lipid derivatives thereof can be substituted in Examples 3 and 5 to obtain similar results. Other antiviral agents, such as, for example, nucleoside analogue phosphates, may also be contained in the aqueous compartments of the liposome (7). The molar percentage of the lipid antiviral agents, such as, for example, nucleoside analogue phosphates, may also be contained in the aqueous compartments of the liposome (7). The molar percentage of the lipid antiviral agent may vary from 0.1 to 100% of the total lipid mixture. Furthermore, mixtures of antiviral nucleoside lipids may be used in constructing the liposomes for therapy of viral diseases (6). It should be further emphasized that the present invention is not limited to the use of any particular antiviral phosphonoacid; rather, the beneficial results of the present invention flow from the synthesis of the lipid derivatives of these materials and the use of liposomes for formulations for the treatment of viral diseases. Thus, regardless of whether a specific antiviral phosphonoacid is presently known, or whether it becomes known in the future, the methods of forming the presently-contemplated lipid derivatives therefrom are based on established chemical techniques, as will be apparent to those of skill in the art, and their incorporation into liposomes is broadly enabled by the preceding disclosure. It should be emphasized again that the present syntheses are broadly applicable to formation of compounds from essentially al phosphonoacids for use in the practice of the present invention.
Accordingly, the invention may be embodied in other specific forms without departing from it spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive, and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All modifications which come within the meaning and range of the lawful equivalency of the claims are to be embraced with their scope.
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32. Bligh, E. G. and W. J. Dyer Can. J. Biochem., 37:911 (1959). | Lipid-containing prodrugs are provided for treating viral infections due to herpes, influenza, hepatitis B, Epstein-Barr, and varicella zoster viruses, as well as cytomegalovirus and derivatives of antiviral agents. The compounds comprise phosphonoacids having antiviral activity which are linked, either through the phosphate group or carboxyl group of the phosphonoacid, to one of a selected group of lipids. Phosphonoacetic acid and phosphonoformic acid are thus linked to phospholipids, glycerolipids, sphingolipids, glycolipids, or fatty acids. The compounds persist, after intracellular hydrolysis, as the antiviral phosphonoacids. The lipid prodrugs are effective in improving the efficacy of antiviral phosphonoacids by prolonging their antiviral activity following administration. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority of German Patent Application, Serial No. DE 10 2014 007 632.6, filed May 22, 2014, pursuant to 35 U.S.C. 119(a)-(d), the content of which is incorporated herein by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method for controlling an operation of an electric machine, a control system for controlling an operation of an electric machine and an electric machine.
[0003] The following discussion of related art is provided to assist the reader in understanding the advantages of the invention, and is not to be construed as an admission that this related art is prior art to this invention.
[0004] An electric machine can, in addition to a rotor and a stator, have as components for controlling phases a control gear, which can be configured as an external switching regulator, a rectifier, an inverter and/or a converter, which may in turn include as electronic components metal-oxide-semiconductor field-effect-transistors (MOSFETs) or bridges with bipolar transistors having insulated gate electrodes (IGBT). A pulse-width-modulated (PWM) clock of such an electric machine may have a frequency of about 1 kHz to about 20 kHz. The external switching regulator may be operated at a frequency of about 100 kHz to about 1 MHz.
[0005] It would therefore be desirable and advantageous to obviate prior art shortcomings and to provide an improved method, a control system and an electric machine.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention, in a method for controlling an operation of a multi-phase electric machine with a stator and a rotor as components, wherein the stator or the rotor comprises permanent magnets, wherein the rotor or the stator comprises a plurality of conductor bars interconnected by connecting elements of at least one circuit board and disposed within a magnetic field of the permanent magnets and having an internal inductance connected, wherein the connecting elements are arranged outside the magnetic field and have an external inductance, wherein each phase includes at least one of the conductor bars, the electric machine is controlled by regulating for each phase of the multi-phase electric machine at least one electrical quantity, which is dependent on the internal and external inductance of a respective phase, to a desired value.
[0007] According to an advantageous feature of the present invention, the at least one electrical quantity controlled to the intended desired value may be a voltage and/or a current measured for the respective phase.
[0008] According to another advantageous feature of the present invention, an actual instantaneous value of the at least one electrical quantity, i.e. of the voltage and/or the current, of a respective phase may be tapped during operation of the electric machine at a tap disposed between the conductor rods and the connecting elements of the respective phase.
[0009] According to another advantageous feature of the present invention, the desired value of the at least one electrical quantity may be calculated and/or adjusted in dependence of at least one mechanical operating parameters of the electric machine by using an algorithm that is used for the feedforward control of the electric machine. The at least one mechanical operating parameter to be taken into account may be a rotation speed of the electric machine and/or an angular position of the rotor relative to the stator.
[0010] The method can be carried out for an electric machine that is used as an electric motor and/or as a generator.
[0011] According to another aspect of the present invention, a control system is configured to control an operation of an electric machine having as components a stator and a rotor. A first of the two components includes several conductor bars, which are interconnected via connecting elements of at least one circuit board. A second of the two components includes permanent magnets. The conductor bars are arranged within a magnetic field of the permanent magnets and have an internal inductance. The connecting elements are arranged outside the magnetic field and have an external inductance. The electric machine has several phases, with each one of the phases encompassing at least one of the conductor bars. The control system is configured to control for each phase of the electric machine at least one electrical quantity that depends on the internal and external inductance of the respective phase to a desired value.
[0012] Advantageously, the control system for each phase may further include a switching regulator and a control unit which is connected upstream of the switching regulators of all phases. The control unit may be configured to perform an algorithm to be used for feedforward control of the electric machine and to provide the desired value of the at least one electric parameter for the respective phase.
[0013] According to another advantageous feature of the present invention, the control system may include for each phase at least one measurement module configured to measure an actual value of the at least one electrical quantity of the respective phase.
[0014] According to another advantageous feature of the present invention, the control system may include at least one inverter which is disposed between contacts connected to an external voltage source of the electric machine and the phases of the electric motor and is adapted to perform switching control for the electric machine. Furthermore, the control system may include an intermediate circuit capacitor which is arranged between the two contacts. Depending on the definition, the control system may include as further components the phases of the electric machine, wherein each phase has an internal voltage source and an internal resistance associated with the at least one conductor bar of the phase, the internal inductance arranged within a magnetic field of the electric machine, and an external inductance arranged outside the magnetic field of the electric machine. The control system is usually arranged in a housing of the electric machine.
[0015] According to another aspect of the present invention, an electric machine includes as components a stator or a rotor, wherein a first component, usually either the stator or the rotor, includes several conductor bars, which are interconnected via connecting elements of at least one circuit board. A second component, usually the rotor or the stator, includes permanent magnets. The conductor bars are arranged within a magnetic field of the permanent magnets and have an internal inductance. The connecting elements of the at least one printed circuit board are arranged outside the magnetic field and have an external inductance. The electric machine has a number of phases. In one embodiment, each phase has the same number of conductor bars, with each of the phases having at least one of the conductor bars. For controlling an operation of the electric machine, at least one electrical quantity which is dependent on the internal and external inductance of the respective phase for each phase of the electric machine must be controlled to a desired value.
[0016] The electric machine also includes an embodiment of the aforedescribed control system and is to be controlled by an embodiment of the method. The conductor bars of the first component of the electric machine may advantageously be arranged in a soft magnetic material.
[0017] In addition, each phase may include an internal power source, an internal resistance associated with the at least one conductor bar of the respective phase, the internal inductance arranged within a magnetic field of the electric machine, and the external inductance arranged outside the magnetic field of the electric machine.
[0018] The internal and external inductances of the respective phase are to be used for carrying out the switching control during operation of the control system and/or of the electric machine, whereas only the internal inductances of the conductor bars arranged inside the magnetic field are to be used for performing a function of the electric machine.
[0019] Furthermore, the first component of the electric machine may advantageously include iron packets to be produced from iron powder as a soft-magnetic material. These iron packets have grooves in which the conductor rods associated with the phases of the electric machine are arranged. Alternatively, iron laminations made of a soft magnetic material and associated with the conductor bars may be used for the first component. Eddy currents can be reduced and a switching frequency of the electric machine can be increased by using the conductor bars embedded in the iron powder.
[0020] The inverter of the electric machine is at least implicitly used for switching control, which is why the electric machine has for each phase an integrated switching regulator capable of achieving a high switching frequency in the order of 100 kHz to 1 MHz.
[0021] The control system of the electric machine, which has an inverter and the switching regulator, may be integrated in the housing of the electric machine, so that the control system is shielded with regard to electromagnetic compatibility (EMC). The control system may include as electronic switching elements metal-oxide-semiconductor field-effect transistors (MOSFETs) and an intermediate circuit capacitor, for example a ceramic chip capacitor arranged between contacts of the control system to an external voltage source.
[0022] Otherwise conventional coils or windings can thus advantageously be omitted when using the conductor bars for the electric machine. The conductor bars or conductive bars, which replace the windings, are interconnected via connecting elements of the circuit board that may be formed as conductor tracks and/or electronic components. Eddy currents can be minimized by embedding the conductor bars in iron powder as a soft-magnetic composite material (SMC, soft-magnetic composite).
[0023] The equivalent circuit of each phase of the electric machine includes a series circuit with an internal voltage source supplying a voltage with a value that is proportional to the value of the rotational speed of the electric machine, and the internal resistance whose value corresponds to a sum of the values of the resistances of the conductor bars, of the connecting elements, of the MOSFETs and of the equivalent resistance (ESR) of the intermediate circuit capacitor. Furthermore, such a series circuit includes the effective internal inductance of the conductor bars of the respective phase, which are arranged within the magnetic field that causes the Lorentz force of the electric machine. The series circuit further includes the external inductance of the connecting elements, for example conductor tracks, of the phase that are arranged on the at least one printed circuit board outside of the magnetic field. The entire inductance, i.e. the internal and the external inductances, is used in this case for a function of the switching controllers for performing the switching control, whereas only the effective internal inductance is used for the function of the electric machine. In general, the voltage supplied by the external power source must usually be divided by inverters designed as switching regulators and assigned each to a respective phase, wherein the external voltage source is distributed among the internal voltage sources.
[0024] The disclosed control system can perform, inter alia, a function of a switching regulator, with which the voltage of an intermediate circuit of a synchronous converter can be controlled to an actual desired instantaneous value of the voltage of each phase and thus reduced. Accordingly, the current flowing through the respective phase can be regulated to an actually desired value and thus reduced. The control can be performed using conventional switching control methods, pulse methods or so-called chopper methods. A number of the switching regulator hereby corresponds to a number of phases, wherein the switching regulators of the control system are separated from one another. In addition, each switching regulator may include an integrated circuit or a chip.
[0025] An actual value of a voltage and/or an actual value of a current can usually be measured for each phase by using the measurement modules, which are also separated from one another. Furthermore, an output stage and one respective module for controlling the voltage and current may be associated with each phase. In this case, an actual value of the current to be measured can be determined, for example, by way of calculation from one or two measured values of the current flowing through the respective phase. The algorithm to be performed by the control system may also be configured as a feed-forward algorithm. A function of the respective switching controller can be executed quickly, for controlling an AC voltage of a respective phase of the rotating electric machine.
[0026] The electric machine and thus the electric motor and/or generator may have a high switching frequency, so that a current flowing through the conductor bars is no longer constant and thus no longer has a superimposed square-wave pattern. The switching frequency thus does not cause any mechanical excitations. In one embodiment, a currently desired setpoint of the voltage and/or current on the conductor bars is calculated by considering, for example, a field-oriented control of the electric machine. The calculated desired points can be taken into account as default for regulating the voltage and/or the current of the respective phase.
[0027] Optionally, a tap at a physical tapping point disposed between the current and/or voltage between a conductor bar and hence an internal inductance and between a connecting element of the respective circuit board and hence an external inductance can be used. Accordingly, a function for switching control of the electric machine can be separated in the circuitry from an actual function of the electric machine.
[0028] Thus, the inverter and the switching regulator designed, for example, as a step-down switching regulator are combined in the control system of the electric machine, wherein the control system is integrated into the housing of the electric machine. One of the two components of the electric machine, which is designed as a stator or a rotor, has iron packets which are formed from iron powder as a soft magnetic composite material. The conductor bars that replace an otherwise conventional coil of an electric machine favor the intended switching control because a number of otherwise conventional windings of the coils can be reduced by using the conductor bars. It is not necessary to design conductor tracks as connecting elements of the circuit boards commensurate with aspects of switching controls. The conductor bars can also be arranged in iron laminations or transformer sheets to provide a soft magnetic material. The conductor bars are arranged in grooves of the iron packets. The intermediate circuit capacitor disposed between contacts or terminals of the control system to the external voltage source forms hereby a small intermediate circuit. The electric machine can typically be operated in the range of an operating voltage of e.g. 6 volts to 17 volts without sacrificing performance. The rotational speed of the electric machine can be increased by increasing the internal voltage of the electric machine.
[0029] The electric machine can achieve a high switching frequency or clock frequency when carrying out the aforedescribed method. Otherwise conventional wires made of copper and coated with varnish can be eliminated by using the conductor bars. The conductor bars may be made of any electrically conductive material, typically a metal such as iron, aluminum or copper. In addition, the conductor bars have larger diameters than the conventional wires. In each case, a conductor bar is constructed to be either rigid or flexible depending on its thickness and has a polygonal or round cross-sectional shape. Parallel windings and delta connections can be realized by employing the conductor bars.
[0030] In one embodiment, a voltage for supplying this electric machine is increased for increasing an output power of an electric machine, if the machine is operated as an electric motor. An intermediate circuit capacitor of the control system can be implemented as ceramic chip capacitor or a film capacitor, thereby achieving steep flanks with minimal slope moderation in the voltage profile of each phase. In addition, the internal and external inductances of the phases are now used not only for generating a torque of an electric machine described as an electric motor, but are now also used for controlling the operation of electric machine. Thus, both the conductor bars arranged within the soft magnetic material and the connecting elements on the at least one circuit board provided for connecting the conductor bars are used at high clock or switching frequencies for performing a switching regulator function. An internal resistance of the phases of the first component is reduced through use of the conductor bars which have a greater diameter than otherwise used conventional wires.
[0031] The otherwise conventional windings of coils are replaced by the connecting elements on the at least one circuit board that can be produced with thick-film technology. The external inductance of the connecting elements of the at least one phase can also be designed as a so-called planar inductance coil. By using an, for example; ceramic chip capacitor for the small intermediate circuit capacitor, excellent high-frequency characteristics and a low series resistance in comparison with an otherwise conventional electrolytic capacitor with a high capacitance can also be attained. All components of the electric machine and of the control system are typically arranged in a housing of the electric machine and thus shielded from the outside. Furthermore, the electric machine when implemented, for example, as an electric motor, can be operated at a low intermediate circuit voltage. Moreover, the conductor rods are able to conduct high currents compared to otherwise conventional wires. Consequently, the full power of the electric machine can be used across a wide voltage range, in which the electric machine is operated.
[0032] The DC link voltage can be adjusted by controlling the voltage. However, the attainable high currents flow only within the electric machine, but not outside the electric machine. Furthermore, the electric machine can be operated quietly. Moreover, an increased pulse-width-modulated frequency can be achieved by controlled operation of the electric machine according to the method. Usually, high current peaks occur in electric machines, which are designed and/or operated as small, high performance motors, with pulse-width-modulation, which are to be buffered with the provided intermediate circuit capacitor of the electric machine. The capacity of this intermediate circuit capacitor is hereby inversely proportional to this frequency. A ceramic capacitor instead of an electrolytic capacitor is used for the intermediate circuit capacitor. Furthermore, a voltage applied to conductor rods can be reduced without the need to increase the size
BRIEF DESCRIPTION OF THE DRAWING
[0033] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
[0034] FIG. 1 shows a schematic diagram a first embodiment of a control system according to the present invention and a first embodiment of an electric machine according to the present invention;
[0035] FIG. 2 shows a schematic diagram of a second embodiment of a control system according to the present invention;
[0036] FIG. 3 shows a schematic diagram of a detail of a third embodiment of a control system according to the present invention; and
[0037] FIG. 4 shows a schematic diagram of a detail of a fourth embodiment of a control system according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] Throughout all the figures, same or corresponding elements may generally be indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
[0039] Turning now to the drawing, and in particular to FIG. 1 , there is shown a first embodiment of the control system 2 according to the invention of the first embodiment of the inventive electric machine 4 which is here entirely arranged in a housing 6 of the electric machine 4 .
[0040] The control system 2 and hence the electric machine 4 are connected by way of contacts 8 , 9 to an unillustrated external voltage source which supplies a DC voltage Ub. A DC link capacitor 10 as a component of the control system 2 is arranged here between the contact 8 representing the positive pole (+Ub) and the contact 9 representing ground potential. Furthermore, the two contacts 8 , 9 are connected to an inverter 12 of the control system 2 designed as a half-bridge. This inverter 12 includes here six metal-oxide semiconductor field-effect transistors (MOSFETs) representing electronic switching elements 14 . In the illustrated embodiment of the control system 2 and thus of the electric machine 4 , the inverter 12 is integrated in the housing 6 of the electric machine 4 and is, at the same time, designed as a switching regulator of the electric machine 4 , in this case as a step-down voltage regulator.
[0041] The electronic switching elements 14 of the inverter 12 are here connected to three phases 16 , 18 , 20 of the electric machine 4 , wherein each phase 16 , 18 , 20 is shown schematically in FIG. 1 by its equivalent circuit diagram: Each phase 16 , 18 , 20 includes here an internal voltage source 22 , wherein a value of a voltage of each of these voltage sources 22 is proportional to a value of a rotational speed of the electric machine 4 . The rotational speed results from a frequency with which a rotor of the electric machine 4 rotates relative to a stator of the electric machine 4 , which are not shown in FIG. 1 . Each phase 16 , 18 , 20 has also an internal resistance 24 that corresponds to a resistance of conductor bars, which form here the phase windings 16 , 18 , 20 of the stator as the first component of the electric machine 2 . The conductor bars are arranged in grooves of iron packets of the first component of the electric machine 4 , wherein the first component is embodied here as a stator of the electric machine 4 , wherein the iron packets are to be manufactured from iron powder. Alternatively, i.e. according to another embodiment, the first component could also be designed as the rotor of the electric machine 4 . Furthermore, each phase 16 , 18 , 20 includes an internal inductance 26 that corresponds to the inductance of the conductor bars arranged within a magnetic field of the electric machine 4 , and an external inductance 28 arranged outside the magnetic field and corresponding to the inductances of the connecting elements of the at least one circuit board.
[0042] FIG. 2 shows details of the second embodiment of the control system 40 , which is designed to control a second embodiment of an electric machine. The electric machine includes here three phases, wherein an internal voltage source 42 of each phase is shown here. This produces during operation of the electric machine a first voltage U for a first phase, a second voltage V for a second phase, and a third voltage W for a third phase. In addition, FIG. 2 shows an internal inductance 44 resulting at least for one conductor bar of a phase. An external inductance 46 of each respective phase of the electric machine is produced by connecting elements disposed on at least one circuit board of the electric machine, wherein the conductor bars are electrically interconnected by these electrical connecting elements.
[0043] FIG. 2 shows as components of the control system 40 a control unit 48 and one of a total of three switching regulators 50 , wherein one respective switching regulator 50 is associated with a respective one of the phases. Furthermore, a DC link capacitor 52 , two electronic switching elements 54 as well as a measuring module 56 are associated with each one of the three switching regulators 50 , wherein the measuring module 56 is here configured to measure a current flowing through at least one conductor bar of a respective phase. FIG. 2 also shows a tap 58 at which a voltage between the internal inductance 44 and the external inductance 46 of the respective phase can be tapped. An actual value of the voltage measured at this tap 58 is transmitted from the tap 58 to the respective switching regulator 50 .
[0044] Furthermore, an actual angle of a rotor of the electric machine relative to a stator of the electric machine and an actual rotational speed of the electric machine are determined as mechanical operating parameters of the electric machine and transmitted to the control unit 48 starting from a node between the voltage sources 42 . Desired values for the voltages U, V, W of the three phases of the electric machine can be determined with the control unit 48 and transmitted to a respective switching regulator 50 by taking into account the actual values of the mechanical operating parameters and of the inductances 44 , 46 as well as by using an algorithm.
[0045] The switching regulator 50 explicitly shown in FIG. 2 is here associated with the first phase, for the voltage U of which the determined desired value is to be adjusted. Likewise, a desired value of a voltage V for the second phase is to be transmitted by the control unit 48 to a switching regulator 50 associated with the second phase, and a desired value of a voltage W for a third phase is to be transmitted by the control unit 48 to a third switching regulator 50 associated with the third phase.
[0046] The detail of third embodiment of the control system 70 illustrated in FIG. 3 includes here an intermediate circuit capacitor 72 , which is arranged here between a contact 74 formed as positive pole and a contact 76 formed as a negative pole of an external voltage source. Furthermore, electronic switching elements 78 , which are each connected downstream of a phase of a plurality of phases of an electric machine to be controlled by the control system 70 , are connected downstream of the intermediate circuit capacitor 72 and the two contacts 74 , 76 . In addition, FIG. 3 shows an external inductance 80 of the electric machine and an internal capacitance 82 and an internal resistance 84 of the respective phase of the electric machine. Each phase of the electric machine includes here conductor bars which are interconnected by way of at least one circuit board, in the present example connecting elements arranged on the circuit board. The illustrated external inductance 80 corresponds to the inductance of the connecting elements of the at least one board. The internal capacitance 82 and the internal resistance 84 correspond to the capacitance and the resistance of the conductor bars of the respective phase. The components shown in FIG. 3 are here also designed as components of a synchronous converter of the control system 70 .
[0047] The detail of the fourth embodiment of the control system 86 schematically illustrated in FIG. 4 also includes an intermediate circuit resistor 72 and electronic switching elements 78 connected upstream by a respective phase of an electric machine to be controlled by this control system 86 . The electric machine includes here also several, namely three phases. Each phase includes conductor bars which are connected upstream of at least one circuit board of the electric machine by way of connecting elements. In detail, FIG. 4 also shows three voltage sources 88 , with one of these voltage sources 88 being assigned to a respective phase. FIG. 4 also shows an internal resistance 90 of the conductor bars of the respective phase, and an internal inductance of the conductor bars 92 of this phase. FIG. 4 also shows an external inductance 94 of the connecting elements of the at least one circuit board of the respective phase. A tap 96 is arranged between the internal inductance 92 and the external inductance 94 , wherein an actual value of a current flowing through the respective phase and/or an actual value of a voltage of the respective phase can be tapped.
[0048] While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit and scope of the present invention. The embodiments were chosen and described in order to explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0049] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein: | A method for controlling an operation of a multi-phase electric machine with a stator and a rotor is disclosed. The stator or the rotor includes permanent magnets, whereas the rotor or the stator includes a plurality of conductor bars interconnected by connecting elements of at least one circuit board and disposed within a magnetic field of the permanent magnets and having an internal inductance connected. The connecting elements are arranged outside the magnetic field and have an external inductance. Each phase includes at least one of the conductor bars. The multi-phase electric machine is controlled by regulating for each phase of the multi-phase electric machine at least one electrical quantity, which is dependent on the internal and external inductance of a respective phase, to a desired value. | 7 |
The invention relates to a motor vehicle door hinge including a first hinge part which can optionally be fixed on one of the door assembly parts—door and door pillar, a second hinge part which can be fixed on the other of the two door assembly parts and which is arranged in a manner such that it can pivot with respect to the first hinge part about a hinge axis, a shaft section which connects a gudgeon of the first hinge part and a gudgeon of the second hinge part to each other in an articulated manner, and a door arrester unit which produces a retaining force which is to be overcome by tensioning a spring unit, wherein preferred retaining angles of the door arrester unit are defined by latching markings in a latching disk, in which at least one immovable cam which protrudes from a cam disk can engage.
BACKGROUND
EP-A-0 931 897 describes a motor vehicle door hinge, in which a first and a second hinge part in each case in the form of a single section and designed as a profiled and forged hinge part are connected to each other in a pivoting articulated manner via a common hinge pin. The hinge can be unhinged by the hinge pin being designed in a manner such that it can be taken out of that hinge part in which the hinge pin is held in a rotationally fixed manner, by releasing a nut. The hinge pin is to be designed to be of an appropriate length. The hinge furthermore comprises an arrester unit which comprises a cam disk, which is secured in a rotationally fixed manner on the outwardly directed end joint of that hinge part through which the hinge pin passes in a pivotable manner by means of a sleeve, and a corrugated disk, which is coupled to the hinge pin via a driver profile and is prestressed in the direction of the cam disk by a disk spring assembly, as a result of which the arresting or braking movement is provided by the relative movement of the corrugated disk and cam disk. The first problem with the known motor vehicle door hinge is the complicated subdivision of the arrester unit into cam disk and corrugated disk, this having to be provided, however, in order to put the disk springs favorably to use. The configuration as a separable motor vehicle door hinge means that the single-section hinge parts, the gudgeons of which absorb the entire load, have to be designed as forged parts or complicated profiles, with the production costs being considerable as a result. In particular, the manufacturing of a hinge pin with a multiplicity of profiles for securing it on the one hinge half, for screwing on the hinge pin tightly and for driving the corrugated disk is complicated and cost-intensive, in particular when taking the tolerances into consideration. Finally, the driving of the corrugated disk via the hinge pin, which is designed with a square bar profile, causes an unfavorable tendency for jamming to occur, as a result of which the axial movability of the corrugated disk is restricted and, in particular in the case of latching movements, there is an unfavorable surface pressure in the narrow region of the corrugated disk. Furthermore—as in other hinges known from practice—a rolled bushing is provided as the sliding bushing, the collar of which is produced by crimping and, as is generally known, has a triangular interruption and therefore a reduced contact area, the crimping causing undesired fluctuations in the thickness in the collar region which also has a disadvantageous effect on the running characteristics of the hinge, such as reduced adhesion of the sliding layer, and so, in series manufacturing, undesirably high tolerances and running fluctuations have to be accepted, and, moreover, the sealing against penetration of impurities from the surroundings is not entirely ensured.
EP-A-0 897 044 describes two types of door hinges comprising two hinge parts which are connected to each other in an articulated manner by a shaft section and are designed with an arresting device, which is provided outside the hinge parts and is provided coaxially on that part of the hinge pin which protrudes over the hinge parts. In a first embodiment, a cage is held by rolling bodies, which are designed as tapered rollers, on a housing which is connected to a hinge part while a latching disk, which is acted upon by a helical spring supported against the housing and has latching markings for the rolling bodies, is carried along by the shaft section and is rotated relative to the cage. In a second embodiment, a latching disk with latching markings for rolling bodies is secured on a housing connected to a hinge part or on a housing connected with the hinge part, and a cage with rolling bodies designed as tapered rollers or balls is carried along by the shaft section and rotated relative to the latching disk, in which case a pressure-distributing ring is acted upon by a spring, which is supported against a supporting plate, in the direction of the rolling bodies in order to press the rolling bodies into the latching markings, the cage and the pressure-distributing ring both having to be moved for this purpose up and down counter to the restoring force of the spring. Both embodiments require a complicated mounting of the multiplicity of mutually rotatable disks by means of ball bearings or the like which are placed in between, and furthermore require the provision of moveable rolling bodies, the rolling resistance of which slackens off severely over time, which means that the characteristic of the arrester unit differs significantly from the original setting. At the same time, this and also the diameters of the rolling bodies cause the arrester unit to have an undesirably large overall height. The parts to be manufactured are numerous and some of them have geometries which can be obtained only in a complicated manner, which means that production and installation are complicated.
EP-A-0 382 170 describes a motor vehicle door hinge, in which the two hinge parts each have two gudgeons which are connected to each other in an articulated manner via the same hinge pin, the hinge pin being secured in a rotationally fixed manner in the two gudgeons of the one hinge part and being mounted in a pivotable manner in the two gudgeons of the other hinge part. This motor vehicle door hinge does not permit any preferred securing at certain opening angles of the motor vehicle door; furthermore, the known hinge requires wings which are deposited outside the base of the parts having the gudgeons and in which the apertures for fixing it onto the door assembly parts are provided.
U.S. Pat. No. 4,332,055 describes a furniture hinge with two U-shaped hinge parts which each have a base with apertures for fixing said hinge onto a wall element and from which in each case two limbs protrude at right angles, the hinge parts being connected to each other via gudgeons, which are provided in the limbs, in a paired manner in each case by means of rivets, the furniture hinge furthermore securing a spring wire on the one hinge part and it being possible for its free ends to interact with projections provided on the other hinge part in order to hold a completely opened or completely closed position of the wall element. Among the disadvantages of the known furniture hinge is that the hinge axis is at the same large distance from both of the hinge parts. The use of a hinge of this type is not suitable in the case of a heavy motor vehicle door.
DE-A-2 342 945 describes a hinge, in which two hinge parts are connected to each other in an articulated manner by a hinge pin, two plate bodies outside the hinge parts enclosing a spring which pushes the two plate bodies apart, the hinge pin passing rotatably through the spring and the two plate bodies, the two plate bodies having a recess by which they are secured on a shaft, which is attached to the one hinge part, in such a manner that the plate bodies are carried along by this hinge part, the hinge pin furthermore having studs which engage around the plate bodies from the outside, protrude over the diameter of the hinge pin and interact with latching markings, which are formed in those sides of the plate bodies which face the studs, and are intended for the engagement of the studs, in such a manner that, when a stud is engaged in an appropriate position, corresponding, for example, to a holding position of a door, the spring is relaxed and, when the position is left, the spring is tensioned. Since the studs are placed fixedly in the hinge pin, the plate bodies have to be designed in a manner such that they can be displaced relative to the hinge pin and therefore also relative to the shaft, which is used to carry along the plate bodies, which means that there is a risk of jamming and, furthermore, of noises being produced. The structural space required by the known device is undesirably large in terms of height and width and furthermore lacks protection against the penetration of impurities. For the assembly, a separate installation aid is required because the studs can only be driven through the hinge pin at the end.
DE-A-198 31 085 describes a hinge with two hinge parts which are designed in each case as an outer and an inner bracket, in which a hinge pin passes through the two limbs of the two brackets, in which, in order to realize an arresting device, a spring which is supported against the one limb of the outer bracket acts upon the sleeve arranged on the hinge pin, and in which, furthermore, two divided tube sections are provided around the hinge pin, said sections being secured in each case by their mutually remote ends on one of the brackets and their mutually facing end sides having an intermeshing cam-type profile comprising depressions and projections running along a closed ring, the spring forcing the two tube sections in each case into positions in which all of the depressions and projections of the one tube section intermesh with all of the projections and depressions of the other tube section. One of the disadvantages of this hinge is the complicated production and installation, with the arresting device also resulting in the hinge axis having an unfavorable and thick configuration, and therefore needing to be at a large distance from the respective base of the brackets. Furthermore, it is inevitable that the one bracket with the associated tube section be inevitably displaced axially relative to the hinge pin during the opening movement, this not being acceptable for a motor vehicle hinge.
EP-A-0 848 128 describes a hinge comprising two hinge parts which are connected to each other in an articulated manner by a shaft section and are designed with an arresting device which is provided outside the hinge parts and is provided coaxially on that part of the hinge pin which protrudes over the hinge parts. In this case, a latching disk with latching markings for rolling bodies is secured on a housing, which is connected to a hinge part, and is decoupled from the hinge pin via a needle bearing. A complicated bearing unit for rolling bodies designed as tapered rollers is carried along in the rotational movement by a supporting plate, which is connected to the shaft section, via intermeshing projections of the supporting plate and recesses of the bearing unit, in which case a sleeve supports the bearing unit for an axial movement relative to the shaft section, which is cylindrical there. For this purpose, the bottom of the recesses in the bearing unit is at a distance from the projections of the supporting plate, which distance restricts the axial displaceability of the bearing plate. One end of a spring unit is supported against the supporting plate, the spring unit using its other end to prestress a shoulder of the bearing unit, the shoulder supporting the rolling bodies via a rigid connection. The carrying-along of the bearing unit via the supporting plate is problematic because there is a risk of it becoming jammed. The arrester unit furthermore requires a complicated mounting of the moveable rolling bodies, the rolling resistance of which severely slackens off over time, as a result of which the characteristic of the arrester unit significantly differs from the original setting. At the same time, the complicated design of the bearing unit and also the diameters of the rolling bodies result in the arrester unit having an undesirably large overall height. The parts which are to be manufactured are numerous and some of them have geometries which can only be obtained in a complicated manner, which means that production and installation are complicated.
DE-A-199 01 263 describes a hinge, in which two hinge parts are connected to each other in an articulated manner by a hinge pin, an arrester unit which is provided outside the hinge parts comprising a disk spring assembly which is arranged concentrically around the hinge pin on an extension thereof and has revolving balls and disks which are designed with recesses in order to carry along said balls, the vertical movement taking place along the hinge pin via longitudinal grooves formed in the latter and being blocked by brake plates.
DE-A-199 36 280 describes a hinge with two hinge parts and a hinge pin connecting said hinge parts, in which an arrester unit which is prestressed by a spring is provided outside the hinge pin and, by means of rollers which are provided at both ends of the arrester unit, presses against running surfaces, which are formed with profiled structures and are provided in addition to the hinge parts.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a motor vehicle door hinge that can be produced and fitted cost-effectively.
The present invention provides a motor vehicle door hinge including a first hinge part which can optionally be fixed on one of the door assembly parts—door and door pillar, a second hinge part which can be fixed on the other of the two door assembly parts and which is arranged in a manner such that it can pivot with respect to the first hinge part about a hinge axis, a shaft section which connects a gudgeon of the first hinge part and a gudgeon of the second hinge part to each other in an articulated manner, and a door arrester unit which produces a retaining force which is to be overcome by tensioning a spring unit, wherein preferred retaining angles of the door arrester unit are defined by latching markings in a latching disk, in which at least one immovable cam which protrudes from a cam disk can engage. The first hinge part and the second hinge part are in each case designed as U-shaped sheet-metal shaped parts with a base and with a first limb and a second limb arranged in each case at right angles to the base, the limbs each having gudgeons, that the first limb of the first hinge part is connected in an articulated manner to the first limb of the second hinge part, that the second limb of the first hinge part is connected via the shaft section to the second limb of the second hinge part, and that the shaft section is secured by the one disk of the cam disk and the latching disk which are acted upon by the spring unit, against mutual rotation while the other disk of the cam disk and latching disk is connected nonrotatably to that hinge part in which the shaft section is rotatable.
The motor vehicle door hinge according to the invention provides, using simple means and without a complicated unhinging function, a favorable latching mechanism which can be produced at reasonable cost and the weight of which is, moreover, low. The hinge parts are designed as sheet-metal parts and can be produced cost-effectively using simple machining methods. The advantageous configuration as U-shaped sheet-metal shaped parts enables the load of the door to be distributed to the articulation points of the gudgeons, of which there are two in each case, apertures for fixing the hinge parts being formed in an advantageously space-saving manner in the base of the U-shaped sheet-metal shaped part, so that an axial projecting length which disadvantageously increases the overall height of the structural space is not required for fixing them on. Furthermore, the advantageous configuration as U-shaped sheet-metal shaped parts advantageously enables a nesting, i.e. an intermeshing, of the two hinge parts and also an overlapping, i.e. in which the limbs and the end joints are arranged in an alternating manner, to be provided, as a result of which the overall height of the motor vehicle door hinge turns out to be similarly compact.
The configuration of the hinge parts as sheet-metal shaped parts makes it possible at the same time for a stop to be formed in a simple manner by production of a bend in the extension of one of the limbs of one of the two hinge parts, said stop restricting the maximum door opening angle. The arrester unit is preferably attached on one side of one of the limbs of one of the two hinge parts, which side faces away from the other hinge part. This enables an arrester unit to be provided which is arranged outside the pivoting region of the other hinge part and is therefore not in the way of its pivoting movement. As an alternative, it is advantageously possible, in order to reduce the overall height, to arrange the arrester unit in a region between the two limbs lying opposite the base of one of the two hinge parts, as a result of which the overall height is reduced overall and the clearance can be used advantageously.
The cam disk has at least one, preferably three or four, immovable cams which protrude in the direction of the latching disk and preferably run radially with respect to the hinge axis, with respect to which the two disks mentioned are arranged perpendicularly. The latching disk has, for each cam, at least one latching recess, but preferably two or three latching recesses per cam, it being possible for one latching recess to be assigned, for example, to a maximum opening position of the associated motor vehicle door and for a further latching recess to be assigned to the closed position of the associated motor vehicle door while further intermediate positions define preferred, partially opened positions of the associated motor vehicle door. It is possible to couple either the cam disk or the latching disk to the shaft section and to pivot it relative to the other disk in each case, which is coupled to a hinge part through which the hinge pin passes with running play. In this case, in the practical implementation, the hinge part will, as a rule, be pivoted relative to the stationary shaft section.
The spring unit of the arrester unit is preferably designed as a helical compression spring which is supported on one side against the disk which is to be carried along by the shaft section and its end which faces away from said disk is supported on a pressure disk which forms an abutment and is arranged preferably in a rotationally fixed manner on the shaft section.
The disk which is carried along by the shaft section preferably comprises an axial, hollow-shaft-like extension which is directed toward the pressure disk and away from the limb and the outer circumference of which forms an insert, which partially passes through the compression spring and centers the latter, and the hollow inner circumference of which is designed for axial, relatively movable, mutual guidance together with the shaft section. In this case, the guidance can take place by means of a polyhedron or axial guide grooves. The hollow shaft is preferably secured against rotation, but can be displaced axially, so that an upward and downward movement of the cam disk is made possible, with corresponding pretensioning of the compression spring, in order to carry out movements when reaching or leaving latching arresting positions.
The disk which is carried along by the shaft section is preferably arranged on the shaft section in a manner such that it can be displaced axially with respect to the shaft section via a guide profile which prevents mutual rotation and preferably engages in the disk and shaft section in an alternating manner, it thereby being assured that said disk has the same orientation as the shaft section. In the case of a shaft section which is carried along by pivoting of the hinge parts, the cam disk is then carried along in accordance with the angled position of the shaft section. In the preferred alternative, the hinge part, which is arranged in a pivoting articulated manner on the shaft section, is rotated away under the disk which is carried along by the shaft section, said disk being moved up along the guide profile counter to the pretensioning of the spring unit and down again owing to the loading of the latter when a latching position in the latching disk has pivoted away under the cam protruding frontally out of the cam disk. The force which is required for the axial displacement and overcomes the pretensioning of the spring constitutes a braking force which is opposed to the pivoting movement of the hinge and has to be overcome during the unlatching operation.
The guide profile of the shaft section is preferably designed as a polygon, it also being possible for the polygon to have rounded corners and vertices. One particularly preferred configuration is that of a polygon configured with a plurality of flanks formed perpendicular with respect to the direction of stress, for example a peripheral tooth profile or rectangular profile which forms vertical guide surfaces or flanks which run essentially radially from the hinge axis or parallel to a radial, an engagement region for a correspondingly protruding profiled design of the disk, for example the cam disk, which is carried along by the shaft being provided between two mutually facing guide surfaces. A correspondingly rounded configuration as a TORX or as an involute profile is likewise possible. This defines a plurality of, preferably six, engagement surfaces which run approximately perpendicular with respect to the tangential introduction of force during rotational actuation, and which, in the case of a rotatable shaft section, ensure the essentially tangential introduction of force on the disk carried along by the shaft section and thereby permit a favorable transfer of force and carrying-along of the disk. However, a rotational movement is preferably not transferred by the shaft section to the disk carried along by the shaft section, and so the disk with the rotational movement, for example the latching disk, and the disk with the axial movement, for example the cam disk, are decoupled and jamming due to a superimposing movement is advantageously avoided.
The predominant part or the entire inner circumference of the hollow-shaft-like extension of the disk which is carried along by the shaft section is preferably formed with a guide profile which is complementary to the guide profile of the shaft section, as a result of which a torsional securing means or a radial carrying-along means is defined which permits axial displacement, but in the unlatching from latching positions does not involve any radial movements or stresses, with the result that no superfluous braking occurs in the axial direction during the radial latching into place or unlatching.
The guide profile of the shaft section is expediently formed over a larger area than the height of the hollow shaft section which is formed with a complementary guide profile and is provided by the disk carried along by the shaft section, which permits an axial displacement at least in the circumference of the protruding cam of the cam disk with guidance reaching at the same time over the entire height of the hollow shaft section.
The disk which is carried along by the shaft section and has a corresponding profiled structure in its hollow shaft section can be formed as a cold extruded part. Another favorable configuration provides a sintered part with which the geometry which is matched to the form-fitting carrying-along or retaining and simultaneous axial guidance of this disk can be produced cost-effectively and at the same time has a low weight and, moreover, defines a material pairing which is low in noise both with respect to the sliding with the other disk and along the hinge pin when these are metal parts. Furthermore, the ends of the spring unit which engages directly on the surface which faces away from the other disk do not need to be protected separately. Particularly if the disk produced as a sintered part is the latching disk, the forming by powder-metallic means enables the difficult configuration of the surface with the latching markings and the torsional securing to be provided on the inside in the hollow shaft section, which surface interacts with the cams, to be realized in one working step, it being possible for the latching recesses to have slightly different widths, for example in order to achieve the effect of a closing aid, without an additional outlay on labor.
The arrester unit expediently comprises a cup-shaped casing which is preferably of water-tight design and is sealed in the impact region with the outer end joint surface by means of an O-ring. Since the compression spring is supported against the pressure disk, the casing can consist of cost-effective materials which are simple to manufacture; in particular, a light-weight sheet-metal material which is too thin for an abutment can be used for this purpose and can have, for example, a water-tight layer vulcanized onto it. This advantageously makes it possible for the casing to be detached without the arrester unit becoming incapable of functioning, and enables, for example, a subsequent lubrication or the like to be provided.
According to a first alternative, a latching disk is arranged in a rotationally fixed manner on the outwardly directed end joint surface of that limb of the hinge part in whose gudgeon the shaft section is held pivotably with a running fit, the latching disk having at least one latching depression in which a latching cam of the cam disk, which cam faces the latching depression, can engage on the relaxation of the spring unit. According to a second alternative, the latching disk and cam disk are interchanged. This makes it advantageously possible to adapt the latching positions defined by the latching depressions in the latching disk as a function of the model selected in each case just by exchange of the latching disk without the hinge part, which can be produced cost-effectively, having to be changed in this case. This advantageously makes possible dimensional degression effects, and, in particular, also the use of sheet-metal shaped parts, the surfaces of which do not require any hardening.
The gudgeons in the hinge part to be fixed on the door pillar are preferably provided in an end of the limbs of its U-shaped sheet-metal shaped part that is remote from the base of said hinge part while the gudgeons on the hinge part to be fixed onto the motor vehicle door are provided in a region of the limbs of the corresponding sheet-metal shaped part that is adjacent to the base of said hinge part. This advantageously enables the hinge axis of the motor vehicle door to be displaced outward in the direction of the door, as a result of which pleasant operating comfort and favorable pivoting paths are ensured.
According to a first preferred improvement of the motor vehicle door hinge according to the invention, the first limb of the first hinge part is connected to the first limb of the second hinge part via a hinge pin stub which is provided outside the shaft section which connects the respective second limbs of the first and of the second hinge parts to each other. Nevertheless, the axes of the shaft section and of the hinge pin stub, which define the pivot axis of the motor vehicle door hinge, are aligned coaxially, thus making possible a smooth-running pivoting movement of the motor vehicle door. The hinge pin stub is preferably designed as a rivet which is held rotatably either directly in the gudgeon of one of the two hinge parts or via a bushing, it being possible for the axial securing of the rivet to be achieved by deformation of its end region. The securing of the two hinge halves via a rivet is cost-effective and at the same time permanent, so that there is no risk of a connecting means gradually becoming loosened.
According to a second preferred improvement of the motor vehicle door hinge according to the invention, the shaft section in the form of a continuous hinge pin passes through all four limbs of the two hinge parts, as a result of which the axis of the shaft section simultaneously defines the pivot axis of the motor vehicle door hinge. For this purpose, the shaft section can be riveted, for axial securing purposes, at its end which faces away from the arrester unit. The shaft section preferably has a stepped cross section which has different, but circular diameters in the regions in which it passes through the gudgeons, so that a favorable, simple process for putting together the arrester unit with the two hinge parts involves the preassembled unit of arrester unit and hinge pin being guided by its end which faces away from the arrester unit through all four gudgeons, it being possible for the graduations in the shaft section to simultaneously form a collar between two mutually facing end joint surfaces, and the end is subsequently riveted. At the same time as providing the nonreleasable connection of the motor vehicle door hinge, this advantageously applies the required pretensioning to the spring unit, and a complicated assembly of the spring unit is not required. The pivoting articulated connections of the two limbs of the two hinge parts are preferably of nonreleasable design in such a manner that unintentional unhinging or losing of parts of the hinge does not occur during assembly.
Further advantages and features of the invention will emerge from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in greater detail below using preferred exemplary embodiments and with reference to the attached drawings.
FIG. 1 shows a partially cutaway side view of a first embodiment of a motor vehicle door hinge according to the invention.
FIG. 2 shows a perspective view of the motor vehicle door hinge from FIG. 1 .
FIG. 3 shows a partially cutaway side view of a second embodiment of a motor vehicle door hinge according to the invention.
FIG. 4 shows a plan view of the motor vehicle door hinge from FIG. 3 .
FIG. 5 shows a schematic side view of the shaft section of the motor vehicle door hinge from FIGS. 1 and 2 .
FIG. 6 shows a cross section through the shaft section along the line VI—VI from FIG. 5 .
FIG. 7 shows an enlarged, partially cutaway view of the motor vehicle door hinge from FIG. 1 together with details of a plastic bushing.
DETAILED DESCRIPTION
The motor vehicle door hinge 1 shown in FIGS. 1 and 2 comprises a first hinge part 2 , which can be fastened to a body part, such as a door pillar, and a second hinge part 3 , which can be fastened to a motor vehicle door. The first hinge part 2 and the second hinge part 3 are connected to each other in a pivoting articulated manner about a pivot axis 5 via a shaft section 4 , which defines a hinge pin.
The first hinge part 2 is designed as a U-shaped sheet-metal folded part and has a base 6 in which two apertures 7 are formed for fixing it to a door pillar, from which base 6 there protrude at right angles an upper limb 8 and a lower limb 9 in which respective round holes 10 and 11 are provided as gudgeons, through which the shaft section 4 passes. Those ends of the two upper and lower limbs 8 , 9 , in which the round holes 10 , 11 are provided, protrude in a manner such that they project for a relatively long distance, to an extent which amounts to more than half of the distance of the two limbs 8 , 9 from each other. Between the protruding regions of the upper and lower limbs 8 , 9 there furthermore protrudes an edge 12 which protrudes at an angle with respect to the base and results in a favorable stiffening of this region.
The second hinge part 3 is likewise a sheet-metal shaped part which is formed in a U-shape and has a base 13 which is intended for fastening it to a motor vehicle door by means of an aperture 14 , an upper limb 15 and a lower limb 16 of the U-shaped hinge part 3 being formed essentially at right angles to the base 13 and having, in a mutually opposite position, respective round holes 17 and 18 which are intended for the passage of the shaft section 4 . At its free end which faces away from the base 13 , the upper limb 15 of the second hinge part 3 has a bevel 19 which is directed toward the lower limb 16 , essentially at a right angle, and which at the maximum opening angle of the motor vehicle door strikes against a stop 20 in the end side of the upper limb 8 of the first hinge part 2 and thereby defines a maximum opening angle of the motor vehicle door hinge 1 or of the motor vehicle door fastened thereto.
It can be seen that the limbs 8 , 9 of the first hinge part 2 and the limbs 15 , 16 of the second hinge part 3 are designed such that they overlap one another, i.e. in the region of the pivoting joints, the upper limb 15 or the lower limb 16 of the second hinge part 3 is arranged in each case on the same side of the respectively upper limb 8 or lower limb 9 of the first hinge part 2 , which results in a compact design of the motor vehicle door hinge 1 .
The arrangement of the gudgeons 10 , 11 of the first hinge part 2 in a position which is at a large distance from the base 6 , and the arrangement of the gudgeons 17 , 18 of the second hinge part 3 in a position near to the base 13 thereof has the advantageous effect that the pivot axis 5 of the motor vehicle door which is to be fixed to the second hinge part 3 runs in the vicinity of said door, thereby resulting in favorable operating comfort.
The configuration of the two hinge parts 2 , 3 as two-section, U-shaped sheet-metal shaped parts enables the load of the parts which are attached to the motor vehicle door hinge 1 to be distributed favorably to two articulation points, as a result of which the use of sheet-metal shaped parts is economically possible wherever, if single-section hinge parts are used, forged parts would be required because of the torsional and torque loading. In the case of the two-section hinge parts 2 , 3 , the levers between the stop points, which are defined by the apertures 7 and 14 , and the two gudgeons 10 , 11 or 17 , 18 in each case are small, so that torques have scarcely any adverse effect on the rotational movement and permit a smooth-running opening and closing of a motor vehicle door.
The shaft section 4 is secured in the upper limb 8 of the first hinge part 2 via a knurl 21 and is guided pivotably through a bushing 22 in the lower limb 16 of the second hinge part 3 and a further bushing 23 in the hole 17 in the upper limb 15 of the second hinge part 3 . A collar 24 of the shaft section 4 protrudes circumferentially between the limbs 8 of the first hinge part 2 and 15 of the second hinge part 3 .
An arrester unit, which is referred to in its entirety by 25 , is provided on that side of the upper limb 15 of the second hinge part 3 that faces away from the collar 24 , the arrester unit defining, as a function of latching positions which are provided, preferred opening angles of the motor vehicle door hinge 1 or of the motor vehicle door as holding positions. The arrester unit 25 comprises a cam disk 26 which is configured with a central hole through which the shaft section 4 passes and which is secured against rotation via an at least partially extensive connection to the shaft section 4 , but permits an axial movement. The cam disk 26 has a flange-like end side 27 , from which a cam 28 protrudes frontally, and a hollow-shaft-like section 29 which bears against the shaft section 4 , faces away from the end side 27 and the outer circumference of which delimits an annular space from the inside. The end side 27 of the cam disk 26 faces a latching disk 30 , which is likewise designed with a central hole in order to allow the shaft section 4 to pass through, but is not connected to the shaft section 4 but rather is secured in a rotationally fixed manner on the upper limb 15 of the second hinge part 3 . This means that, owing to a relative pivoting of the first hinge part 2 relative to the second hinge part 3 , the rotational movement of the shaft section 4 simultaneously involves a relative rotation of the cam disk 26 and latching disk 30 .
At the outer end of the shaft section 4 , a pressure disk 31 is arranged on said shaft section and forms an abutment for a compression spring 32 , which is of helical design and is supported by its other end on that surface of the cam disk 26 which faces away from the end side 27 and pretensions said cam disk in the direction of the latching disk 30 . The pretensioning on account of the compression spring 32 means that, during the pivoting movement of the second hinge part 3 relative to the first hinge part 2 , a braking occurs, if the cam 28 leaves a latching position in the latching disk 30 , and the spring is relaxed and therefore a preferred, stable holding position is arrived at at an angled position in which the compression spring is relaxed again. This simple mechanism permits the door to be secured in preferred opening positions, it being possible for the preferred opening positions to be changed with little outlay by exchange of the latching disk or of the cam disk.
The arrester unit 25 furthermore comprises a housing 33 , which is a thin-walled, cup-shaped sheet-metal part which engages over the cam disk 26 , the compression spring 32 and the pressure disk 31 and also over the end of the shaft section 4 and is advantageously secured on an offset of the latching disk 30 , and the impact region of which is secured by an O-ring 34 . The housing 33 therefore rotates together with the latching disk 30 and the second hinge part 3 .
The upper region of the motor vehicle door hinge 1 can be seen more precisely in detail in partially cutaway form in FIG. 7 . It can be seen, in particular, that the bushing 23 completely covers the contact surface of the latching disk 30 with the shaft section 4 and, moreover, has an outwardly angled collar section 23 a which isolates an end side of an insert 30 a of the latching disk 30 from the collar 24 , the insert 30 a being pressed into the hole 17 in the upper limb 15 of the second hinge part 3 or being inserted in such a manner that the latching disk 30 is connected in a rotationally fixed manner to the second hinge part 3 . The first hinge part is, as explained, connected in a rotationally fixed manner to the shaft section 4 via the knurl 21 , so that the bushing 23 obtains particular significance—with respect to the mounting, which is low in bearing movements, and the freedom of play of that region of the shaft section 4 which passes through the bushing 23 . In the region of its free end, the collar section 23 a is set outward again through approximately 60°, with the result that the frontal region of the end side of the insert 30 a of the latching disk 30 , which region protrudes over the hole 17 , is likewise covered by the bushing 30 and is therefore shielded from the outside, in particular against impurities and corrosion attacks, in a favorable and dimensionally accurate manner and without being affected by tolerances.
For this purpose, the bushing 23 is first of all press-fitted with an oversize, as a result of which first of all an increased bearing torque arises because of friction. For this purpose, in a first step of a particularly preferred process for producing a motor vehicle door hinge 1 with a defined bearing torque, the bushing 23 is produced by plastic injection molding onto the latching disk 30 before the motor vehicle door hinge 1 is assembled. This advantageously renders a corrosion coating for the latching disk 30 to protect the running surfaces superfluous. This advantageously results in a seamless plastic bushing which has at least approximately uniform properties over its entire circumference. After the motor vehicle door hinge 1 has been assembled, the overdimensioned bearing torque constitutes an increased resistance during opening and closing of the motor vehicle door hinge. In a separate process step, the bearing torque of the bushing 23 , which torque is initially overdimensioned in a specific manner, is reduced by heat treatment. For this purpose, use is advantageously made of a surprising effect, according to which, in the assembled state, the stresses in the bushing 23 relax because of the press fit to the shaft section 4 , and the bearing torque falls to a desired, low and uniform level, the freedom from play being maintained at the same time in the abovementioned system. The heat treatment may also be brought about by a separate, if appropriate also local, for example inductive, heating. The heat treatment preferably takes place in one working step which is not provided until after the hinge has been fitted into the body shell of a motor vehicle (in which case spare parts are to be treated in a corresponding manner without being fitted) at the same time as the cataphoretic dip coating and subsequent drying, the material of the bushing advantageously being coordinated, for relaxation purposes, with the temperatures which occur during the coating and/or subsequent drying.
The process described above advantageously and directly provides a motor vehicle door hinge—if appropriate fitted in a motor vehicle—which has a play-free bearing point which seals off the mechanism of the arrester unit 25 and at the same time has a low bearing torque which permits a smooth-running pivoting of the motor vehicle door hinge between the latching positions. At the same time, the bushing which is produced by plastic injection molding is far superior in the region of its collar section 23 a , which is loaded in the axial direction of the motor vehicle door hinge 1 by the compression spring 32 of the arrester unit 25 , to a conventional bushing in respect of the uniformity of the geometry, and therefore can more intensely be loaded, as a result of which it is possible to provide sheet-metal folded parts for the hinge halves and at the same time not to have an adverse effect on the running properties of the hinge. The resulting motor vehicle door hinge is thereby more compact and, at the same time, cheaper to manufacture.
The bushing 22 and the hole 18 may also be manufactured in accordance with the bushing 23 explained in detail above.
The motor vehicle door hinge 1 ′ which is shown in FIGS. 3 and 4 differs from the motor vehicle door hinge 1 from FIGS. 1 and 2 essentially by the hinge parts 2 and 3 overlapping in a different way by the two limbs 8 , 9 of the first hinge part 2 being articulated on the respectively mutually facing, inner surface of the upper limb 15 and of the lower limb 16 of the second hinge part 3 . Furthermore, the shaft section 4 is not formed as a continuous hinge pin but rather, in addition to its function in the arrester unit 25 , only connects the joint in the region of the upper limbs 8 , 15 of the first and second hinge parts 2 , 3 . In the description of the motor vehicle door hinge 1 ′, the same reference numbers therefore refer to the same or technically comparable parts as in the motor vehicle door hinge 1 from FIGS. 1 and 2 .
The articulated connection between the lower limb 9 of the first stop part 2 on the body and the lower limb 16 of the second door hinge 3 on the door takes place via an articulated connection 35 outside the shaft section 4 , which connection will be explained in greater detail below.
The articulated connection 35 as defined by a hinge pin stub which is arranged coaxially on the hinge axis 5 , is designed as a rivet 36 and is held in a rotationally fixed manner by means of a hollow rivet 37 in the hole 18 in the lower limb 16 of the second hinge part while that section of the rivet 36 which passes through the hole 11 in the lower limb 9 of the first hinge part 2 is mounted pivotably by means of a bushing 38 . The rivet 36 is advantageously secured axially by crimping that section of the rivet 36 protruding over the end joint surface facing away from the limb 16 . As an alternative, the articulated connection 35 of the two limbs 9 , 16 may also be interchanged.
In FIGS. 5 and 6 , the shaft section 4 from the motor vehicle door hinge 1 according to FIGS. 1 and 2 is illustrated schematically. Given an appropriate shortening below the circumference knurl 21 , a shaft section of corresponding design can also be used in the motor vehicle door hinge 1 ′ from FIGS. 3 and 4 .
It can be seen that the shaft section 4 is circumferentially provided with a guide profile 40 in that region in which said shaft section passes through the arrester unit 25 and is surrounded by the hollow shaft section 29 , said guide profile comprising a plurality of protruding, rib-like projections 41 and depressions 42 which are defined in between them and form a type of peripheral rectangular tooth profile or trapezoidal tooth profile, this guide profile 40 enabling the cam section 26 to be displaced axially along the hinge axis 5 .
The inner circumference of the hollow shaft section 29 of the cam disk 26 is designed with a guide profile which is complementary to the guide profile 40 on the shaft section 4 , a torsional securing between the radial flanks 43 , which impact against each other in pairs and are directed radially (only the flanks 43 of the guide profile 40 of the shaft section 4 can be seen in FIG. 6 ) being brought about in a favorable manner at the transition from projections 41 to depressions 42 (and vice versa) of the two guide profiles. Moreover, the cam disk 26 centers itself on the shaft section 4 , so that, upon an introduction of force which is brought about by the displacement of the latching disk 30 and is tangential to the shaft section 4 , the stressed flanks 43 , which are directed in each case in an opposed manner, absorb the forces, with the result that the shaft section 4 absorbs the forces acting on the cam disk 26 over its entire circumference and a favorable distribution of the torques being applied is thereby established.
It can be seen that a total of six projections 41 and six depressions 42 are provided, each having an angled segment of approximately 60°. The projections 41 and depressions 42 are provided lying opposite each other in pairs; as an alternative, however, they may also be provided lying opposite each other with a gap. The depressions 42 define an inside diameter of approximately 9.4 mm and the projections 41 define an external diameter of approximately 12.9 mm, the projections 41 and the depressions 42 being formed such that they lie opposite each other in pairs, as a result of which a comparatively large portion of approximately 30% of the diameter of the shaft section 4 is available as the flank 43 for the resistance against the tangential introduction of force.
The invention has been explained in detail above with reference to two preferred exemplary embodiments. It has to be understood that, in principle, other two-section hinge parts may also be provided according to the invention with an arrester function.
The invention has been explained in detail above with reference to two preferred exemplary embodiments, in which the cam disk 26 is coupled to the shaft section 4 and the latching disk 30 is coupled to the second hinge part 3 . It has to be understood that similarly the latching disk 30 can be coupled to the shaft section 4 and the cam disk 26 can be coupled to the second hinge part 3 . In both cases, either the first hinge part 2 can be coupled to the door and moved, as a result of which the second hinge part 3 and the associated disk are not moved and the first hinge part 2 , the shaft section 4 and the associated disk are moved relative to the second hinge part. However, it is preferred for the door to be fixed onto the second hinge part 3 , as a result of which the disk assigned to the shaft section 4 is pivoted up and down and the other disk, which is assigned to the second hinge part 3 , is pivoted away below the one disk assigned to the shaft section 4 . | The invention relates to a motor vehicle door hinge comprised of a first hinge part ( 2 ), a second hinge part ( 3 ), a shaft section ( 4 ), which joins a hinge eye ( 10 ) of the first hinge part ( 2 ) and a hinge eye ( 17 ) of the second hinge part ( 17 ) to one another in an articulated manner, and of a door arrester unit ( 25 ), which produces a holding force that is to be surmounted by tensioning a spring unit ( 32 ). Preferred holding angles of the door arrester unit ( 25 ) are stipulated by detent markings. The aim of the invention is to create a motor vehicle door hinge that can be economically produced and mounted. To this end, the hinge parts ( 2, 3 ) are provided in the form of U-shaped sheet metal shaped parts with hinge eyes ( 10, 11; 17, 18 ) that are placed in limbs ( 6, 7; 15, 16 ) of the hinge parts ( 2, 3 ), and the shaft section ( 4 ) is prevented from rotating with the one ( 26 ) of the cam disk ( 30 ) and detent disk ( 26 ) that is subjected to the action of the spring unit ( 32 ), whereas the other ( 30 ) of the cam disk ( 30 ) and detent disk ( 26 ) is joined in a non-rotatable manner to the hinge part ( 3 ) in which the shaft section can rotate. | 8 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent application Ser. No. 09/124,095 filed Jul. 29, 1998, entitled, “Padded Raised Flooring Panels and Coverings,” and U.S. patent application Ser. No. 60/123,883 filed Mar. 11, 1999, entitled, “Raised Floor Tape Locator System for Carpet Tile,” both which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates to raised panel or access flooring systems and floor coverings, including carpet and carpet tile and resilient sheet and tile products.
BACKGROUND OF THE INVENTION
[0003] Myriad materials have been used for flooring and floor coverings in buildings, including virtually every natural and human-made material imaginable, such as wood, stone, concrete, cork, plastics, paint, carpets, rugs, vinyl sheets and tiles, sawdust, rushes, and animal skins, to name just a few. Rugs and carpets in a wide variety of materials, patterns and constructions have been manufactured for centuries, particularly for use in homes. As recently as the middle of the twentieth century, carpets and rugs were virtually never used in commercial and industrial buildings like manufacturing facilities, stores and offices. Floors in such locations utilized “hard surface” materials like concrete, concrete compositions, wood or sheet materials like linoleum. Beginning in approximately the late 1960's and 1970's, carpet and carpet tiles began to be used extensively in commercial and “light” industrial buildings, a trend that was accelerated by the advent of new carpet technologies that provided more durable and attractive products and by the popularity of “open” floor plan offices.
[0004] As a result of these developments, the comfort and aesthetic appeal of carpet and carpet tile have come to be widely expected in offices and other commercial environments.
[0005] Floor structures in most office and commercial buildings are concrete. Typically, a modest amount of cabling in conduits and the like are buried in the concrete. Drop ceilings are frequently used in office and other commercial buildings to conceal the many other infrastructure elements normally found in buildings, such as electricity and communications cabling; water and sewage pipes; and heating, ventilation and air conditioning (HVAC) ducts. However, difficulty in accessing these elements and the cabling needs of some computer installations have led to the increased use of raised panel flooring. Raised panel flooring, also known as access flooring, typically includes multiple rigid floor panels which are supported by a pedestal and stringer structure that rests on the concrete slab floor of the building. An example is shown in U.S. Design Pat. No. D370,060, entitled “Modular Grid Understructure,” dated May 21, 1996, which is incorporated herein by this reference. The panels provide a stable floor, while the support structure creates a space or “subfloor” under the panels and above the concrete slab floor for routing infrastructure elements.
[0006] Rigid flooring panels are typically constructed of aluminum, steel, wood, concrete or various combinations thereof. For example, flooring panels may be made of concrete or wood encased in a steel shell. These unyielding surfaces are uncomfortable and noisy to walk on. Also, bare metal surfaces (or even painted or coated surfaces) may be unattractive, creating an unpleasant environment, particularly in light of the expectations mentioned above that have developed as a result of widespread use of carpet in office and commercial environments. Thus, access floors often are covered with a sound and shock absorbent material, such as carpet tile. The use of carpet tiles also improves the aesthetic appearance of the floor.
[0007] Carpet tiles can have a wide variety of constructions. However, carpet tiles typically include at least two layers: a top or “face” layer and a bottom or “backing” layer. The face layer is a relatively thin textile fiber layer, typically tufted, fusion bonded, woven or needle punched. The backing layer is a relatively thick resilient pad that contributes many desirable properties to the overall tile, such as cushioning and sound attenuation. The backing layer is hidden from view under the face layer.
[0008] Accessing the subfloor requires removal and reinstallation of the rigid panels and any carpet tiles or other floor covering lying on the panels. Frequent movement of the tiles, traffic on the floor and other contacts with the tiles often damage the tiles, requiring replacement. The damage to the tiles is typically restricted to the face layer of the tile; the backing layer is rarely damaged. Moreover, purely cosmetic damage to the backing layer can be ignored since the backing is not visible. In contrast, even minor damage to the facing layer may necessitate replacement of the entire tile. Thus, as a result of minor damage to only one portion of the tile, the entire tile must be discarded. The disposal and/or recycling of both the face and backing layers is particularly difficult, because, due to the dissimilarities in materials, the various carpet components must be separated prior to recycling. As a result, damaged carpet tiles are often discarded, creating disposal costs and environmental problems. Alternatively, recyclers are forced to used complex and expensive recycling systems that can separate the dissimilar materials. It would be desirable to provide systems for use with access flooring which minimizes the disposal, recycling and/or replacement cost of damaged tiles while providing the aesthetic and functional characteristics of carpet tile or other conventional floor treatments.
[0009] One approach in the art was a steel panel with welded side flanges and a tile having a carpet square bonded thereto and a base plate having flanges with an inward projection that snaps onto the steel panel as disclosed by U.S. Pat. No. 4,996,818 issued to Bettinger, Mar. 5, 1991. In Bettinger, the entire tile including the bonded carpet and the base plate are removed. Bettinger does not provide for detaching only the carpet portion of the tile. Attempts to remove the bonded carpet from the tile are likely to destroy the carpet leaving it unusable. Thus, with Bettinger, the entire tile must be removed and not just the bonded carpet. Thus, a need still exists for a system and method that provides for detaching the upper carpet portion of a floor covering of a raised access floor panel system where the carpet is not destroyed and may be reused.
SUMMARY OF THE INVENTION
[0010] This invention addresses these limitation by presenting a relatively thick, resilient pad is bonded directly to and covers the entire surface of an access floor panel. The pad provides the functional characteristics of conventional floor treatments by absorbing impacts, attenuating sound and contributing to the desired “feel” when standing or walking on the floor. “Installation” of the pad occurs in the factory where it is bonded to the panel, rather than on-site, thereby simplifying on-site activities.
[0011] Modules of “reinforced face cloth” having only a face layer and a stabilizing layer are used to cover the pad. The reinforced face cloth modules provide the desired aesthetic effect of conventional floor treatments. The reinforced face cloth modules also extend the life of the pad by reducing wear.
[0012] In one embodiment, the reinforced face cloth modules are not bonded to the padded floor panels. Alternatively, the modules may be bonded lightly to the pad with a pressure sensitive adhesive that allows easy removal. The pressure sensitive adhesive prevents the module from sliding without limiting the ability to remove the module from the pad. In either case, damaged or worn modules can be replaced with a minimum of material usage and dramatically lower cost than if conventional floor treatments were replaced. Furthermore, because the pad and the modules are at most only lightly bonded together, the complexity and cost of separating the modules from the pad and recycling either or both the pad and the module is reduced.
[0013] In an alternative embodiment of this invention, the reinforced face cloth modules affix to the pad utilizing hook and loop fasteners.
[0014] The pad may be cast directly onto the panel or may be manufactured separately and bonded to the panel with an adhesive. In the event the pads are cast directly onto the panel, additional pads may be manufactured separately for use to replace damaged pads. Alternatively, damaged pads may be repaired by filling in the damaged area with an appropriate repair material, or panels having damaged pads may simply be replaced.
[0015] The reinforced face cloth modules may be manufactured in sizes corresponding to the panels or may be manufactured in any desired standard sizes and distributed on the floor independent of the panel interfaces.
[0016] Accordingly, it is an object of the present invention to provide aesthetic and wear coverings for raised flooring panels which are easily replaced with a minimum of waste.
[0017] Another object of the present invention is to provide shock absorbent and sound attenuating coverings for raised flooring panels in which the coverings are affixed to the panel.
[0018] Another object of the present invention is to provide coverings for raised flooring panels having an inexpensively replaced face cloth module.
[0019] Another object of the present invention is to provide coverings for raised floor panels which minimize waste and reduce recycling costs.
[0020] Other objects, features and advantages of the present invention will become apparent with reference to the drawings, the following description of the drawings and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a perspective view of a room with a partially installed raised floor with corners of components of the panel covering partially lifted to show the structure of the covering.
[0022] [0022]FIG. 2 is an elevation view of a raised flooring panel and covering taken along line 2 - 2 in FIG. 1.
[0023] [0023]FIG. 3 is a side elevation view of a hook and loop fastener interposed between a reinforced face cloth module and a pad.
[0024] [0024]FIG. 4 shows a side elevation view of a raised flooring panel having a recess adapted to receive a hook and loop fastener.
[0025] [0025]FIG. 5 shows a side elevation view of a raised flooring panel having a recess without utilizing a hook and loop fastener.
DETAILED DESCRIPTION
[0026] [0026]FIG. 1 illustrates the installation of a raised floor system 10 using covering 12 in accordance with the present invention. Raised floor 10 includes support columns 14 and floor panels 16 . Columns 14 are typically distributed on the floor of a room at intervals that coincide with the intersection 18 of the corners of adjacent panels 16 .
[0027] Referring to FIG. 2, each panel 16 is covered with a pad 20 . The padded panels 16 are covered with reinforced face cloth modules 22 . Pad 20 may be made of any durable, resilient material. Suitable materials include solid, flexible polyvinyl chloride (PVC); foamed PVC; solid or foamed polyurethane, solid or foamed modified bitumen products such as urethane modified bitumen; or any other materials which provide the desired characteristics. If PVC products are used, they may be made from recycled materials. In particular, urethane modified bitumen, such as that disclosed in U.S. Pat. No. 5,096,764, entitled “Printable Carpet Tile and Method,” the entirety of which is incorporated herein by this reference, may be used to produce suitable pads 20 .
[0028] The appropriate thickness and other properties of pad 20 should be determined by reference to the anticipated environment. For instance, pad 20 may be made thicker to create additional shock absorption or thinner where minimized weight is important. Pad 20 may be cast directly onto panel 16 using known manufacturing methods. Pad 20 also may be cast or otherwise formed separately and bonded to panel 16 using any suitable adhesive. In either case, additional pads 20 may be manufactured separately for use as replacement pads.
[0029] Pads 20 cover the entire upper surface of panel 16 . Thus, when panels 16 are installed as shown in FIG. 1, a continuous, gap free surface is formed. Panels 16 are not visible under pads 20 . As shown in FIG. 2, panels 16 may have tabs, flanges or other interlocking means 30 for joining each panel to an adjacent panel. The top surfaces of joining means 30 need not be covered by pads 20 as they will be concealed under the edge of the adjoining panel 16 (and that panel's corresponding pad 20 ).
[0030] Reinforced face cloth modules 22 are made of a topcloth layer 24 and a stabilizing layer 26 . Topcloth layer 24 may be any desirable surface, such as a woven, tufted, fusion bonded, needle punched or any other suitable textile layer or, alternatively, linoleum, vinyl or any other form of sheet or tile or other suitable floor treatment product.
[0031] Stabilizing layer 26 may be made of non-woven fiberglass or other suitable materials in the minimum amount necessary to provide the desired dimensional stability. Stabilizing layer 26 is dimensionally stable and thereby serves to stabilize reinforced face cloth module 22 so that it lies flat, i.e., it prevents module 22 from curling up at the edges or assuming a dome-like shape. Stabilizing layer 26 is not a polymeric layer alone. The stabilizing layer 26 is a layer that stiffens and substantially reinforces polymer materials and cannot be an amorphous polymer. Typically the stabilizing layer 26 is fiberglass and could be other polymer fibers but cannot be amorphous polymers that tend to stretch, grow, and dome. Layers 24 and 26 may be bonded together with adhesives or other suitable means. For example, layer 26 may be made up of a sheet of non-woven fiberglass encased in an adhesive or plastic, such as the urethane modified bitumen material described above. Layer 26 may be pressed against layer 24 before the adhesive or plastic material cures, thereby bonding the layers together. Using urethane modified bitumen encapsulation as an adhesive reduces the amount of material required to assemble a complete module and simplifies the manufacturing process.
[0032] Reinforced face cloth modules 22 may be made to fit panels 16 exactly or may be made in sizes that differ from the panel dimensions. In either case, as shown in FIG. 1, reinforced face cloth modules 22 are placed on the floor formed by pads 20 in such a manner as to completely cover pads 20 . If reinforced face cloth modules 22 are the same size as pads 20 , they may be (but need not necessarily be) placed so that the interfaces between adjacent reinforced face cloth modules 22 coincide with the interfaces between adjacent pads 20 . Alternatively, or if reinforced face cloth modules 22 do not match the size of pads 20 , reinforced face cloth modules 22 may be positioned without regard to the interfaces between adjacent pads 20 .
[0033] If face cloth modules 22 are sufficiently stable, they may be positioned without any means for bonding them to pad 20 . Alternatively, pressure sensitive or other adhesives or other means can be utilized to secure module 22 in place atop pads 20 . Suitable adhesives include, but are not limited to acrylic-based pressure sensitive adhesives.
[0034] Although the foregoing is provided for purposes of illustrating, explaining and describing certain embodiments of the floor covering the present invention in particular detail, modifications and adaptations to the described floor covering and other embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention as described in the following claims.
[0035] For instance, FIG. 3 shows an additional means for affixing reinforced face cloth modules 22 to pads 20 . FIG. 3 shows an alternative embodiment for affixing the reinforced face cloth modules 22 to pads 20 . Hook and loop fasteners 40 attach the reinforce face cloth modules 22 to the pads 20 . Hook and loop fasteners 40 serve to accurately hold a floor covering 22 in place on the panels 16 while the modules 10 are removed to another location.
[0036] In another alternative embodiment shown in FIG. 4, hook and loop fasteners 40 position in a recess 42 of the panel surface 16 . Hook and loop fasteners 40 recessed in the pads 20 eliminate even minute deflections in the upper surface of the reinforced face cloth modules 22 . The recess 42 can be about half the thickness of the hook and loop fastener 40 or the recess 42 can equal the thickness of the hook and loop fastener 40 .
[0037] In yet another alternative embodiment shown in FIG. 5, the recess 42 can be utilized without the hook and loop fastener 40 . Many recess configurations are possible ranging from a single hook and loop fastener 40 system to one with many hook and loop fasteners 40 configured in a variety of groupings. For instance, a corner recess system in which any combination of locators can be used. Alternatively, a perimeter arrangement recess system can serve to locate and hold reinforced face cloth modules 22 in place. | Panels ( 16 ) for use with access flooring ( 10 ) having a thick, resilient pad ( 20 ) bonded directly to and covering the entire surface of the panel ( 16 ). The pad ( 20 ) acts like the backing layer of a conventional floor treatment by absorbing impact and attenuation sound. A reinforced face cloth module ( 22 ) having only a face layer ( 24 ) and a stabilizing layer ( 26 ) is used to cover the pad ( 20 ) to protect the pad from wear and to provide an attractive floor treatment. The reinforced face cloth module ( 22 ) can be detachable or bonded directly to the pad. Alternatively, hook and loop fasteners can affix the pad to the face cloth module. | 8 |
FIELD OF THE INVENTION
[0001] Generally the present invention relates to manufacturing methods and related products. In particular, however not exclusively, the present invention pertains to manufacturing methods of ballistic armors and ballistic armor structures/products related thereof
BACKGROUND OF THE INVENTION
[0002] Ballistic protection concerns protection against kinetic energy or pressure caused by projectiles such as bullets, gravity bombs, rockets etc.. Ballistic armor works by decreasing the energy density of the projectiles, for example by affecting the shape or postion of the projectile, by breaking the projectile and/or by decelerating the velocity of the projectile. Ballistic armor against pressure caused by ammunition works by absorbing or directing the energy of the shock wave.
[0003] A ballistic armor may be produced of almost any material when the mass is sufficient enough. However, especially land, sea and air vehicles benefit when the armor is as light as possible, and further when the armor works as the load-bearing structure. Often there is also a requirement for the armor to fit into a small space, i.e. practically speaking the thickness of the structure needs to be as thin as possible.
[0004] Traditionally, metallic structures, for example High Hardness Steels have been used in the production of ballistic armors. However, the cores of some projectiles aimed for penetrating armors, i.e. the penetrator, have such a high hardness that the hardness of the metallic armor structures are insufficient to cause damage to these penetrators. Therefore, the armor structure in these cases works by absorbing the kinetic energy of the projectile. The armor structures intended against these penetrators become excessively massive as a monolithic metallic structure, especially when applied to vehicles.
[0005] As known from prior art, ceramic elements and metallic ceramic composites, such as aluminum oxide (Al2O3), silicon carbide (SiC), boron carbide (B4C), tungsten carbide (WC), boron nitride (BN), silicon nitride (Si3N4), carbon nitride (C3N4), titanium diboride (TiB2), may be used in ballistic armors. Such materials may have a hardness sufficient to generate damage to the projectiles. Ceramic materials are known to have high compressive strength, but at the same time weak tensile strength.
[0006] The simplest construction principle when using ceramic elements in a ballistic armor is gluing rectangular prism ceramic elements, such as bricks, to a frame structure, such as a fiber composite laminate. The manufacturing methods when using ceramics most often require piling the elements manually on a panel-shaped mold of the desired final product, i.e. because the aftertreatment (for example cutting into shape) of the ceramic elements is difficult due to their high hardness. Typical armors that have ceramics glued to a frame structure do not withstand bending load. Therefore, such armors do not work as load-bearing structures in vehicles, for example. Instead these armor structures form a structural parasitic weight (excessive weight).
[0007] According to prior art it is also known that ballistic armors may be improved by, either fully or partly, encapsulating ceramic elements. This is known to
i) delay the fracturing of the ceramic surface and the start of the penetration ii) slow down the cracking of the ceramic element iii) keeping the ceramic material in contact with the penetrator and thus increasing the erosion of the penetrator iv) affecting the fracturing and shaping of the ceramic elements caused by a shock wave with the adaption of the ceramic elements and the encapsulating material's acoustic impedance.
[0012] Prior art tells that the shock resistance of ceramic elements increases significantly when molten metal, such as aluminum, is casted on top of the ceramic elements. The big difference in the ceramic elements' and aluminium's thermal expansion creates a compressing pretension for the ceramic elements when the molten metal cools down to solid material contracting at the same time.
[0013] The manufacturing complexity is a common characteristic for the presented structures. The known structures are also limited to a predefined shape. It has been difficult to adapt existing solutions to serial production as well. Even though there is a clear benefit due to the fact that the ceramic elements get a pretension when compressed by a metal casing, one disadvantage is that the existing methods require high accuracy for dimensional tolerances.
SUMMARY OF THE INVENTION
[0014] The objective is to at least alleviate the problems described hereinabove not satisfactorily solved by the known arrangements, and to provide feasible methods to manufacture ballistic armors and to provide feasible ballistic armors related thereof.
[0015] The aforesaid objective is achieved by the embodiments of a system in accordance with the present invention.
[0016] Accordingly, in one aspect of the present invention, a method for manufacturing a ballistic armor comprises at least the steps
aligning armor elements infront of a casing provider arrangement, and supplying a casing around the armor elements such that the armor elements remain inside the casing.
[0019] In one embodiment the casing provider arrangement is a metal profile extrusion arrangement extruding a metal profile around the armor elements.
[0020] In a further, either supplementary or alternative, embodiment the casing provider arrangement is a metal direct extrusion or indirect extrusion arrangement.
[0021] In a further, either supplementary or alternative, embodiment the casing provider arrangement is a pultrusion arrangement.
[0022] In a further, either supplementary or alternative, embodiment the armor elements are ceramic elements. The armor elements may be ceramic tiles and/or bricks, for example. The ceramic elements may be rectangular, triangular, cylindrical and/or any other shape suitable for such application. In some preferable embodiments, the rectangular tiles may be 25×25 mm-100×100 mm with a thickness of 3-25 mm, for example. As is understood, other dimensional combinations are possible as well.
[0023] In a further, either supplementary or alternative, embodiment the armor elements are hard steels, metal matrix composites and/or fiber composites.
[0024] In a further, either supplementary or alternative, embodiment the armor elements are aligned in a row infront of the casing provider arrangement.
[0025] In a further, either supplementary or alternative, embodiment the armor elements are arranged to stay in place, such as with a stopper, when the armor elements are covered with the casing.
[0026] In a further, either supplementary or alternative, embodiment the armor elements are supported with guides on at least two sides such that the guides move forward when the casing is supplied around the armor elements.
[0027] In another aspect of the present invention a method for inserting elements to a casing structure comprises at least the steps
manufacturing a casing, and inserting armor elements in the cavities of the casing.
[0030] In one embodiment the armor elements are aligned on a conveyor that inserts the armor elements in the cavities of the casing.
[0031] In a further, either supplementary or alternative, embodiment the armor elements are attached inside the casing by casting or injecting adhesive material inside the casing via arranged channels.
[0032] In a further, either supplementary or alternative, embodiment the armor elements are attached inside the casing by welding a gap arranged to the casing such that the contraction of the weld clamps the armor elements to their places inside the casing.
[0033] In a further, either supplementary or alternative, embodiment the armor elements are inserted in the casings after the extrusion process. The armor elements may be inserted in the casings during tension leveling or heat treatment, such as hardening or artificial ageing.
[0034] In a further, either supplementary or alternative, embodiment the armor elements are attached inside the casing by mechanical forming such as mangling, rolling, compression molding or other suitable methods.
[0035] In a third aspect of the present invention a ballistic armor comprises
a number of armor elements capsuled in a casing, and a casing forming a number of longitudinal cavities for the armor elements.
[0038] In one embodiment the cavities and armor elements are arranged in layers such that the cavities and armor elements in each layer is overlapping the cavities and layers in an adjacent layer.
[0039] In a further, either supplementary or alternative, embodiment the casing is a metallic casing.
[0040] In a further, either supplementary or alternative, embodiment the armor elements are ceramic elements. In a further, either supplementary or alternative, embodiment the armor elements are hard steels, metal matrix composites and/or fiber composites.
[0041] In a further, either supplementary or alternative, embodiment the ballistic armor comprises two layers of cavities and armor elements.
[0042] In a further, either supplementary or alternative, embodiment the ballistic armor comprises a number of intermediate elements between the armor elements, which intermediate elements differ by material attributes from the armor elements.
[0043] In a further, either supplementary or alternative, embodiment the casing has a curved structure and wherein the armor elements are arranged in a curved formation.
[0044] In a further, either supplementary or alternative, embodiment the cavities and armor elements has varying shapes, such as triangular and/or rectangular shapes, and/or sizes.
[0045] In a further, either supplementary or alternative, embodiment at least two casings are connected to each other.
[0046] In a further, either supplementary or alternative, embodiment the attachment means allow the casings to turn relative to each other.
[0047] In a further, either supplementary or alternative, embodiment the attachment means are shoulder structures that are attached to each other by welding, glueing and/or mechanical attachments.
[0048] In a further, either supplementary or alternative, embodiment the cavities and armor elements are arranged such that the layers of armor elements overlap each other in a connecting point of the attachment means.
[0049] In a further, either supplementary or alternative, embodiment the ballistic armor is attached to a frame structure, such as the frame of a vehicle.
[0050] In a further, either supplementary or alternative, embodiment the ballistic armor is configured to shield against projectiles' penetrators kinetic energy and/or protect against the pressure caused by explosives.
[0051] In another, either supplementary or alternative, embodiment the ballistic armor is configured to protect as add-on armor. Alternatively, the ballistic armor is configured to protect as a stand-alone armor. In a stand-alone structure the ballistic armor may comprise a fixed structure that provides sufficient rigidity and/or the ballistic armor may comprise an attachable separate structure that provides sufficient rigidity.
[0052] In a further, either supplementary or alternative, embodiment the ballistic armor comprises from rigid and solid material formed material layers that are arranged in a specific order in relation to each other.
[0053] In a further, either supplementary or alternative, embodiment the ballistic armor structure may comprise other material layers that may or may not function as ballistic armor.
[0054] In a further, either supplementary or alternative, embodiment the casing is arranged in connection with the ceramic elements inside the casing by heat shrinking, hot-forming, cold-forming, casting an adhesive material, injecting an adhesive material, gluing, welding and/or other suitable methods.
[0055] The utility of the present invention follows from a plurality of factors depending on each particular embodiment. Due to thermal expansion an extruded profile may, in some embodiments, when cooling down compress the ceramic elements giving them a pretension. In some embodiments the production may be automated. In some embodiments the structure may function both as the ballistic armor and the load-bearing structure, for example in vehicles or fixed constructions. In some embodiments the structure may be provided as a modular elements. By combining/attaching ballistic armors one may be able to easily build ballistic armors according to different shapes and/or sizes. In some embodiments a damaged ballistic armor may be easily changed to a new one.
[0056] In this application a “projectile” describes any object moving with a high velocity such as a frag (fragmentation), a bullet or (other) ammunition.
[0057] In this application a “penetrator” describes the part of a projectile, either the whole projectile or part of it, such as a bullet or its core, that penetrates into a ballistic armor structure and which kinetic energy the ballistic armor is supposed to dampen.
[0058] The expression “a number of” refers herein to any positive integer starting from one (1), e.g. to one, two, or three.
[0059] The expression “a plurality of” refers herein to any positive integer starting from two (2), e.g. to two, three, or four.
[0060] Different embodiments of the present invention are disclosed in the dependent claims.
BRIEF DESCRIPTION OF THE RELATED DRAWINGS
[0061] Next the invention is described in more detail with reference to the appended drawings in which
[0062] FIGS. 1 a and 1 b are sketches of an embodiment of a manufacturing method of a ballistic armor utilizing an extrusion process in accordance with the present invention.
[0063] FIG. 2 is a sketch of an embodiment of a manufacturing method of a ballistic armor utilizing a direct extrusion process in accordance with the present invention.
[0064] FIG. 3 is a sketch of an embodiment of a manufacturing method of a ballistic armor utilizing an indirect extrusion process in accordance with the present invention.
[0065] FIG. 4 is a sketch of an embodiment of a manufacturing method of a ballistic armor in accordance with the present invention with a focus on the ballistic elements' placement in relation to the mandrel of an extruder.
[0066] FIG. 5 is a sketch of an embodiment of a manufacturing method of a ballistic armor utilizing a pultrusion process in accordance with the present invention.
[0067] FIG. 6 is a sketch of an embodiment of a method for inserting armor elements inside a casing.
[0068] FIG. 7 is a sketch of an embodiment of a method for inserting armor elements inside a casing utilizing a conveyor.
[0069] FIG. 8 is a sketch of an embodiment of a method for inserting armor elements and intermediate elements inside a casing.
[0070] FIG. 9 is a sketch of an embodiment of a method for inserting armor elements and intermediate elements inside a casing with a focus on the casing cut off
[0071] FIG. 10 is a sketch of an embodiment to attach armor elements to a casing structure utilizing adhesive materials inside the casing.
[0072] FIG. 11 is a sketch of an embodiment to attach armor elements to a casing structure by welding a gap of the casing.
[0073] FIG. 12 is a sketch of an embodiment of a ballistic armor structure in accordance with the present invention.
[0074] FIG. 13 is a sketch of an embodiment of a curved ballistic armor structure in accordance with the present invention.
[0075] FIG. 14 is a sketch of an embodiment of a ballistic armor structure with armor elements of different shapes and/or sizes in accordance with the present invention.
[0076] FIG. 15 is a sketch of an embodiment of a ballistic armor structure wherein a plurality of casings are attached to each other.
[0077] FIG. 16 is a sketch of an embodiment of a ballistic armor structure wherein a plurality of casings are attached to each other and wherein the attachment means turn relative to each other.
[0078] FIG. 17 is a sketch of an embodiment of a ballistic armor structure wherein a plurality of casings are attached to each other utilizing shoulder structures as attachment means.
[0079] FIG. 18 is a sketch of an embodiment of a ballistic armor structure applied to a frame structure.
[0080] FIG. 19 is a sketch of an embodiment of a ballistic armor structure applied to a vehicle frame.
[0081] FIG. 20 is a flow diagram of an embodiment of a manufacturing method in accordance with the present invention.
[0082] FIG. 21 is a flow diagram of an embodiment of a method for inserting armor elements to a casing structure in accordance with the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0083] FIG. 1 a illustrates an embodiment of a manufacturing method 100 in accordance with the present invention. Armor elements 102 , such as ceramic tiles, are arranged in connection with a metal profile extrusion arrangement 104 . The armor elements 102 are aligned after the die 106 of the metal profile extrusion arrangement 104 . The metal profile extruder comprises a mandrel 108 and a mandrel holder 110 .
[0084] The armor elements 102 are supported with guides 112 and a stopper 114 . The metal profile from the metal profile extrusion arrangement pushes the guides 112 forward. The stopper 114 keeps the armor elements 102 in place such that the metal profile settles around the armor elements 102 such that the armor elements remain inside the metal profile.
[0085] FIG. 1 b illustrates an embodiment of a manufacturing method 100 b in accordance with the present invention. The arrows 103 b represent the malleable material compressed flow. A tongue 105 b divides the material flow. The metal profile extrusion arrangement 104 b comprises a weld chamber 107 b and a bearing 109 b that forms the extruded metal profile 111 b . The extruded metal profile 111 b pushes the guides 112 b forward. Rollers 115 b are arranged on both sides of the armor elements to compress the extruded metal profile 111 b around the armor elements. The rollers 115 b may also straighten and/or press forward the metal profile 111 b . The armor elements are supported with a stopper 114 b.
[0086] Metal profile extrusion materials may be e.g. aluminium, brass, copper, lead, tin, magnesium, zinc, steel and/or titanium.
[0087] Ceramic elements may comprise for example aluminium oxide, silicon carbide, boron carbide and/or any other ceramic material suitable for ballistic armor and/or suitable for other structural purposes of the present invention.
[0088] FIG. 2 illustrates an embodiment of a manufacturing method 200 in accordance with the present invention. Armor elements 202 are aligned after a direct extrusion arrangement 204 . The armor elements 202 may be arranged directly after the die 206 . The billet 216 is driven by a punch 218 with a dummy block 220 . The billet 216 is inside a billet chamber 222 . The billet 216 is pushed through a die 206 . The die 206 forms the billet to a metal profile that is guided around the armor elements 202 such that the armor elements remain inside the metal profile. There may be intermediate elements 224 a , 224 b between the armor elements 202 . Such intermediate elements 224 a , 224 b may be produced from a material that distinguishes from the material of the armor elements 202 . The intermediate elements may be manufactured from similar material as the billet for the metal profile, or other material suitable for cutting and machining with standard tools. The intermediate elements may be utilized later on to cut the armor structure on the location of the intermediate elements, for example. Additionally, alternatively, the ballistic armor may be attached to another surface by utilizing the intermediate elements, for example by screwing through the intermediate elements. The armor elements and/or intermediate elements may be supported with guides 212 and a stopper 214 . The guides 212 may be pushed forward by the extruded profile.
[0089] FIG. 3 presents an embodiment of a manufacturing method 300 in accordance with the present invention. Armor elements 302 are aligned after an indirect extrusion arrangement 304 . The armor elements 302 may be arranged directly after the die 306 . The billet 316 is inside a billet chamber 322 . The billet is driven by a punch 318 with a dummy block that comprises die 306 . The die 306 forms the billet to a metal profile that is guided around the armor elements 302 such that the armor elements remain inside the metal profile. The armor elements 302 may be supported with guides 312 and a stopper 314 .
[0090] FIG. 4 illustrates the position of the armor elements 402 in relation to the mandrel of the metal profile extrusion arrangement. FIG. 4 presents the billet 416 , a mandrel holder 406 , armor elements 402 , a die 406 and an extruded metal profile 426 . The extruded metal profile 426 forms a metallic casing around the armor elements 402 . The armor elements 402 and the metallic casing 426 forms an embodiment of a ballistic armor in accordance with the present invention.
[0091] FIG. 5 illustrates an embodiment of a manufacturing method 500 in accordance with the present invention. Armor elements 502 are aligned after a pultrusion arrangement 505 . Fibers 528 are impregnated with resin 530 and pulled via a guide 532 through a die 534 . Resin 530 may for example be polyester, polyurethane, vinylester and/or epoxy. A conveyor 536 may be arranged after the pultrusion arrangement such that the formed casing is guided around the armor elements 502 such that the armor elements remain inside the casing. The armor elements may be supported with a stopper 514 and/or guides. The casing may be manufactured from a fiber composite, such as carbon fiber.
[0092] FIG. 6 presents an embodiment of a method 600 for inserting armor elements 602 inside a metal profile/casing 626 . The metal profile/casing 626 comprises cavities 638 in which the armor elements 602 may be inserted.
[0093] FIG. 7 presents an embodiment of a method 700 for inserting armor elements 702 inside a metal profile/casing 726 utilizing a conveyor 736 . The metal profile/casing comprises cavities 738 in which the armor elements 702 may be inserted. The conveyor belt may have an adhesive surface, such as fiber tape or aluminum tape, which allows to place the armor elements on the conveyor belt. The conveyor belt may be fitted with a reel or strip of tape, such as aluminium tape or fiber tape, with adhesive surface which allows to attach the armor elements on the tape placed on the conveyor belt. The tape with the armor elements may be inserted inside the cavity of the metal profile.
[0094] FIG. 8 presents an embodiment of a method 800 for inserting armor elements 802 and intermediate elements 824 inside a metal profile/casing 826 . The metal profile/casing 826 comprises cavities 838 in which the armor elements 802 and intermediate elements 824 may be inserted. The intermediate elements 824 may distinguish from armor elements 802 by material, dimensioning, shape or any other feature. The intermediate elements may have similar cross sectional dimensions as the armor elements, but different length. The intermediate elements may be of similar material as the billet material for the metal casing. The intermediate elements may also be of material with acoustic impedance differing considerably from the acoustic impedance of the armor element material and/or the acoustic impedance of the metal casing material. The intermediate elements 824 may for example act as acoustic impedance shaping elements between the armor elements 802 .
[0095] FIG. 9 presents an embodiment of a method 900 for inserting armor elements 902 a , 902 b and intermediate elements 924 inside a metal profile/casing 926 . The intermediate elements 924 may distinguish from armor elements 902 a , 902 b by material, dimensioning, shape or any other feature. The intermediate elements may have similar cross sectional dimensions as the armor elements, but different length, for example. The intermediate elements may be manufactured from similar material as the billet for the metal profile, or other material suitable for cutting and machining with standard tools. The intermediate elements 924 may for example allow to cut off, make openings or in other ways shape the ballistic armor from the desired location 940 . By selecting a suitable material for the intermediate elements 924 may allow to cut off or in other ways shape the ballistic armor structure with more conventional working methods than would be needed for cutting off the ballistic armor at the location of the armor elements 902 a , 902 b.
[0096] FIG. 10 presents an embodiment of a method 1000 to attach the armor elements 1002 to the metallic casing/profile 1026 with channels 1042 by casting, injecting or any other means applying suitable material inside the casing/profile 1026 .
[0097] FIG. 11 presents an embodiment of a method 1100 to attach the armor elements to the metallic casing/profile 1126 a , 1126 b by welding 1144 a , 1144 b , 1144 c a gap 1146 a , 1146 b , 1146 c in the metallic casing/profile 1126 a , 1126 b . The contraction of the weld 1144 a , 1144 b , 1144 c clamps the armor elements to their places inside the casing/profile 1126 a , 1126 b into a prestressed state.
[0098] FIG. 12 presents an embodiment of a structure of a ballistic armor 1201 in accordance with the present invention. The ballistic armor comprises a metallic casing 1226 . The metallic casing comprises cavities 1238 a - f . The cavities may be filled with armor elements 1202 a - d . The casing may comprise cavities in layers.
[0099] The cavities in different layers may be overlapping each other. Thereby, the armor elements may also in different layers overlap each other.
[0100] FIG. 13 presents an embodiment of a structure of a ballistic armor 1301 wherein the metallic casing 1326 has a curved form and wherein the cavities and armor elements 1302 are arranged in a curved formation within the casing. The armor elements 1302 and the cavities for the armor elements may be rectangle formed. FIG. 14 presents an embodiment of a structure of a ballistic armor 1401 wherein the metallic casing 1426 comprises cavities with varying shapes and/or sizes. Armor elements 1402 a , 1402 b with varying shapes and/or sizes may be inserted in the cavities. Two layers of rectangular shaped cavities and armor elements and one layer of triangular shaped cavities and armor elements are presented in FIG. 14 . The triangular shaped armor elements and cavities may be arranged overlappingly such that they together form a rectangular like set, for example. The triangular shaped cavities may also be left empty or may be used for example for chaneling conduits, liquids or gasses.
[0101] FIG. 15 presents an embodiment of ballistic armor casings 1526 a , 1526 b , 1526 c attached to each other. The casings 1526 a , 1526 b , 1526 c have cavities that are filled with armor elements 1502 . The casings have 1526 a , 1526 b , 1526 c attachment means 1548 , 1550 for attaching casings to each other. A casing may have a ‘male’ attachment mean 1548 on one side and a ‘female’ attachment mean 1550 on one side, for example.
[0102] FIG. 16 presents an embodiment of ballistic armor casings 1626 a , 1626 b , 1626 c attached to each other, wherein the casings may turn relative to each other. The attachment means 1648 , 1650 functions as pivotal points such that the casings may turn relative to each other. In FIG. 16 is also presented an embodiment of the ballistic armor, wherein the ballistic armor functions as a retractable door curtain 1652 or similar structure.
[0103] FIG. 17 presents an embodiment of ballistic armor casings 1726 a , 1726 b attached to each other, wherein the casings comprise attachment means 1748 , 1750 that are shoulder structures. The attachment means 1748 , 1750 may be attached to each other for example by welding, glueing, mechanical attachments or any other suitable means. The cavities and armor elements 1702 are arranged such that the layers of armor elements also overlap in the connecting point.
[0104] FIG. 18 presents an application for the ballistic armor according to the present invention. The casing 1826 may be attached to a frame structure 1854 with attachment elements 1856 a , 1856 b . The attachment elements may be attached to the frame structure 1854 with screws 1858 a , 1858 b , for example. FIG. 19 presents an application for the ballistic armor 1901 , wherein the ballistic armors are used as shields for vehicles. The casings 1926 a , 1926 b , 1926 c are attached to the frame 1954 a , 1954 b of the vehicle with attachment elements 1956 a - e . The casings 1926 a , 1926 b , 1926 c may be supported with a flange 1960 of the vehicle. The casings 1926 a , 1926 b , 1926 c may be attached to each other as well.
[0105] FIG. 20 is a flow diagram of an embodiment of a manufacturing method in accordance with the present invention.
[0106] At method start-up 2002 , preparatory actions may take place.
[0107] At 2004 , armor elements are aligned infront of a casing provider arrangement. A casing provider arrangement may be an extrusion or pultrusion arrangement, for example.
[0108] At 2006 , a casing is supplied around the armor elements such that the armor elements reami inside the casing. The armor elements may be ceramic elements, for example.
[0109] At 2008 , the armor elements are kept in place for example with a stopper. A stopper may prevent the armor elements of moving when the casing is supplied around the armor elements.
[0110] At 2010 , the armor elements are supported with guides, for example. The casing may push the guides forward when the casing is supplied around the armor elements.
[0111] At 2012 , the method execution is ended.
[0112] FIG. 21 is a flow diagram of an embodiment of a method for inserting armor elements to a casing structure in accordance with the present invention.
[0113] At method start-up 2102 , preparatory actions may take place.
[0114] At 2104 , a casing is manufactured. The casing may be manufactured according to suitable methods. The casing may be a metal profile.
[0115] At 2106 , armor elements are aligned on a conveyor.
[0116] At 2108 , the armor elements are inserted in the cavities of the casing. The armor elements may be inserted by utilizing a conveyor as presented in step 2106 . The elements may be inserted by other means as well, for example manually.
[0117] At 2110 , the armor elements are attached to the casing structure. Adhesive material, such as molten metal, may be supplied inside the casing via arranged channels. Alternatively a gap arranged to the casing may be welded.
[0118] At 2112 , the method execution is ended.
[0119] The dotted boxes in FIGS. 20 and 21 can be considered as alternative embodiments.
[0120] Consequently, a skilled person may on the basis of this disclosure and general knowledge apply the provided teachings in order to implement the scope of the present invention as defined by the appended claims in each particular use case with necessary modifications, deletions, and additions. | A method for manufacturing a ballistic armor, includes at least the steps of aligning armor elements in front of a casing provider arrangement, and supplying a casing around the armor elements such that the armor elements remain inside the casing. Further, the method for inserting armor elements to a casing structure, includes at least the steps of manufacturing a casing, and inserting armor elements in the cavities of the casing. Further, a ballistic armor including a number of armor elements capsuled in a casing, and a casing forming a number of longitudinal cavities for the armor elements are also described. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an electrical machine and to a drive device.
Drive devices, preferably hybrid drive devices, in particular comprising an internal combustion engine and an electrical machine, are used, for example, in order to drive motor vehicles. The electrical machine in the motor vehicle, which electrical machine operates as a motor and a generator, has an axle or shaft on which the stator or rotor is arranged.
Waste heat is produced in the electrical machine, in particular in the stator and/or rotor, and therefore it is necessary to cool the electrical machine. The stator and rotor are arranged within a housing of the electrical machine. A spiral or helical channel for conducting a cooling fluid for cooling the electrical machine is incorporated in the housing. The axle around which the spiral cooling channel is wound corresponds to the axis of the shaft of the electrical machine in this case. After the cooling fluid is introduced into the channel, the cooling fluid absorbs heat and thus is at a higher temperature. This leads to non-uniform temperature distribution over the axial length of the electrical machine. Therefore, the absorption of heat by the cooling fluid is disadvantageously reduced.
DE 199 28 247 B4 describes a motor having a motor housing, a stator of cylindrical shape which is mounted on the motor housing, an internal rotor which is arranged in a rotatable manner within the stator, an external rotor which is arranged in a rotatable manner about the stator, with the internal rotor, the stator and the external rotor being arranged in a concentric manner and having a plurality of pins for mounting the stator on the motor housing, with a cooling system being provided which has a plurality of pairs of cooling channels which are formed in the stator, a coolant inlet opening for introducing coolant into the cooling channels, a coolant outlet opening for diverting coolant from the cooling channels, with the coolant inlet opening and the coolant outlet opening being provided at an axial end of the internal rotor and being connected to the cooling channels, a coolant return section for connecting each pair of cooling channels, with the coolant return section being provided at another axial end of the internal rotor, and with the cooling channels being formed from the stator and the plurality of pins.
SUMMARY OF THE INVENTION
An electrical machine, in particular for a motor vehicle, comprising a housing, a shaft having an axis, a stator and a rotor, at least one channel for conducting a cooling fluid for cooling the electrical machine, with the geometry or the orientation of at least one section of the at least one channel being designed to the effect that the cooling fluid flows through the at least one channel with a deviation of less than 40°, in particular exclusively, in the direction of the axis of the shaft.
The axial flow of cooling fluid in the at least one channel produces a substantially constant temperature distribution in the axial direction of the electrical machine. As a result, the heat absorption by the cooling fluid can be improved, in particular on account of the greatest quantity of heat being given off by the stator and/or the rotor in the region of the central plane of the electrical machine.
In particular, the geometry or the orientation of the at least one channel is designed to the effect that, in at least a first pair of two sections of the at least one channel, the cooling fluid in an A section flows in the opposite direction to a B section. When the cooling fluid flows in the opposite and axial direction with a deviation of less than 40 degrees in the A section and in the B section, the heat can be particularly effectively absorbed and uniformly distributed by the cooling fluid because distribution takes place in the axial direction on account of the opposite direction.
In a further refinement, a component stream of cooling fluid can in each case be conducted though the A section and through the B section of the at least one channel. Splitting the cooling fluid into two component streams which are each conducted through the A section and the B section has the advantage that, after the two component streams are combined, it is possible to thoroughly mix these separated streams.
In a supplementary embodiment, the two component streams are substantially identical, for example with a deviation of less than 30%.
The geometry or the orientation of the at least one channel is designed to the effect that the cooling fluid in the A section and in the B section flows to an axial end face of the electrical machine or of a component of the electrical machine. The cooling fluid flowing in the A section and the B section is therefore conducted from a central plane of the electrical machine in each case to the two axial end faces of the electrical machine. The greatest amount of waste heat is released in the region of the central plane, that is to say in the center of the electrical machine, and therefore said waste heat is conducted to the axial end faces and there heat can be given off by the cooling fluid to the surrounding area.
In one variant, the geometry or the orientation of the at least one channel is designed to the effect that, in at least a second pair of two sections of the at least one channel, the cooling fluid in a C section flows in the opposite direction to a D section.
Expediently, a component stream of cooling fluid can in each case be conducted through the C section and through the D section of the at least one channel.
In a further embodiment, the two component streams are substantially identical, for example with a deviation of less than 30%.
In particular, the geometry or the orientation of the at least one channel is designed to the effect that the cooling fluid in the C section and in the D section flows to a central plane of the electrical machine or of a component of the electrical machine, said central plane being perpendicular to an axis of the shaft. The central plane is expediently at the same distance from both axial end faces of the electrical machine or a component of the electrical machine.
In a further refinement, the cooling fluid can be conducted though two curve sections of the at least one channel from the at least one first pair comprising the A section and the B section to the at least one second pair comprising the C section and the D section, and/or vice versa. In the two curve sections, the cooling fluid is conducted from the first pair to the second pair, and vice versa. In the two curve sections, the cooling fluid flows at least partially in the radial direction, and therefore the cooling fluid can also be conducted through the housing and/or the stator in the radial direction as a result.
In a supplementary variant, the at least one first pair comprising the A section and the B section and the at least one second pair comprising the C section and the D section are fluidically separated from one another by means of a separating crosspiece. The separating crosspiece permits structurally simple fluidic separation of the first pair comprising the A section and the B section from the second pair comprising the C section and the D section.
In a further variant, the cooling fluid can be conducted through the electrical machine in the radial direction, for example by it being possible to conduct the cooling fluid through at least two curve sections of the at least one channel and/or through at least one connecting section of the at least one channel.
In a further refinement, the cooling fluid can be conducted through at least one connecting section of the at least one channel from the at least one first pair comprising the A section and the B section to the at least one second pair comprising the C section and the D section, and/or the cooling fluid can be conducted through at least one connecting section of the at least one channel from the at least one second pair comprising the C section and the D section to the at least one first pair comprising the A section and the B section.
The cooling fluid flows at least partially in the radial direction in the at least one connecting section, and therefore the cooling fluid can also be conducted through the electrical machine in the radial direction as a result. Furthermore, the component streams of the cooling fluid, which component streams are conducted through the C section and the D section, are combined in the at least one connecting section, and therefore possible temperature differences in the region between the C section and the D section can be substantially compensated for by through mixing in the at least one connecting section. In addition, the at least one connecting section is preferably arranged in the region of a central plane of the electrical machine, the greatest quantity of heat being released in the region of said connecting section. The connection section, in particular the flow cross section of the connecting section, is, in this case, preferably designed to the effect that the cooling fluid is conducted through the connection section in a turbulent stream. This results firstly in good admixing of the cooling fluid and secondly heat can be absorbed particularly effectively in the case of a turbulent stream, this having the advantage that a particularly effective cooling action of the cooling fluid is also possible in the at least one connecting section on account of the turbulent stream in the region of the electrical machine with the greatest need for cooling because the greatest quantity of heat is produced in said region.
In particular, the at least one channel is formed in the housing and/or in the stator, and/or the cooling fluid is a liquid, in particular an oil or a water/glycol mixture, and/or the cooling fluid can be conducted through the at least one channel in the radial and axial direction of the electrical machine, and can preferably be conducted in a meandering manner, in particular with opposing axial flow.
A drive device according to the invention, preferably a hybrid drive device, in particular for a motor vehicle, comprises preferably an internal combustion engine, in particular for driving the motor vehicle, preferably at least one housing, at least one electrical machine, which is preferably arranged in the at least one housing and has a stator and a rotor, with the at least one electrical machine being designed in accordance with an electrical machine as described in this property right application.
In a further refinement, the at least one housing has two or more parts.
In an additional refinement, the housing has one part.
In a further refinement, the at least one electrical machine operates as a motor and/or as a generator.
A motor vehicle according to the invention comprises an electrical machine which describes this property right application and/or a drive device as described in this property right application.
In a further refinement, the motor vehicle comprises rechargeable batteries. The batteries supply electrical power to the electrical machine and, when the motor vehicle is decelerated by means of the electrical machine, the batteries can be charged by the electrical power generated by the electrical machine. In addition, the batteries can also be charged when the vehicle is stationary, for example by a public power supply system. In particular, the batteries are in the form of lithium ion batteries.
BRIEF DESCRIPTION OF THE DRAWINGS
One exemplary embodiment of the invention will be described in greater detail below with reference to the attached drawings, in which:
FIG. 1 shows a highly schematic illustration of a hybrid drive device,
FIG. 2 shows a side view of an electrical machine,
FIG. 3 shows a section A-A according to FIG. 2 ,
FIG. 4 shows a perspective view of the housing of the electrical machine according to FIG. 1 comprising a channel for conducting a cooling fluid,
FIG. 5 shows a plan view of the housing of the electrical machine according to FIG. 1 comprising the channel for conducting the cooling fluid, and
FIG. 6 shows a view of a motor vehicle.
DETAILED DESCRIPTION
A drive device 1 , in the form of a hybrid drive device 2 , for a motor vehicle 3 is illustrated in FIG. 1 . The hybrid drive device 2 for a motor vehicle 3 comprises an internal combustion engine 4 and also an electrical machine 5 which operates as a motor 32 and a generator 33 , in each case for driving or decelerating the motor vehicle 3 . The internal combustion engine 4 and the electrical machine 5 are connected to one another by means of a drive shaft 20 . The mechanical coupling between the internal combustion engine 4 and the electrical machine 5 can be established and broken by means of a clutch 19 . Furthermore, an elasticity means 21 is arranged in the drive shaft 20 which couples the internal combustion engine 4 and the electrical machine 5 to one another. The electrical machine 5 is mechanically coupled to a differential transmission 23 . A converter 22 and a transmission 28 are arranged in the drive shaft 20 which connects the electrical machine 5 and the differential transmission 23 to one another. The drive wheels 25 are driven by means of the differential transmission 23 via the wheel axles 24 .
Other options (not illustrated) besides the arrangement illustrated in FIG. 1 of the internal combustion engine 4 and the electrical machine 5 for the motor vehicle 3 are also feasible. For example, the electrical machine 5 can be arranged on the side of the internal combustion engine 4 and can be mechanically connected to the internal combustion engine 4 by means of a belt or a chain or by gear wheels (not illustrated) instead of the drive shaft 20 depicted in FIG. 1 . In addition, the electrical machine 5 could be arranged on a transmission, for example a differential transmission, or the electrical machine 5 can operate as a wheel hub motor and/or as a wheel hub generator, that is to say it can be arranged in the region of a wheel hub (not illustrated).
FIGS. 2 and 3 show the electrical machine 5 for the hybrid device 2 in the form of an internal pole machine in a first embodiment with a stationary stator 6 and a rotating rotor 7 of the hybrid drive device 1 in a highly simplified illustration, and therefore electrical lines, the windings of the stator 6 and of the rotor 7 , and fixing means for the stator 6 , for example, are not illustrated or are illustrated only in a highly simplified manner. A shaft 8 comprises metal, for example steel, on which the rotor 7 is arranged in a concentric manner, with the shaft 8 and the rotor 7 being mounted on the stationary housing 9 by means of a bearing (not illustrated). The shaft 8 , the rotor 7 and the stator 6 are arranged within the housing 9 . The stator 6 is arranged, concentrically around the rotor 7 , on a housing 9 , said stator being mounted on said housing by means of fixing means (not illustrated). The stator 6 can also be mounted on the housing 9 without additional fixing means, for example by means of a compression joint and/or shrink-fit joint. The housing 9 is produced, for example, by means of a lost foam casting process, an investment casting process or a permanent mold casting process. The wall thickness of the housing 9 is, for example, in the range of from 2 to 6 mm. In this case, the shaft 8 is connected to the drive shaft 20 of the hybrid drive device 2 within the hybrid drive device 2 and/or constitutes a part of the drive shaft 20 .
The electrical machine 5 has a channel 11 for conducting a cooling fluid for cooling the electrical machine 5 . The channel 11 is integrated in the housing 9 of the electrical machine 5 . An inlet opening 36 for introducing the cooling fluid into the channel 11 and an outlet opening 37 for discharging cooling fluid from the channel 11 are formed in the outer face of the housing 9 of the electrical machine 5 ( FIGS. 2 to 5 ). The inlet opening 36 and the outlet opening 37 are formed in the region of a central plane 29 of the electrical machine 5 . The central plane 29 is perpendicular to an axis 30 of the shaft 8 . The greatest quantity of heat is given off by the stator 6 and/or the rotor 7 in the region of the central plane 29 . On account of the introduction of the cooling fluid into the inlet opening 36 in the region of the central plane 29 , the cooling fluid is therefore fed in in that region in which the greatest amount of heat is released within the electrical machine 5 , and therefore particularly effective cooling is possible in this critical region of the electrical machine 5 . The channel 11 constitutes a part of the cooling circuit 10 (not completely illustrated) of the electrical machine 5 having lines for the cooling fluid and having a heat exchanger or radiator for cooling the cooling fluid.
After the cooling fluid is introduced into the inlet opening 36 , the channel 11 splits into an A section 15 and into a B section 16 ( FIGS. 4 and 5 ). The A section 15 and the B section 16 form a first pair 13 of sections 15 , 16 of the channel 11 . The A section 15 and the B section 16 are both oriented in the axial direction, and therefore the cooling fluid flows in the axial direction of the electrical machine 5 in the A section 15 and in the B section 16 . On account of the cooling fluid being split into the A section 15 and the B section 16 , the cooling fluid in the A section flows in the opposite direction to in the B section 16 . The cooling fluid therefore flows to an axial end face 26 of the electrical machine 5 both in the A section 15 and in the B section 16 . The housing 9 , as a component 27 of the electrical machine 5 , has two axial end faces 26 ( FIGS. 4 and 5 ).
After flowing through the A section 15 of the channel 11 , the cooling fluid enters a curve section 31 of the channel 11 and flows further into a C section 17 of the channel 11 . Furthermore, the cooling fluid flowing through the B section 16 flows, in an analogous manner, through a further curve section 31 into a D section 17 of the channel 11 ( FIGS. 4 and 5 ). The C section 17 and the D section 18 together form a second pair 14 of sections 17 , 18 of the channel 11 . The cooling fluid flows in the axial direction of the electrical machine 5 in the C section 17 and in the D section 18 . The A section 15 , the B section 16 , the C section 17 and the D section 18 constitute sections 12 of the channel 11 in which the cooling fluid flows exclusively in the axial direction. Furthermore, the cooling fluid flows in opposing directions in the C section 17 and the D section 18 , and therefore the cooling fluid flows from the axial end face 26 to the central plane 29 of the electrical machine 5 . The first pair 13 and the second pair 14 are fluidically separated from one another or sealed off from one another by means of a separating crosspiece 34 . The two component streams of cooling fluid flowing through the C section 16 and the D section 17 are combined with one another and thoroughly mixed in a connecting section 35 of the channel 11 and flow to a further first pair 13 comprising an A section 15 and a B section 16 of the channel 11 . After flowing through the connecting section 35 , the cooling fluid is again split into two component streams, into a further first pair 13 comprising the A section 15 and the B section 16 . This flow process is repeated until the cooling fluid has flowed from the inlet opening 36 , around the entire circumference of the housing 9 , to the outlet opening 37 . At the outlet opening 37 , the cooling fluid is again conducted out of the housing 9 and cooled by means of a heat exchanger (not illustrated) of the cooling circuit 10 and then introduced into the inlet opening 36 again.
The cooling fluid therefore flows through the channel 11 in the housing 9 both in the axial direction and in the radial direction of the electrical machine 5 in a meandering manner. As a result, particularly effective and uniform cooling of the electrical machine 5 , in particular of the housing 9 , is possible on account of this opposing flow pattern of the cooling fluid in the housing 9 . The greatest quantity of heat is produced in the region of the central plane 29 of the electrical machine 5 . Here, the heat is absorbed by the cooling fluid and enters the first pair 13 comprising the A section 15 and the B section 16 on the two axial end faces 26 of the electrical machine 5 . Significantly less heat is given off by the stator 6 at the two axial end faces 26 than in the region of the central plane 29 . As a result, the temperature of the housing 9 in the region of the axial end faces 26 is lower than in the region of the central plane 29 . The cooling fluid can therefore give off heat to the housing 9 in the region of the axial end face 26 , for example in the region of the curve sections 31 of the channel 11 . This enables uniform temperature distribution in the axial direction of the housing 9 , and therefore the housing 9 can also give off heat to the surrounding area in a uniform manner. The connecting sections 35 of the channel 11 have a small flow cross-sectional area, and therefore the cooling fluid flows through the connecting sections 35 in a turbulent manner. This advantageously firstly permits particularly effective heat absorption by the cooling fluid in the region of the central plane 29 of the electrical machine 5 , and secondly particularly effective through mixing of the component streams from the C section 17 and the D section 18 of the cooling fluid is possible as a result.
Overall, the drive device 1 and the electrical machine 5 according to the invention have significant associated advantages. The cooling fluid is conducted through the channel 11 in the radial and axial direction of the electrical machine 5 in a meandering manner, and therefore the housing 9 can be uniformly cooled. | The invention relates to an electric motor, in particular for a motor vehicle, comprising a housing ( 9 ), a shaft ( 8 ) having an axle ( 30 ), a stator and a rotor, at least one channel ( 11 ) for conducting a coolant for cooling the electric motor ( 5 ), wherein the geometry of the alignment of at least one section ( 12 ) of the at least one channel ( 11 ) is designed such that the coolant flows in the direction of the axle ( 30 ) of the shaft ( 8 ) through the at least one channel ( 11 ), having a deviation of less than 40°. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a method, and to apparatus for carrying out the method, for facilitating the transfer of a fibrous web in a paper-making machine from a first foraminous belt to a second foraminous belt. In conventional Fourdrinier paper-making machines, the fibrous web formed on a wire is usually transferred from the wire to a felt by any of a number of known pickup devices. A common form of pickup system that is used in instances in which both the web and the felt have suitable moisture contents, relative to each other, the felt is merely brought into engagement with the web, such as by leading it around a plain roll, and the web will naturally stick to the felt and will thereafter cling to the underside of the felt, even when the felt runs horizontally. In many cases, for example, in the manufacture of thin fibrous webs with low basis weights and high water and air permeability, relatively high speed paper-making machines are used. Several machines for making low basis weight paper, such as tissue and similar light grades, involve the use of two wires or a wire and a felt that are brought together to form a convergent paper-forming zone, sometimes a curved paper-forming zone, where the water is extracted from the stock through one or both wires. One form of such a machine is described and shown in U.S. Pat. No. 3,326,745. In the machine described in that patent, the forming zone is constituted by a converging arcuate space formed between a wire and a felt that are led around part of the perimeter of the forming roll. In such machines, the web and felt both have relatively high moisture contents after formation of the web and the web naturally follows the felt when the felt and wire separate.
It is difficult to separate lightweight fibrous webs, say those with a basis weight of 25 g/m 2 or less, from a forming wire and transfer it to a relatively dry felt when the paper-making machine runs at a speed greater than about 1300 m/min (4000 ft./min). Among the problems that occur at separation is the clinging of pieces of fibers or small pieces of web to the wire when the web is separated from the wire. With the lightweight grades of sheet, the number of long fibers that lend strength to the sheet per unit of sheet area is relatively small, and the area of contact between the fibers in the sheet is not significantly greater than the area of contact between the fibers and the wire.
In machines in which the stock is drained under significant pressure through the wire during the web forming and consolidating process, such as in the case of machines having two wires or a wire and felt trained to define a converging pressure nip constituting the forming zone, the ends of many of the fibers are forced through the strands of the wire, and capillary forces develop between the wire and the fiber ends on the side of the wire opposite from the side on which the web is carried. Such capillary forces hold the ends of the fibers against the outside of the wire and result in a relatively strong adhesion of the web to the wire. Inasmuch as the web is of relatively low strength, complete fibers or pieces of fiber and small parts of the web frequently break away from the web when the web is separated from the wire, thereby tending to make the wire dirtier, clog the wire, cause increased wire wear and result in a substantial loss of controlled forming conditions.
SUMMARY OF THE INVENTION
There is provided, in accordance with the present invention, a method, and an apparatus for carrying out that method, of facilitating the transfer of a fibrous web in a paper-making machine from a first foraminous belt to a second foraminous belt. The method is applicable primarily to the transfer of fibrous webs of a basis weight of about 25 g/m 2 or less, that are being made at paper-making machine speeds in excess of about 1300 m/min. The invention makes it possible to separate the web from a wire without leaving any pieces of the web or objectionable amounts of fibers or fiber pieces on the wire. The use of the method and apparatus of the present invention thus ensures clean separation of the web from the wire so that the web can thereafter be readily transferred to a felt, preferably a relatively dry felt.
In accordance with the invention, the transfer of a fibrous web from a paper-making wire to a felt is facilitated by applying water to the side of the wire opposite from the side on which the web is carried partially to wet the web. Either before or after wetting the web, a felt is led into engagement with the web, and while the felt is in engagement with the web, the water or gas pressure on the wire side of the web is caused to exceed the water or gas pressure on the felt side of the web.
The wetting of the web substantially reduces the capillary forces acting between the strands of the wire and the fibers and pieces of fibers that are close to the strands of the wire, particularly fiber ends that protrude through the wire and tend to cling to the outside of the wire. The creation of a water or gas pressure differential between the wire and felt sides of the web assists in reducing the adhesion between the web and the wire to a minimum. The combination of reducing capillary forces between the strands of the wire and the fibers of the sheet and reducing adhesion between the web and the wire make it possible to transfer the web to a relatively dry felt while leaving the web in good condition and leaving the wire in clean condition.
The invention also makes it possible to employ a paper-making wire having a relatively high drainage capacity and to use a relatively dry felt, the dry felt being a particular advantage in processing the web in the drying section of the machine in that the dry felt can accept water from the web. It has been found quite unexpectedly that the wetting of the web, in accordance with the method of the present invention, does not offset to any significant degree the advantage of using a relatively dry felt to carry the web to and through the drying section of the machine. Only a relatively small quantity of water is needed to reduce the capillary forces between the sheet fibers and the strands of the wire to the point that the web is readily separated from the wire. It is sufficient to apply water to the wire and web in an amount of approximately 10 kg per kg dry weight of the web, and with conventional felts, that amount of water added to the web adds only about 0.2 kg of water per kg total dry weight of the web and felt. Generally, the felt can be dried such that it is led into engagement with the web with a water content of about 0.3 to about 0.4 kg water per kg dry weight of felt. Even when the additional water is added to the web in accordance with the method of the present invention, the ratio of total water content of the web and felt to the total dry weight of the web and felt is substantially less than the ratio that exists in conventional pickup systems, which is usually in the upper part of the range of from 1.5 to 3.5 kg water per kg total dry weight of the web and felt.
For a better understanding of the invention, reference may be made to the following description of some exemplary embodiments considered in conjunction with the figures of the accompanying drawings. Each of the FIGS. 1-6 of the drawings is a schematic side elevational view of a different embodiment of the invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
In the embodiment illustrated in FIG. 1, a paper-making wire 1 carries a newly formed fibrous web 13 from a forming section of the paper-making machine, and the wire and web are moving from left to right in the figure. The forming section of the machine may be of various types, such as the type shown in U.S. Pat. No. 3,326,745 or any of several types of paper-forming machines in which paper-making stock is drained under a relatively substantial hydrostatic pressure such as between two wires or a wire and a felt wrapped around part of the perimeter of a forming roll, over a curved fixed supporting structure or guided between supports or rolls, all of which types of forming devices provide a convergent forming zone in which hydrostatic pressure is developed in the stock to assist in draining the stock rapidly. In the case of forming rolls and shoes, substantial centrifugal forces assist in draining water from the stock through the wire. Such types of forming devices are known in the art and therefore are not described here or shown in the drawings.
The wire 1 travels from the forming section and is guided around a wire roll 3. A felt 5 is led in around a felt roll 7 into engagement with the web 13 on the wire at a point intermediate the end of the forming zone (not shown) and the wire roll 3 and travels conjointly with the wire and web to a suction pickup roll 9 having a suction box 11 extending along a part of the circumference of the roll. The line or zone of engagement between the suction pickup roll, which line or zone is designated by the reference numeral 15, constitutes a pickup point where the web 13 is picked off the wire and transferred to the felt by reason of a reduction in the gas pressure on the felt side of the web, relative to the gas pressure on the wire side of the web, due to suction in the suction box 11 in the pickup roll. The pressure differential across the web persists throughout the extent of the suction box and holds the web 13 on the felt 5 against the centrifugal force exerted on the web as it turns around the pickup roll. The felt 5 separates from the pickup roll near the end of the suction box, and the web 13 is carried by the felt to the drying section of the machine.
In the embodiment of FIG. 1, the transfer of the web from the wire to the felt is facilitated by applying water from a water supply conduit 17 that extends transversely across the wire and has a slot 19 that is co-extensive with the width of the web and faces the wire and the web. Water under pressure is supplied at a quantity and under pressures, using suitable controls (indicated schematically), to the conduit 17. The conduit 17 is pressed against the wire and is preferably sealed along either side of the slot, thus confining the stream of water to generally the area of the slot. A backup bar 21, which can be replaced by a roll, supports the wire web and felt against the pressure of the conduit against the wire. As described above, the application of water to the underside of the wire reduces capillary forces between the fibers of the web and the strands of the wire. Moreover, the hydrostatic pressure of the water assists in releasing the web from the wire. The pressure differential created by the suction box completes the separation of the web from the wire and the transfer of the web to the felt.
For the most part, the embodiments of FIGS. 2 to 6 of the drawings are the same as the embodiment of FIG. 1, and it is sufficient, therefore, merely to describe the differences. The same reference numerals are used throughout the drawings to assist in correlating the above description of FIG. 1 to the components in the embodiments of FIGS. 2 to 6.
In FIG. 2, the water conduit 17 is located relatively close to the felt lead-in roll 7, and no backing bar or roll 21 (see FIG. 1) is needed. The pickup roll is replaced by a suction box 23 and the web and felt travel to a felt turning roll 7', the web clinging to the underside of the felt between the suction box 23 and the turning roll 7'.
The only difference between the embodiments of FIGS. 2 and 3 is the addition of a turning roll 7" located very close to the suction box 23, thus moving the web transfer point 15 from the trailing edge of the suction box (see FIG. 2) to the zone of engagement between the turning roll 7' and the felt.
In the embodiment of FIG. 4, the wire 1, web 13 and felt 5 run conjointly over the water conduit 17, under a suction box 23, which creates a gas pressure differential across the web tending to remove it from the wire, and then around a segment of the circumference of a suction roll 9. The wire 1 then separates and is led around a wire roll 3. The suction in the suction box 11 of the suction roll 9 transfers the web to the felt, and the felt carries the web around the circumference of the suction roll 9 and presses it against a drying roll 25. Inasmuch as the drying roll is smoother than the felt, the web will stick to the drying roll at the outgoing side of the nip between the suction roll and the drying roll. The nip between the suction roll 9 and the drying roll 25 constitutes a press nip in which the web is partly dewatered. It is, of course, apparent to those skilled in the art that the web is dewatered along runs over suction boxes 23 and runs around the suction rolls 9 in each of the embodiments.
In the embodiment of FIG. 5, a water spray pipe 27 and an air pipe 29 having a slot 31 are used instead of the water supply conduit 17. The spray pipe 27 produces the wetting of the web while air under pressure is delivered to the pipe 29 and supplies a stream of air through the slot 31, which passes through the wire and creates a pressure differential across the web to reduce the adherence between the wire and the web. The web is separated from the wire and transferred to the felt at a transfer point 15 constituted by the zone of engagement of the suction roll with the wire, web and felt. In FIG. 6, the felt is not brought into engagement with the web until after water is applied from a water conduit 17 (or a spray pipe 27), but engages the web along the conjoint run of the wire, web and felt at a suction box 23 which creates a pressure differential that dewaters the web and reduces the adherence of the web to the wire. The felt is led away from the wire around a turning roll 7', the web separating from the wire and transferring to the felt at a transfer point 15 coincident with the downstream edge of the suction box 23. | The transfer of a fibrous web in a paper-making machine from a first foraminous belt to a second foraminous belt is facilitated by applying water to the side of the first belt opposite from the side on which the web is carried partially to wet the web, leading the second belt into engagement with the fibrous web before or after wetting it, and after the web is wet, and while the second belt is in engagement with the web, causing the water or gas pressure on the side of the web adhering to the first belt to exceed the water or gas pressure on the side of the web adjacent to the second belt. | 3 |
FIELD OF THE INVENTION
[0001] The illustrated and described embodiments of the present invention relate generally to architectural finish attachment assemblies and, more particularly, to architectural finish attachment assemblies used for attaching architectural finishes to building structures and to the methods of attaching architectural finishes to building structures using architectural finish attachment assemblies.
BACKGROUND OF THE INVENTION
[0002] An architectural finish in the form of moldings can transform a standard doorway into a grand archway and a fireplace mantle into a room's centerpiece. Or, an architectural finish in the form of wall cladding can provide a wall with an aesthetically pleasing finish, such as a stucco styled finish. Architectural finishes, such as moldings, cornices, and wall claddings, are widely used in the homebuilding industry as a way to increase the aesthetic and economic value of a home. To obtain market share and to establish a reputation, builders are seeking out variations on classic architectural finishes.
[0003] In the recent past, architectural finishes were typically formed from stone/concrete, wood, or stucco. With a number of advancements made within the foam industry, many builders are now utilizing pre-coated foam architectural finishes. One reason for their popularity is that they have a similar look and feel to precast, natural stone products, wood, or stucco, at the same time providing a significant reduction in raw material and installation costs. The foam based architectural finishes are also being used to accommodate climates adverse to wood and to offset rising wood costs.
[0004] In a typical construction, a mesh is applied to a foam core, which is in turn coated and topped with a stone like or other finish to create a product that is strong and aesthetically pleasing. The resulting product may be one-tenth the weight of precast stone. Further, the resultant product is easier and costs less money to install. It can be made in any shape and size. The manufacturing time is considerably less as well, and the cost is around 40 percent less for the installation of a foam product versus a precast product.
[0005] The foam base is easily formed into any shape, allowing designers wide latitude in designing the shape of the architectural finishes. The design aspects for coated foam products are infinite and have become extremely popular with architects and interior designers alike. The foam is dimensionally stable, resistant to expansion, contraction, warping, rotting, and twisting. Additionally the foam is not a nutrient source for insects, which is important in humid and termite-prone climates.
[0006] Although previously developed foam-based architectural finishes are effective, they are not without their problems. It has been discovered that previously developed architectural finishes are not well adapted for easy attachment to a building structure. In previously developed attachment methods, a permanent adhesive was applied to a back of the architectural finish, such as a stucco styled finish panel, in a prescribed pattern. A hot melt glue gun was then used to apply holt melt glue to the back of the finish panel. The finish panel was then quickly applied to the wall. The holt melt glue temporarily held the finish panel to the building structure while the permanent adhesive cured.
[0007] Although effective, this process has several drawbacks. For example, the method requires the installer to purchase hot melt glue guns and carry them around the job site, and locate power sources and rig extension chords between the hot melt glue guns and the power sources. Further, the installer is subject to injury from burns received from the hot melt glue gun. Additionally, the installer has very little time to set and position the finish panel before the hot melt glue dries. Further still, the installer has only one shot at correctly installing and positioning the panel, since once the hot melt glue dries, the panel often cannot be removed for realignment without damaging the panel. Also, due to the large size of the finish panel, it can take the installer a while to apply a sufficient amount of the hot melt glue to the finish panel such that the hot melt glue first applied starts to cure by the time the last of the hot melt glue is applied and the panel installed. For at least these reasons, previously developed application methods and attachment assemblies are cumbersome, labor intensive, costly, increase a potential of injury to the installer, do not permit realignment of the architectural finish, and decrease the quality of the installation of the product.
[0008] Thus, there exists a need for a method and an architectural finish attachment assembly which permits an architectural finish to be more easily attached to a building structure, that is reliable, permits realignment of the panel during initial installation, and/or is inexpensive to manufacture.
SUMMARY OF THE INVENTION
[0009] One embodiment of a method performed in accordance with the present invention for attaching an architectural finish to a building structure using an architectural finish attachment assembly having a spike is disclosed. The method includes attaching the architectural finish attachment assembly to the building structure with the spike facing outward from the building structure and applying an adhesive to the architectural finish. The method further includes impaling the architectural finish upon the spike such that the architectural finish is attached to the building structure with the adhesive in contact with the building structure and permitting the adhesive to permanently cure to adhere the architectural finish to the building structure.
[0010] Another embodiment of a method performed in accordance with the present invention for attaching an architectural finish to a building structure using an architectural finish attachment assembly having a spike is disclosed. The method includes placing the architectural finish attachment assembly against the building structure and attaching the architectural finish attachment assembly to the building structure with the spike facing outward from the building structure by passing a fastener through a preformed fastener aperture in the architectural finish attachment assembly and into the building structure. The method also includes applying an adhesive to the architectural finish and impaling the architectural finish upon the spike such that the architectural finish is removably attached to the building structure with the adhesive in contact with the building structure. The method further includes permitting the adhesive to cure to permanently adhere the architectural finish to the building structure while the architectural finish attachment assembly holds the architectural finish in place.
[0011] One embodiment of an architectural finish attachment assembly formed in accordance with the present invention for coupling an architectural finish to a building structure is disclosed. The architectural finish attachment assembly includes a base structure having a first surface adapted to engage the building structure and a second surface disposed opposite the first surface and a spike extending outward at an incline from the second surface, the spike adapted to impale the architectural finish for removably coupling the architectural finish to the building structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing aspects and many of the attendant advantages of this invention will become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0013] FIG. 1 is a perspective view of one embodiment of an architectural finish attachment assembly formed in accordance with the present invention;
[0014] FIG. 2 is a cross-sectional view of the architectural finish attachment assembly of FIG. 1 depicting the architectural finish attachment assembly in an installed state, coupling an architectural finish to a wall;
[0015] FIG. 3 is an exploded isometric view of the architectural finish attachment assembly, architectural finish, and wall of FIG. 2 showing the inner facing surfaces of the architectural finish attachment assembly, architectural finish, and wall;
[0016] FIG. 4 is an exploded isometric view of the architectural finish attachment assembly, architectural finish, and wall of FIG. 3 showing the outer facing surfaces of the architectural finish attachment assembly, architectural finish, and wall;
[0017] FIG. 5 is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of FIGS. 1-4 ;
[0018] FIG. 6 is an elevation view of the spike of FIG. 5 ;
[0019] FIG. 7 is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of FIGS. 1-4 ;
[0020] FIG. 8 is an elevation view of the spike of FIG. 7 ;
[0021] FIG. 9 is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of FIGS. 1-4 ;
[0022] FIG. 10 is an elevation view of the spike of FIG. 9 ;
[0023] FIG. 11 is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of FIGS. 1-4 ;
[0024] FIG. 12 is an elevation view of the spike of FIG. 11 ;
[0025] FIG. 13 is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of FIGS. 1-4 ;
[0026] FIG. 14 is an elevation view of the spike of FIG. 13 ; and
[0027] FIG. 15 is an isometric view of an alternate embodiment of an architectural finish attachment assembly formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Referring to FIGS. 1-4 , one embodiment of an architectural finish attachment assembly 100 formed in accordance with the present invention is illustrated and described. Generally described, the architectural finish attachment assembly 100 may be used to couple an architectural finish 102 to a building structure 104 . For instance, the architectural finish attachment assembly 100 may be used to temporarily attach the architectural finish 102 to the building structure 104 while a permanent adhesive 106 cures, permanently attaching the architectural finish 102 to the building structure 104 .
[0029] Turning to FIGS. 1 and 2 , and in light of the above general description of the architectural finish attachment assembly 100 , the structural components of the architectural finish attachment assembly 100 will now be described in detail. The architectural finish attachment assembly 100 may include a retainment assembly 108 , a base structure 110 , and one or more fastener apertures 112 . The base structure 110 may be a planar base plate having a perimeter of any geometric shape or combination of shapes, one suitable example being a rectangular 2.5 inch×2.5 inch plate as illustrated. The base structure 110 may have a first or inner surface 124 adapted to engage or be in proximity to the building structure 104 and a second or outer surface 126 adapted to engage or be in proximity to the architectural finish 102 .
[0030] Although the base structure 110 is illustrated and described as being planar, it will be appreciated by those skilled in the art that the base structure may also be contoured so as to be other than a planar structure. For instance, the base structure may to be cooperatively shaped to match a specific building structure shape, a few suitable example being an L-shaped base structure 110 adapted to conform to a corner of a building structure 104 (a few suitable examples being a stucco, brick, cementitious, or wood wall) or a contoured base structure 110 adapted to cooperatively conform to a contoured portion of the building structure 104 . The base structure 110 may be made of a rigid or semi-rigid material, a few suitable examples being plastic or metal, such as 22 gauge galvanized steel.
[0031] The base structure 110 may also include one or more fastener apertures 112 . The fastener apertures 112 pass through the base structure 110 and permit a fastener 116 to pass therethrough when the architectural finish attachment assembly 100 is coupled to the building structure 104 . The fastener apertures 112 also help in providing a template to aid an installer in correctly positioning and spacing the fasteners 116 when the architectural finish attachment assembly 100 is coupled to the building structure 104 . Although the base structure 110 is illustrated and described as having one or more fastener apertures 112 , it will be appreciated by those skilled in the art that the fastener apertures 112 are optional and may be eliminated. For instance, in one working embodiment, the base structure 110 is absent of fastener apertures 112 and the base structure 110 is simply adhered to the building structure 104 with an adhesive. In still another embodiment, the base structure 110 is absent of fastener apertures 112 and the fasteners 116 are simply driven through the base structure 110 without the aid of preformed fastener apertures 112 . Therefore, although fastener apertures 112 and fasteners 116 are illustrated and described with respect to the illustrated embodiment, it should be apparent to those skilled in the art that the fastener apertures 112 and fasteners 116 are illustrative in nature and non-limiting, and may be eliminated without departing from the spirit and scope of the present invention.
[0032] The retainment assembly 108 may include one or more spikes 114 . The spikes 114 may extend substantially perpendicularly outward from the base structure 110 , or may extend at other angles relative to the base structure 110 , a few suitable examples being at angles exceeding about 45, 55, 65, 75, or 85 degrees relative to the base structure 110 . The spikes 114 may be integrally formed with the base structure 110 or may be a separate structure coupled to the base structure 110 . The spikes 114 may be made from any rigid or semi-rigid material, a few suitable examples being plastic or metal, such as galvanized steel or aluminum.
[0033] In the illustrated embodiment, a perimeter shape of the spikes 114 is cut or stamped into the base structure 110 , and then the spikes 114 are bent from an orientation coplanar with the base structure 110 to an orientation wherein the spikes 114 are inclined relative to the base structure 110 , for instance so as to be substantially perpendicular to the base structure 110 . Once the spikes 114 are bent up as described, spike cut-out apertures 118 remain in the base structure 110 , the spike cut-out apertures 118 having a perimeter shape substantially identical to the perimeter shape of the spikes 114 .
[0034] The spikes 114 may be shaped in any suitable manner having sufficient strength to puncture the architectural finish without collapsing or excessively bending. In FIGS. 1-4 , spikes 114 are illustrated which are planar with a constant width base and a tip which tapers to a point. Preferably, the planar surface of each spike 114 is horizontally oriented to provide a “support shelf” for supporting the weight of the architectural finish 102 and to impede the architectural finish 102 from sliding downward as the adhesive securing the architectural finish 102 to the building structure 104 cures. Although the spikes 114 are illustrated and described as being horizontally oriented, it should be apparent to those skilled in the art that the planar surface of each spike may be oriented in any other direction, such as vertical, etc.
[0035] In one embodiment, the illustrated spikes 114 are between about ¼ inch to ½ inch in height and about ⅛ inch to ½ inch in width. A few suitable alternate embodiments of spikes 114 suitable for use with and within the spirit and scope of the present invention are shown in FIGS. 5-14 . For instance, FIG. 5 shows a top view and FIG. 6 is an elevation view of an alternate embodiment of a spike 214 which is arcuate in shape. FIG. 7 shows a top view and FIG. 8 is an elevation view of an alternate embodiment of a spike 314 which is in the form of a hollow cylinder. FIG. 9 shows a top view and FIG. 10 is an elevation view of an alternate embodiment of a spike 414 which is planar in shape and which has an arrow shaped distal end with a pair of barbs 490 to aid in retention of the architectural finish upon the spike 414 . FIG. 11 shows a top view and FIG. 12 is an elevation view of an alternate embodiment of a spike 514 which is formed of two planar panels intersecting each other at an incline to form a X-shaped spike. FIG. 13 shows a top view and FIG. 14 is an elevation view of an alternate embodiment of a spike 614 which is cylindrical in shape to form a spike that is in the form of a pin. The spikes may be treated to provide a more slip resistant exterior surface, a few suitable examples of surface treating include galvanizing, distressing, twisting, curling, and roughening of the surface.
[0036] Referring to FIGS. 2-4 and in light of the above description of the structure of the architectural finish attachment assembly 100 , the installation of the architectural finish attachment assembly 100 will now be described. One or more architectural finish attachment assemblies 100 may be coupled to the building structure's 104 waterproof and code-compliant face or to an approved water-resistant membrane 113 of the building structure 104 via passing the fasteners 112 through the fastener apertures. For instance, the fasteners 116 may be screws or nails which are driven through the fastener apertures 112 , such that a head of the screw or nail clamps the base structure 110 to the building structure 104 . An adhesive or sealant may be applied to and around the heads of the fasteners 116 to seal the heads to impede moisture infiltration. Alternately, the architectural finish attachment assemblies 100 may simply be adhered to the building structure 104 without the use of fasteners 112 as discussed above, through the use of an approved adhesive.
[0037] A permanent adhesive 106 is strategically applied to a back surface 122 of the architectural finish 102 in accordance with well known techniques in the industry and upon the architectural finish attachment assemblies 100 . The architectural finish 102 is then pressed towards the building structure 104 such that the architectural finish 102 is impaled upon the spikes 114 and the permanent adhesive 106 contacts the building structure 104 . The spikes 114 of the architectural finish attachment assembly 100 hold the architectural finish 102 upon the building structure 104 until the permanent adhesive 106 cures, permanently adhering the architectural finish 102 to the building structure 104 .
[0038] If the initial installation of the architectural finish 102 is for any reason misaligned and needs adjustment, the architectural finish 102 may be simply pulled outward from the building structure 104 (as long as the permanent adhesive 106 has not yet cured). This causes the spikes 114 to pull out of the architectural finish 102 to permit the architectural finish 102 to be realigned and re-impaled upon the architectural finish attachment assembly 100 to attach the architectural finish 102 in the correct position.
[0039] Referring to FIG. 15 , an alternate embodiment of an architectural finish attachment assembly 700 is shown. The architectural finish attachment assembly 700 of FIG. 15 is substantially identical to the previously described embodiments in structure and use, and therefore, for the sake of brevity, only the aspects of the architectural finish attachment assembly 700 which depart from the previously described embodiments will be discussed herein. Generally stated, the architectural finish attachment assembly 700 of FIG. 15 departs from the previously described embodiments in that the fastener apertures of the previous embodiments have been removed and replaced with permanently attached building structure spikes 750 .
[0040] The building structure spikes 750 are adapted to be driven into a building structure to attach the architectural finish attachment assembly 700 to the building structure. The building structure spikes 750 may be shaped in any suitable manner permitting their attachment to a particular building structure. For instance, the building structure spikes 750 may be planar and triangular shaped as illustrated, or may take another form, such as the form of any of the above illustrated and described architectural finish spikes of the previously described embodiments. The building structure spikes 750 extend outward at an incline from an inner surface 752 of the base structure 710 of the architectural finish attachment assembly 700 , generally in an opposite direction of the architectural finish spikes 714 . In the illustrated embodiment, the building structure spikes 750 are oriented substantially perpendicular to the inner surface 752 of the base structure 710 , however other angles of inclination relative to the inner surface 752 are suitable for use with and within the spirit and scope of the present invention, such as angles exceeding about 45, 55, 65, 75, and 85 degrees. Preferably, the building structure spikes 750 are oriented parallel and in an opposite direction relative to the architectural finish spikes 714 .
[0041] In the illustrated embodiment, the building structure spikes 750 are offset from the spikes 714 used in impaling the architectural finish, thereby permitting an installer to strike the outer surface 753 of the base structure 710 directly above the building structure spikes 750 without hitting the architectural finish spikes 714 . Although a specific number of building structure spikes 750 are illustrated and described, it should be noted to those skilled in the art that any number of building structure spikes 750 may be used, a few suitable examples being a single building structure spike 750 , two or more, three or more, four or more, etc.
[0042] The building structure spikes 750 may be integrally formed with the base structure 710 or may be separate structures coupled to the base structure 710 . The spikes 750 may be made from any rigid or semi-rigid material, a few suitable examples being plastic or metal. In the illustrated embodiment, a perimeter shape of the building structure spikes 750 is cut or stamped into the base structure 710 , and then the spikes 750 are bent from an orientation coplanar with the base structure 710 to an orientation wherein the spikes 750 are inclined relative to the base structure 710 , for instance so as to be substantially perpendicular to the base structure 710 . Once the spikes 750 are bent up as described, spike cut-out apertures 754 remain in the base structure 110 , the spike cut-out apertures 754 having a perimeter shape substantially identical to the perimeter shape of the building structure spikes 750 .
[0043] While the 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. | An architectural finish attachment assembly ( 100 and 700 ) formed in accordance with the present invention for coupling an architectural finish ( 102 ) to a building structure ( 104 ). The architectural finish attachment assembly includes a base structure ( 110 and 710 ) having a first surface ( 124 and 752 ) adapted to engage the building structure and a second surface ( 126 and 753 ) disposed opposite the first surface and a spike ( 114, 214, 314, 414, 514, 614 , and 714 ) extending outward at an incline from the second surface, the spike adapted to impale the architectural finish for removably coupling the architectural finish to the building structure. | 4 |
BACKGROUND
[0001] The invention relates generally to a system and method for controlling an engine driving a generator based on engine conditions and generator load.
[0002] Engine-driven generators are commonly used to provide electrical power in locations where conventional electrical power is not readily available. Both gasoline and diesel engines are used to drive such generators, and the power produced is typically either 120 VAC or 240 VAC. An engine-driven generator may be used to supply power to a welding gun (e.g., torch, arc, or the like) for applications such as, for example, stick electrode welding, MIG welding, TIG welding, etc. These welding systems include a control system to regulate the power produced by the generator, thereby making it suitable for arc welding, plasma cutting, and similar operations.
[0003] Typical welding systems offer the user little customizable control over the engine settings. For example, the engine may employ an engine governor to control the engine speed. When the welding gun or an auxiliary device is connected to the system and turned on, the engine speed may increase to the speed required to power the load. This speed increase may be determined by a generic governor curve which slowly increases the engine speed to substantially prevent overshooting the required speed. No distinction is made between the weld load and the auxiliary load, such as a light, which may require significantly less power to operate than the welder.
[0004] In addition, during periods of non-use of the typical welding system, the engine speed may be reduced to an idle speed. However, this idle speed may still consume a great deal of energy and produce substantial noise levels. A user may have no choice but to endure these inconveniences or to manually turn the engine off when it will not be used for some time. The engine must then be manually restarted before the welding gun may be used again.
BRIEF DESCRIPTION
[0005] In accordance with certain aspects of the invention, a method for controlling an engine-driven generator/welder includes monitoring for a voltage and/or current draw on welding and auxiliary outputs of the generator, and controlling the speed of the internal combustion engine based upon the detected draw.
[0006] There is further provided a method for controlling an engine-driven generator/welder, including monitoring for a demand on a welding output of the generator, increasing the speed of the internal combustion engine using a custom control regime based on preset operating parameters when the demand is detected, and transitioning to an engine speed control regime based upon the engine speed.
[0007] The invention also provides an engine-driven generator/welder system, including an internal combustion engine, a generator driven by the internal combustion engine, and a controller configured to detect a weld demand on the welding power generator and to control the internal combustion engine at least in part based upon the detected weld demand and/or preset operating parameters.
DRAWINGS
[0008] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0009] FIG. 1 is a diagrammatical overview of an integrated engine and generator control scheme in accordance with certain aspects of the invention, permitting improved control of engine and generator functions;
[0010] FIG. 2 is a block diagram of an engine-driven generator/welder system according to an embodiment of the present invention;
[0011] FIG. 3 is an engine speed graph according to an embodiment of the present invention;
[0012] FIG. 4 is a flow chart illustrating an engine control process for producing a series illustrated in the engine speed graph of FIG. 3 according to an embodiment of the present invention;
[0013] FIG. 5 is a flow chart illustrating a further engine control process for producing another series illustrated in the engine speed graph of FIG. 3 according to an embodiment of the present invention;
[0014] FIG. 6 is another engine speed graph according to an embodiment of the present invention;
[0015] FIG. 7 is a flow chart illustrating another engine control process for producing a series illustrated in the engine speed graph of FIG. 6 according to an embodiment of the present invention;
[0016] FIG. 8 is a flow chart illustrating still another engine control process for producing yet another series illustrated in the engine speed graph of FIG. 6 according to an embodiment of the present invention;
[0017] FIG. 9 is a further engine speed graph according to an embodiment of the present invention;
[0018] FIG. 10 is a flow chart illustrating yet another engine control process for producing a series illustrated in the engine speed graph of FIG. 9 according to an embodiment of the present invention; and
[0019] FIG. 11 is an engine speed graph produced via a combination of the engine control processes illustrated in FIGS. 4 , 5 , 7 , and 9 according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0020] The present invention relates to control of an engine driving an electrical generator. An engine powering a generator/welder may include controls which affect the engine speed, ignition, fuel injection, spark timing, and any other controllable parameter of the engine based on various inputs. Such inputs may include, for example, currents or voltages supplied to loads, such as a welding gun and/or an auxiliary device, preset welding parameters, and time.
[0021] FIG. 1 is a diagrammatical overview of an exemplary integrated engine and generator control scheme in accordance with aspects of the present invention. As described in greater detail below, the system can be applied to a range of engines, such as gasoline engines and diesel engines. Moreover, the engine may include a wide range of measurable, observable and controllable parameters, such as, by way of example only, fuel flow, throttle position, speed, torque, power, spark advance (e.g., for gasoline engines), and so forth. Certain of these controls may be implemented mechanically, electromechanically or electronically, such as through the use of an electronic governor. In general, the engine will be started and will operate at speeds as determined by an integrated controller illustrated in FIG. 1 . The integrated controller can cause the engine to operate at particular speeds depending upon optimal operating conditions, draw by particular loads, as summarized in greater detail below, and so forth.
[0022] In the embodiment illustrated in FIG. 1 , the engine will drive a generator. Indeed, while the generator represents a load for the engine, the generator is, itself, a power source for electrical loads. In the diagrammatical illustration of FIG. 1 , other electrical power sources may also be included in the system, such as batteries, grid converters configured to draw power from an electrical grid and to provide it to electrical loads. In certain presently contemplated systems, the generator will operate in parallel with other electrical power sources such as batteries and grid converters. In terms of the engine operation, the loads are drawing electrical power from the generator, and/or other electrical power sources, can influence the control of the engine by the intermediary of the integrated controller. Thus, electrical parameters may be sensed for the generator, batteries, grid converters, and other electrical power sources and the integrated controller may use these sensed parameters to control the operation and performance of the engine. It should also be noted that the integrated controller may also regulate certain functions of the electrical power sources. For example, the controller may regulate a field of the generator so as to control power production by the generator in accordance with needs of electrical loads and coordinated with speed and torque control of the engine. In presently contemplated applications, the electrical power sources will generate controlled electrical power which is available for a variety of loads. The electrical power may be a function of the speed at which the engine turns the generator and the number of poles included in the generator, or this power may further processed as described below.
[0023] FIG. 1 also illustrates a number of exemplary loads that may draw electrical power from the electrical power sources, including the engine-generator set. In the presently contemplated embodiments, these include a welder and certain auxiliary loads. As will be appreciated by those skilled in the art, the welder requires significant power for creation of electrical arcs used to fuse metals in welding operations. The welder illustrated in FIG. 1 may convert power from the generator to power appropriate for the particular welding operation to be performed. As also described below, such welding operations may require constant voltage output regimes, constant current regimes, or various pulsed regimes, depending upon the nature of the welding operation. Auxiliary loads may include both alternating current and direct current loads, with output from the power sources being converted as necessary for the particular loads. In certain embodiments, the integrated controller may operate the engine at appropriate speeds and power levels to accommodate both welding loads and auxiliary loads. For example, tools, lights, and other loads designed to operate on alternating current at frequencies of a power grid (e.g., 60 Hz in North America) may require the engine to operate at specific speeds, depending upon the number of pulls of the generator. The integrated controller may sense output of the generator and output of the loads, or draw by the loads to regulate engine speed accordingly.
[0024] Other loads that may be powered by the system illustrated in FIG. 1 may include a battery charger. In many mobile applications, for example, it may be useful to drive the engine as an auxiliary power source to charge a vehicle battery. Several other loads are also illustrated in FIG. 1 , by way of a non-exhaustive list. Such other loads may include plasma cutters, wire feeders, alternating current sources used for specific operations, such as tungsten inert gas (TIG) welding, various welding accessories, power converters, such as inverters and choppers, and so forth. As with the welder and the auxiliary loads discussed above, the integrated controller may coordinate operation of the engine and/or generator to accommodate such loads based, for example, upon detection of connections, power draw, signatures of particular tools, and so forth.
[0025] The integrated controller may also take into account for control of the engine and/or generator, inputs from a variety of sources, several of which are listed in the diagram of FIG. 1 . Presently contemplated sources for control include various operator inputs. Such operator inputs may be included in a control panel or human interface on the welders/generator cabinet. By way of example, operator inputs may set weld parameters as discussed below. However, operator inputs may also include manual override of speeds, manual input of desired noise or fuel usage, and so forth. Inputs may also be networked as illustrated in FIG. 1 . Such networked inputs may include, for example, inputs received via a dedicated network connection, a LAN connection, a WAN connection, wirelessly, and so forth. Indeed, any of the inputs or even controlled parameters are regulated by the integrated controller may be input by an operator or by a network. Other input sources may include commands or requests for specific power or electrical parameters from any one of the loads coupled to the electrical power sources. Such inputs may further include devices coupled directly or indirectly to the engine and not through the electrical power sources. For example, in certain applications the engine may drive other devices (not shown in FIG. 1 ) such as air compressors, hydraulic pumps, and so forth, and the integrated controller may receive inputs indicating that such devices are active and join power from the engine, and alter the engine speed, fuel flow rate, output torque or power, and so forth based upon such inputs.
[0026] The integrated controller itself may take any suitable form, and will typically include one or more power supplies and one or more processors with associated memory for storing sensed parameter values, control programs, and so forth. Because the system, in many applications, will be mobile, the integrated controller will typically be packaged in a robust manner capable of operation in difficult environmental conditions along with the engine, generator, and other components of the system. The processor may include any suitable digital processor, such as microprocessors, field programmable gate arrays, and so forth. Memory devices may be provided as part of the processor package, such as in the case of a field programmable gate array, an additional memory may include flash memory, random access memory, read only memory, programmable read only memory, and so forth. The control routines for regulating operation of the engine and the generator may be written in any suitable computer language, and such code is considered to well within the ambit of those skilled in the art based upon the various control regimes discussed below.
[0027] The degree of integration of control implemented by the integrated controller may vary depending upon the sophistication of the control regimes envisaged. For example, as described in greater detail below, the integrated controller may sense certain electrical parameters of the power sources, and particularly those of the generator, and perform relatively simple operations, such as speed control based on throttle positions, fuel flow rate, and so forth for the engine. Much more sophisticated control regimes may, however, be implemented in which the controller regulates both parameters of the engine and parameters of the generator to accommodate particular loads and power needs.
[0028] As discussed above, depending upon the engine design, the generator design, and the anticipated loads, the integrated controller may perform various functions specifically adapted for those machines. In certain presently contemplated applications, for example, many functions of the engine may be controlled mechanically, and the engine may be based upon carborated fuel mixing. In other applications, the engines will include fuel injected versions. Mechanical or electronic governors may be accommodated, with carborated fuel mixing or fuel injection. As will be appreciated by those skilled in the art, for mechanical governors, the controller generally will not control the throttle position. Similarly, engines in the system may be single cylinder, twin cylinder, three cylinder or more, and may be liquid or air cooled.
[0029] As also mentioned above, control may be based upon the particular design of the generator and any other electrical power sources in the system. For example, in certain presently contemplated designs, the generator may employ an electrical rheostat for field control. Such field control may be regulated by the integrated controller. In such applications, the integrated controller may also control injectors for the engine, and all of such control may be based upon inputs from a welder, auxiliary loads of various types, and so forth.
[0030] FIG. 2 illustrates an engine driven welding and power generating system 10 in accordance with an embodiment of the present invention. The system 10 generally includes an engine 12 , a weld generator 14 , and a generator 16 for providing auxiliary power output. An integrated control system includes an engine controller 18 and a welder controller 20 , which can be fully or partially integrated to receive inputs for control from the engine, the weld generator and the auxiliary generator, and produce outputs for control of the engine, the generator, or both. The weld generator provides power for a welder 22 , which may be controlled by the weld controller 20 . The welder will typically include a welding gun (e.g., a MIG or TIG torch, stick handle, etc.). Various auxiliary loads or devices 24 (e.g., lights, power tools, radios, etc.) may be powered by power from the auxiliary generator 16 . The engine 12 may be a gasoline or diesel engine which drives the generators.
[0031] As illustrated in FIG. 2 , the controller 18 may receive inputs from the engine 12 , a user interface 52 , and/or power outputs from the generators. For example, sensors disposed within or coupled to the engine 12 may provide engine information to the controller 18 relating to engine operating conditions, settings, transient conditions, and so forth. Exemplary sensors may include a temperature sensor 26 , an oxygen sensor 28 , a manifold pressure sensor 30 , an RPM sensor 32 , a crank position sensor 34 . Further engine sensors may detect information regarding the throttle position, the fuel injection rate, the spark timing, mass air flow rate, and so forth. In addition, sensors coupled to the one or more power outputs of the generators 14 and 16 may provide information about loads drawing power from the generators (e.g., the welder 22 and/or the auxiliary loads 24 ). For example, a voltage sensor 36 and/or a current sensor 38 may be coupled to power output lines of the generator 14 to enable the controller to determine whether a load (e.g., welder 22 ) is drawing power from the generator, and the level of power draw. Similarly, a voltage sensor 40 and/or a current sensor 42 may be coupled to power output lines of generator 16 to detect draws from that generator. User inputs (e.g., preset operating parameters) may also be supplied to the controller via the user interface 52 . Exemplary preset operating parameters may include current and voltage requirements, process type (e.g., constant current, constant voltage, MIG, TIG, stick), wire electrode or stick size, and so forth. The user interface 24 may be integral with the system or may be an independent device, such as, for example, an input panel, a remote control system, and so forth. The user interface 24 may include, for example, a user input device such as a keypad, a keyboard, a mouse, a touch-screen, dials, switches, potentiometers, LEDs, lights, etc., and a display, such as a monitor, a CRT display, an LCD screen, etc.
[0032] In addition to receiving engine, process, and load information from inputs, the controller may send control signals to various engine systems. As described in more detail below, the controller may process some or all of the information gathered from the sensors 38 - 42 and/or input via the user interface 52 to alter engine operation settings. For example, the controller may manage an engine governor 44 (e.g., via a throttle plate), the ignition or crank timing 46 , a fuel injector 48 and its timing, a spark timer 50 , or any other engine component which may be controlled. To process all of the signals input to and output from the controller, the controller may, for example, include discrete analog and/or digital circuits, a logic device, a microprocessor, a microcontroller, a programmable logic controller, a field-programmable gate array, a complex programmable logic device, etc.
[0033] FIG. 3 is a graph 54 of generator speed 56 (e.g., revolutions per minute) versus time 58 in accordance with embodiments of the present invention. Referring generally to FIG. 2 for the components of system 10 and to FIG. 3 for the graph 54 , an idle speed 60 may be around 1800-2400 rpm for an internal combustion engine such as a two-cylinder gas engine. In another embodiment, a diesel engine may operate with an idle speed around 600-1200 rpm. The engine 18 powering the weld generator 14 and the auxiliary generator 16 may operate at an operating speed 62 . Generally, the normal operating speed 62 is the engine speed at which a synchronous power output frequency is produced. American devices typically utilize a 60 Hz frequency, and other devices utilize a 50 Hz frequency. The normal operating speed 62 of an exemplary two-cylinder gas engine may be about 3600 rpm, producing an alternating current with a frequency of about 60 Hz. An engine-driven four-pole generator may produce a 60 Hz frequency at about 1800 rpm. The engine operating speed 62 may be approximately based on the following equation:
[0000]
s
=
120
f
P
,
(
1
)
[0034] where s is the speed of the engine (rpm), f is the target frequency (Hz), and P is the number of poles in the generator. Other idle and operating speeds 60 and 62 may be used depending, for example, on the engine type (e.g., gasoline or diesel) and the engine design (e.g., number of cylinders, number of poles, etc.).
[0035] A trace 64 illustrates ramp-up of the engine speed 56 from the idle speed 60 to the operating speed 62 as observed in traditional engine control systems. For example, the welder 22 and/or the auxiliary load 24 may be turned on at a time 66 . Due to the increase in required torque when the engine load is increased, the speed 56 of the engine 12 initially decreases. After some time, the engine governor 44 detects the change in the engine speed 56 and increases the fuel flow rate to increase the engine speed 56 to compensate for the increased load. The engine speed 56 then increases to the operating speed 62 based on a governor curve. A traditional rpm-based control regime may utilize a generic governor curve to ramp up the engine speed 56 to the required speed for a given load (and to maintain the speed in an rpm-closed loop). That is, the engine speed 56 is ramped up relatively slowly so that the required speed for a given load is not greatly surpassed (i.e., to limit “overshoot”). To reach and maintain the operating speed 62 , the controller may employ various control techniques, such as, for example, closed-loop control, open-loop control, PID control, direct pole placement, optimal control, adaptive control, intelligent control, non-linear control, etc. After a time 68 , the engine speed 56 is generally constant at the operating speed 62 . As can be seen in the graph 54 , the trace 64 exhibits a significant droop after the load is introduced before the governor 44 begins to ramp up the engine speed 56 .
[0036] In contrast, a trace 70 illustrates an improved technique for ramping up the engine speed 56 when the welder 22 draws power from generator 14 . A user may input settings, such as the required current and voltage for the welder 22 , via the user interface 52 . The controller may then sense when the welder 22 is operative by monitoring the drawn voltage and current via the sensors 36 and 38 on the welding power output. Upon detection of a draw on the generator 14 , the controller may send a signal to the engine governor 44 to immediately begin ramping up the engine speed 56 based on a modified governor curve. For example, the user-input settings may be utilized in a lookup table, an algorithm, etc. to determine the governor curve which most efficiently increases the engine speed 56 to the desired operating speed 62 . The controller 22 may store information on any number of input-specific governor curves in addition to the generic governor curve. When the welder 22 begins to draw power at the time 66 , the engine speed 56 may decrease briefly under the load. However, because a signal is sent to the engine governor 44 as soon as the draw is detected, the governor 44 begins ramping up the engine speed 56 much faster than in the traditional engine control system illustrated by the trace 64 . Therefore, the engine speed 56 may be generally constant at the operating speed 62 after a time 72 . The delay from the onset of engine loading to the time 72 may be significantly less than that to the time 68 (traditional control) at which the trace 64 maintains the operating speed 62 .
[0037] Furthermore, the controller may employ different control regimes at different times in the ramp-up and speed maintaining process. For example, trace 70 illustrates a preset-based control regime further illustrated in FIG. 4 . In contrast, trace 64 illustrates a traditional rpm-based control regime. As can be seen in the graph 54 , the preset-based control regime (trace 70 ) could overshoot the operating speed 62 to a greater extent than the rpm-based control regime (trace 64 ). This phenomenon may be attributed to the techniques employed by the respective control regimes in increasing the engine speed 56 . To combine the increased speed ramp-up in the preset-based control regime with the stabilization of the rpm-based control regime, the controller may switch from one control regime to the other, such as depending on the engine speed 56 . For example, at a time 74 , as the engine speed 56 approaches the target operating speed 62 using the preset-based control regime (trace 70 ), the controller may switch to the rpm-based control regime (trace 64 ). By changing control regimes, the benefits of each type of control may be optimized.
[0038] FIG. 4 illustrates a process 76 by which the trace 70 ( FIG. 3 ) may be generated. Referring to FIG. 2 for the components of system 10 , to FIG. 3 for the graph 54 , and to FIG. 4 for the process 76 , preset operating parameters may be input (block 78 ), such as via the user interface 52 . The preset operating parameters may include, for example the current and voltage required by the welder 22 , a welding regime, details of the regime, etc. The engine load may then be determined based on the input settings for the welder 22 (block 80 ). That is, the idle speed 60 , the operating speed 62 , and/or the anticipated load to achieve the requisite current and voltage outputs for the welder 22 may be determined. For example, a lookup table, an algorithm, etc. may be utilized to determine the engine load, the idle speed 60 , and/or the operating speed 62 required for the load. These may be determined empirically, a priori, by testing of the engine under anticipated load conditions. After the operating parameters are input, the engine 12 may idle for a period of time (block 82 ), for example, while the user prepares the welder 22 . When the welder 22 becomes operative (e.g., an arc is struck), the controller senses a draw on the generator 14 (block 84 ). The controller may then send a signal to the engine governor 44 , ignition/crank input 46 , the fuel injector 48 , the spark timer 50 , etc., to begin ramping up the engine speed 56 from the idle speed 60 to the operating speed 62 (block 88 ). The ramp-up process may utilize an engine governor curve based on the user input settings and the anticipated operating speed 62 . For example, if the welder 22 requires output power that is generated when the generator operates at a speed 62 of 3600 rpm, the controller may adjust the engine operating settings to open the engine throttle to the requisite position for operating the engine at 3600 rpm. The engine then quickly ramps up to the operating speed 62 .
[0039] FIG. 5 illustrates a process 90 by which the engine control regime may be changed. Referring to FIG. 3 for the graph 54 and to FIG. 4 for the process 90 , the engine speed 56 may ramp up using the preset-based control regime (block 92 ). The engine speed 56 may then be monitored (block 94 ) and compared to the target operating speed 62 (block 96 ). If the engine speed 56 is not near the operating speed 62 , the ramp up continues using the preset-based control regime (block 92 ). However, if the engine speed 56 is near the operating speed 62 , the rpm-based control regime may be implemented (block 98 ). The threshold after which the engine speed 56 may be considered “near” the operating speed 62 may be a preset value, a user-input value, a percentage of the operating speed 62 , or another appropriate level.
[0040] FIG. 6 is a graph 100 of the engine speed 56 versus the time 58 in accordance with embodiments of the present invention. Referring generally to FIG. 2 for the system 10 components and to FIG. 6 for the graph 100 , in addition to the idle speed 60 and the rated speed 62 , a low idle speed 102 and an engine off speed 104 (i.e., stopped) are illustrated. For example, an engine with an idle speed 60 of 1800 rpm may have a low idle speed 102 of around 1600 rpm, although other low idle speeds 102 may be implemented. Reducing the engine speed 56 or turning the engine off during non-use serves to cool the engine and to reduce noise and fuel consumption when not servicing a load. In another embodiment, a high idle speed 105 may be implemented to anticipate demand of the welder 22 based on preset operating parameters. For example, if the engine has an idle speed 60 of 1800 rpm and a preset operating speed 62 of 3600 rpm, the high idle speed 105 may be approximately 3000 rpm. The high idle speed 105 , for example, may enable a faster increase to the operating speed 62 when the engine idles intermittently.
[0041] Traces 106 , 108 , and 114 illustrate possible energy-saving techniques which may be implemented in the system 10 . For example, if there is no draw on the generators after a time 110 , the engine speed 56 may decrease from the idle speed 60 to the low idle speed 102 (trace 106 ), or operation of the engine may be temporally interrupted (trace 108 ), reducing the engine speed 56 to the engine off speed 104 . Upon detection of a draw on the engine at a time 112 , the engine speed 56 may ramp up to the operating speed 62 using any of the control techniques discussed above. Furthermore, a combination of the low idle speed 102 and the engine off speed 104 may be employed, as illustrated by a trace 114 . For example, the engine speed 56 may decrease to the low idle speed 102 after the time 110 and may then decrease to the engine off speed 104 after a time 116 .
[0042] In another embodiment, the engine speed 56 may initially decrease from the operating speed 62 to the high idle speed 105 . Upon detection of a draw on the generators, the engine speed 56 may return to the operating speed 62 . However, if there is no draw detected after the time 110 , the engine speed 56 may decrease from the high idle speed 105 to a lower speed (e.g., the idle speed 60 , as illustrated by the trace 109 ; the low idle speed 102 ; the engine off speed 104 ; or another engine speed 56 ). It should be noted that the times 110 , 112 , and 116 may be different for different idle regimes. For example, it may be desirable to maintain the engine at the high idle speed 105 for a shorter period of time than for the idle speed 60 before transitioning to a lower engine speed 56 .
[0043] Turning to FIG. 7 , a process 118 by which the traces 106 , 108 , and 114 ( FIG. 6 ) may be generated is illustrated. Referring to FIG. 2 for the system 10 components, to FIG. 6 for the graph 100 , and to FIG. 7 for the process 118 steps, the engine 18 may operate at the high idle speed 105 or the idle speed 60 (block 120 ). The controller may monitor the current and voltage draws on the power outputs to determine if a load is drawing on the generators (block 122 ). If there is no draw, the engine speed 56 may be decreased to the idle speed 60 (e.g., from the high idle speed 105 ), to the low idle speed 102 (e.g., from the idle speed 60 or the high idle speed 105 ), or to the engine off speed 104 (e.g., from the idle speed 60 , the low idle speed 102 , or the high idle speed 105 ) (block 124 ). After the engine speed 56 decreases, the controller may continue to monitor the current and/or voltage from the generators via the sensors 36 - 42 (block 126 ). If either the welder 22 or the auxiliary load 24 draws a current and/or voltage, the engine may restart and/or the engine speed 56 may be ramped up to the operating speed 62 (block 128 ). In addition, a switch may be used to restart the engine after shutdown. For example, the welder 22 may include a switch so that the engine can be started remotely. If there is no draw on the generators, the engine speed 56 may remain at the idle speed 60 or the low idle speed 102 , or the engine may remain off (block 124 ). It should be noted that while four idle/off speeds are illustrated in the graph 100 ( FIG. 6 ) and the process 118 ( FIG. 7 ), any number and/or combination of idle/off speeds may be implemented in accordance with the present disclosure.
[0044] FIG. 8 illustrates a process 130 which incorporates multiple reductions in the engine speed 56 , as illustrated by the trace 114 ( FIG. 6 ). Referring to FIG. 2 for the system 10 components, to FIG. 6 for the graph 100 , and to FIG. 8 for the process 130 steps, the engine may idle at the idle speed 60 (block 132 ). The controller may monitor the engine speed 56 and/or the current and voltage draws on the generators to determine how long the engine has been at idle (block 134 ). If the engine 18 has not been at idle for the predetermined time, the engine speed 56 may remain at the idle speed 60 (block 132 ). However, if the engine has been at idle for a predetermined time, the engine speed 56 may decrease to the low idle speed 102 (block 136 ). The controller may then continue to monitor the engine speed 56 to determine how long the engine has been at the low idle speed 102 (block 138 ). If the engine has not been at the low idle speed 102 for the predetermined time, the engine speed 56 may remain at the low idle speed 102 (block 136 ). If the engine has been at the low idle speed 102 for a predetermined time, the engine may be temporally shut off, decreasing the engine speed 56 to the engine off speed 104 (block 140 ). After the engine shuts down, the controller may continue to monitor the sensors 36 - 42 for a load (block 142 ). If either the welder 22 or the auxiliary load 24 is turned on (i.e., begin to draw power, or demand power), the engine 18 may restart and the engine speed 56 may be ramped up to the rated speed 62 (block 144 ). In addition, a switch may be used to restart the engine after shutdown. For example, the torch 20 may include a switch so that the engine can be started remotely. If no load is detected, the engine may remain off (block 140 ). It should be understood that different combinations of idle speeds may be implemented in the process 130 , and any number of speeds may be employed to implement a gradual reduction in the engine speed 56 .
[0045] Turning to FIG. 9 , a graph 146 of the engine speed 56 versus the time 58 is illustrated in accordance with embodiments of the present invention. FIG. 2 is generally referred to for the system 10 components, and FIG. 9 is referred to for the graph 146 . In this aspect of the present invention, an “intelligent overspeed” 148 may be implemented to improve power output for welding, particularly when an auxiliary load 24 is not drawing power from generator 16 or is not sensitive to the frequency supplied by the generator 16 . It may be desirable to increase the speed 56 of the engine, and therefore the output of the generator 14 , when performing high-amperage processes, such as, for example, gouging, wire welding with a large wire, stick welding with a large stick, or processes involving multiple inverters. A trace 150 illustrates the use of the intelligent overspeed 148 . At a time 152 , the engine speed 56 may be increased from the normal operating speed 62 to a higher speed 148 . The higher speed 148 may be an engine speed 56 at which the welder 22 operates more efficiently (e.g., 3700-3800 rpm for a 2-pole gasoline engine, or 2400-3000 rpm for a 4-pole diesel engine). Other speeds 148 may be implemented depending on the operating parameters of the system and the welder 22 . In addition, the speed 148 may be a preset value, a user-input value, a value determined based on the weld settings, or any approximate speed.
[0046] In order to generate power at a higher frequency without damaging frequency-dependent auxiliary loads 24 , it may be desirable to provide a control scheme that prevents the engine speed from increasing when a frequency-dependent auxiliary load 24 is being utilized. For example, the system may be equipped with a proprietary auxiliary power socket in addition to or in place of a standard auxiliary socket. A frequency-independent auxiliary load may have a corresponding proprietary plug such that only frequency-independent auxiliary loads may be plugged into the auxiliary power socket. In the corresponding control regime, then, the engine speed 56 may not be increased if power is being drawn from the standard power socket but may be increased if power is being drawn from the proprietary power socket. In another embodiment, the controller may determine whether an attached auxiliary load is frequency-dependent. The engine speed may be increased only if there is no frequency-dependent auxiliary load drawing power from the system. Furthermore, in another embodiment, the system may include power management technology which regulates output voltage independent of input voltage, frequency, phase, etc. For example, Auto-Line™ technology, available from Miller Electric, may provide such power stability. The auxiliary sockets may therefore have regulated power output, while the weld power output may be variable-frequency.
[0047] FIG. 10 illustrates a process 154 by which the trace 150 ( FIG. 9 ) may be generated. Referring to FIG. 2 for the system components, to FIG. 9 for the graph 146 , and to FIG. 10 for the process 154 , the engine may operate at the operating speed 62 (block 156 ). That is, the welder and/or the auxiliary load may draw power from the generator. Using the sensors 36 - 42 , the controller may determine whether power is being drawn from the weld power output and/or the auxiliary power output of the generators (blocks 158 and 162 ). If welding power is not being drawn (i.e., the welder is not being operated), and if a frequency-dependent auxiliary load is drawing power (i.e., a frequency-dependent device is being utilized), the engine speed 56 may be maintained at the normal operating speed 62 (block 160 ). However, if welding power is being drawn (i.e., the welder is in use) and there is no frequency-dependent auxiliary load drawing power (i.e., no auxiliary device is in use, or only a frequency-independent auxiliary device is in use), the controller may increase the engine speed 56 to the higher speed 148 (block 164 ). By increasing the engine speed 56 , the generators are able to output power at a higher frequency. The welding gun 14 may operate more efficiently using the higher frequency power.
[0048] Finally, FIG. 11 illustrates a graph 166 of the engine speed 56 versus the time 58 illustrated in accordance with embodiments of the present invention. Referring to FIG. 2 for the system 10 components and to FIG. 11 for the graph 166 , a trace illustrates the combination of multiple aspects of the present invention. For example, the engine may start at the idle speed 60 . At a time 170 , the controller may detect a draw on the generator by the welder. Based on preset operating parameters input at the user interface, the engine speed 56 may ramp up quickly using the preset-based control regime. At a time 172 , as the engine speed 56 approaches the target operating speed 62 , the controller may switch to the rpm-based control regime. The engine speed 56 may then stabilize at the operating speed 62 . After a time 174 , the controller may determine that neither the welder nor an auxiliary load is not in use and reduce the engine speed 56 to the idle speed 60 . After no detected power draw for a further time 176 , the controller may reduce the engine speed 56 to the low idle speed 102 . Likewise, if no draw is detected after a time 178 , the controller may shut down the engine, effectively reducing the engine speed to the engine off speed 104 . When a load is detected at a time 180 , the controller may turn the engine on and ramp up the engine speed 56 to the operating speed 62 . Once again, the controller may transition from the preset-based control regime to the rpm-based control regime at a time 182 . At a time 184 , if the controller determines that there is not a frequency-dependent load on the engine (e.g., only the welder is in operation, or the welder and a non-frequency dependent device are in operation), the engine speed 56 may be further ramped up to the higher speed 148 .
[0049] It should be appreciated that any or all of the embodiments disclosed herein may be implemented in a single system, generator/welder, or generator. While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A system and method are provided for controlling an internal combustion engine driving a generator/welder or a stand-alone generator. Controlling the engine may include altering the engine speed based upon a detected demand on the generator and/or operating parameters of a welder. For example, the engine speed may be increased based on a detected draw on the generator and/or the operating parameters of the welder. In addition, the engine speed may be automatically decreased to a non-standard idle speed or the engine may be automatically turned off if no demand is detected for a period of time. Additionally, the engine speed may be increased if only frequency-insensitive demands are detected on the generator. Combinations of these and further methods may be executed. Various devices are provided for implementing the above methods. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Patent Application Ser. No. 61/609,532, filed Mar. 12, 2012, which is incorporated by reference herein.
BACKGROUND
Field
The disclosed concept pertains generally to electrical switching apparatus and, more particularly, to relays, such as, for example, aircraft relays.
Background Information
FIG. 1 shows a conventional electrical relay 2 including a movable contact 4 , which makes or breaks a conductive path between main terminals A 1 and A 2 . Terminals X 1 and X 2 electrically connect to solenoid actuator coil windings 6 , 8 . On many relays, the actuator coil has two separate windings or a partitioned winding used to actuate closure of separable main contacts, such as 10 , and to hold the separable main contacts 10 together in a relay closed or on state. The need for the two coil windings 6 , 8 is the result of the desire to minimize the amount of electrical coil power needed to maintain the relay 2 in the closed state.
A typical normally open relay has a spring (not shown) on its armature mechanism (not shown) that holds the separable main contacts 10 open. In order to initiate movement of the armature mechanism for closure, a relatively large magnetic field is generated to provide sufficient force to overcome the inertia of the armature mechanism and, also, to build up enough flux in the open air gap of its solenoid (not shown) to create the desired force. During closure motion of the armature mechanism, both coil windings 6 , 8 are energized to produce a sufficient magnetic field. After the main contacts 10 close, the reluctance of the magnetic path in the solenoid is relatively small, and a relatively smaller coil current is needed to sustain the force needed to hold the main contacts 10 together. At this point, an “economizer” or “cut-throat” circuit (not shown) can be employed to de-energize one of the two coil windings 6 , 8 to conserve power and to minimize heating in the solenoid.
The economizer circuit (not shown) is often implemented via an auxiliary relay contact 12 (E 1 -E 2 ) that is physically driven by the same solenoid mechanism (not shown) as the main contacts 10 . The auxiliary relay contact 12 simultaneously opens as the main contacts 10 close, thereby confirming complete motion of the armature mechanism. The added complexity of the auxiliary contact 12 and the calibration needed for the simultaneous operation makes this configuration relatively difficult and costly to manufacture.
Alternatively, the economizer circuit (not shown) can be implemented by a timing circuit (not shown) which pulses a second coil winding, such as 8 , only for a predetermined period of time, proportional to the nominal armature mechanism operating duration, in response to a command for relay closure (i.e., a suitable voltage applied between terminals X 1 -X 2 ). While this eliminates the need for an auxiliary switch, it does not provide confirmation that the armature mechanism has closed fully and is operating properly.
There is room for improvement in relays.
SUMMARY
This need and others are met by embodiments of the disclosed concept in which a relay comprises: a first terminal; a second terminal; a third terminal; a fourth terminal; separable contacts electrically connected between the first and second terminals; an actuator coil comprising a first winding and a second winding, the first winding electrically connected between the third and fourth terminals, the second winding electrically connected between the third and fourth terminals; a processor; an output; a first voltage sensing circuit cooperating with the processor to determine a first voltage between the first and second terminals; and a second voltage sensing circuit cooperating with the processor to determine a second voltage between the third and fourth terminals, wherein the processor is structured to determine that the separable contacts are closed when the first voltage does not exceed a first predetermined value and the second voltage exceeds a second predetermined value and to responsively output a corresponding status to the output.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the disclosed concept can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram of a conventional electrical relay.
FIG. 2 is a block diagram in schematic form of a circuit for sensing a direct current (DC) voltage on relay terminals in accordance with an embodiment of the disclosed concept.
FIGS. 3A and 3B are block diagrams in schematic form of other current limiting circuits for the DC voltage sensing circuit of FIG. 2 .
FIG. 4 is a block diagram in schematic form of a circuit for sensing alternating current (AC) or an inverted voltage on relay terminals in accordance with another embodiment of the disclosed concept.
FIG. 5 is a block diagram in schematic form of a circuit for sensing a direct differential terminal voltage in accordance with another embodiment of the disclosed concept.
FIG. 6 is a block diagram in schematic form of a circuit for indirect differential DC terminal voltage sensing in accordance with another embodiment of the disclosed concept.
FIG. 7 is a block diagram in schematic form of a circuit for indirect differential AC or inverted terminal voltage sensing in accordance with another embodiment of the disclosed concept.
FIG. 8 is a block diagram in schematic form of a relay including two terminal voltage sensing circuits for the main contacts (or load terminals) and the coil control terminals in accordance with another embodiment of the disclosed concept.
FIG. 9 is a block diagram in schematic form of a relay including two ground referenced terminal voltage sensing circuits for the main contacts (or load terminals) and the coil control terminals in accordance with another embodiment of the disclosed concept.
FIG. 10 is a block diagram in schematic form of a relay including two dual input/dual output terminal voltage sensing circuits for the main contacts (or load terminals) and the coil control terminals in accordance with another embodiment of the disclosed concept.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As employed herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality).
As employed herein, the term “processor” shall mean a programmable analog and/or digital device that can store, retrieve, and process data; a controller; a computer; a workstation; a personal computer; a microprocessor; a microcontroller; a microcomputer; a central processing unit; a mainframe computer; a mini-computer; a server; a networked processor, or any suitable processing device or apparatus.
As employed herein, the statement that two or more parts are “connected” or “coupled” together shall mean that the parts are joined together either directly or joined through one or more intermediate parts. Further, as employed herein, the statement that two or more parts are “attached” shall mean that the parts are joined together directly.
The disclosed concept is described in association with aircraft relays, although the disclosed concept is applicable to a wide range of electrical relays.
Referring to FIG. 2 , by providing voltage sensors, such as 20 , in order that the voltages at the main contacts 10 or load terminals (A 1 -A 2 ) and the coil control terminals (X 1 -X 2 ) of FIG. 1 are known, control of the relay 2 can be optimized and diagnostic information can be obtained. Specifically, if the voltages at the load terminals (A 1 -A 2 ) are monitored, then the timing of contact closure can be determined and, hence, could be employed by an alternative mechanism to energize the two coil windings 6 , 8 . For example and without limitation, a suitable processor, such as an embedded microcontroller or an analog control circuit, can be employed as a main controller to switch off a second coil winding (e.g., without limitation, employing a solid state power transistor; a switch; a signal relay). Furthermore, if the main controller knows the two sets of terminal voltages, then by employing suitable deductive logic, basic diagnostics and/or health monitoring of the relay 2 can be performed on a continuous basis. For example, if there is no voltage applied to the coil control terminals (X 1 -X 2 ) (i.e., an open command), yet the load terminals (A 1 -A 2 ) both have equal, but non-zero voltages on them, then this could indicate that the main contacts 10 are welded and are incapable of opening.
The example electronic circuit 20 of FIG. 2 can be employed to sense voltages across two input terminals 22 , 24 . This circuit 20 can sense both AC and DC voltages, although only a positive voltage is acknowledged. If a difference in properly polarized voltage is present across the input terminals 22 , 24 , then the series combination of rectifier diode 26 , zener diode 28 , current limiting diode 30 and input light emitting diode (LED) 32 of opto-isolator 34 begin to conduct. The diode 26 protects the opto-isolator LED 32 from reverse voltages and may be omitted if reverse voltages are not expected. The zener diode 28 sets a minimum voltage needed for detection. This can be employed to avoid false detection of a stray voltage or noise on the input terminals 22 , 24 . The current limiting diode 30 controls the current such that a suitable current flows regardless of the input terminal voltage. The diode 30 can be replaced by a plurality of series-connected diodes (not shown) if terminal voltages are expected to exceed the diode's rated reverse voltage. In that case, as is conventional, a suitable voltage balancing resistor network (not shown) can be employed parallel to the series-connected diodes. The photo-transistor detector 36 of the opto-isolator 34 outputs a suitable logic output 38 to a processor (e.g., microprocessor) (not shown) to determine the state of the system operatively associated with the two input terminals 22 , 24 . If the logic output 38 is employed to sense an alternating current (AC) voltage, the logic output 38 can be suitably filtered or time averaged since, otherwise, it is only active (i.e., logic low in this example) during the positive half cycle of an input AC voltage.
FIGS. 3A and 3B show a suitable combination of a resistor 40 and a JFET 42 , and a resistor 44 and a depletion-mode MOSFET 46 , respectively, that can be substituted for the current limiting diode 30 of FIG. 2 .
FIG. 4 shows a bi-polar circuit 50 corresponding to the circuit 20 of FIG. 2 . The bi-polar circuit 50 operates in the same manner, except that both positive and negative terminal voltages can generate an output logic signal 52 . This allows detection of both positive and negative half-cycles of an AC signal at input terminals 54 , 56 . Some suitable processing of the output logic signal 52 is employed by a monitoring circuit (not shown), in order to account for output interruptions near the AC waveform zero-crossings.
FIG. 5 shows another circuit 60 for sensing differential AC or DC voltages across two input terminals 62 , 64 . The example circuit 60 has an advantage over the circuits 20 , 50 of FIGS. 2 and 4 and provides a relatively high input impedance with relatively less loading of the input terminals 62 , 64 (i.e., there are relatively very low leakage currents). The operational amplifier 66 is configured as a common differential amplifier. Resistors 68 , 70 , 72 , 74 are selected to provide an overall gain (or attenuation) of the amplifier stage, such that an appropriate voltage is presented at the op-amp output 76 for driving the opto-isolator input LEDs 78 , 80 . The op-amp output signal 82 is proportional to the differential voltage on the input terminals 62 , 64 . Since a minimum voltage is needed to bias the input LEDs 78 , 80 on, this circuit 60 provides no logic output with near zero input voltages. This circuit 60 also can avoid false detection of a stray voltage or noise on the input terminals 62 , 64 . Diodes 84 and 86 clamp the input voltage protect the op-amp 66 from relatively high input voltage transients. The op-amp 66 employs an independent, isolated power supply (not shown) for power; however, if a plurality of circuits, such as 60 , are employed to sense a plurality of other terminal pairs (not shown) at similar voltage levels, then a common power supply (not shown) can be employed for these circuits.
FIG. 6 shows a circuit 90 including two voltage comparators 92 , 94 to detect the presence of voltage on the main relay terminals (A 1 -A 2 ). This circuit 90 senses the presence of voltage with respect to a common ground reference 96 , such as for example and without limitation, the chassis of an aircraft (not shown) in which a corresponding relay (not shown) is installed. The example circuit 90 employs two resistor divider networks, 98 , 100 and 102 , 104 , to indirectly present proportionately scaled voltages at the non-inverting (+) inputs of the two comparators 92 , 94 . By comparing these voltages to a predetermined voltage reference, Vref, each of the two comparator outputs 106 , 108 represents the corresponding terminal input voltage and provides a high-level logic signal if the corresponding terminal input voltage is above a predetermined value as determined by the ratio of the corresponding resistor divider network resistances and the predetermined voltage reference Vref voltage. The example circuit 90 senses positive DC voltages.
Alternatively, AC voltages can be detected if diodes (not shown) are added at the inputs in series with the resistors 98 and 102 , and processing of the output signals is provided as was discussed, above, in connection with the circuit 20 of FIG. 2 . As with that circuit 20 , only the positive half-cycle voltage is detected. If the monitoring circuit (not shown) is powered from a chassis-referenced power supply (not shown), then the same power supply can power the two comparators 92 , 94 .
FIG. 7 shows a window comparator-based sensing circuit 110 , which can sense AC voltages. This circuit 110 works similar to the circuit 90 of FIG. 6 , except that the comparators 112 , 114 , 116 , 118 are configured in pairs to produce logic-high outputs 120 , 122 when each corresponding input terminal voltage is near zero. The near zero range is determined by the ratios of the resistor divider networks, 124 , 126 and 128 , 130 , and the voltage reference levels, Vref_1>0 and Vref_2<0. The example comparators 112 , 114 , 116 , 118 have open collector outputs in order to logic-OR their outputs to implement the window comparator function. Alternatively, the two outputs of each window comparator pair can employ an exclusive-OR discrete electronic logic gate (not shown) or the main controller circuit (not shown) can generate a single output signal that switches states only if both sensed input terminal voltages are unequal, as would be the case if the corresponding relay contacts (not shown) were open. As with the circuit 90 of FIG. 6 , the power supply (not shown) of the main controller circuit (not shown) is referenced to the chassis ground 96 .
The voltage sensing circuits 20 , 50 , 60 , 90 , 110 of FIGS. 2 and 4-7 are non-limiting examples of circuits to sense relay terminal voltages, although a wide range of suitable voltage sensing circuits may be employed. FIG. 8-10 show examples of relay systems 140 , 240 , 340 including these voltage sensing circuits. In FIG. 8 , both of the load terminals (A 1 -A 2 ) and the coil control terminals (X 1 -X 2 ) of relay 141 are monitored by one of these voltage sensing circuits, such as the direct differential terminal voltage sensing circuit 60 of FIG. 5 . A relay controller module 142 receives the logic outputs 144 , 146 of the voltage sensing circuits 20 , 50 or 60 and uses suitable logic (e.g. without limitation, as shown in Table 1, below, which shows diagnostics with only voltage sensing) to determine the state of the relay main contacts 10 . The term “V High” means that the input terminal voltage is above a corresponding suitable predetermined threshold voltage for that terminal, and the term “V Low” means that the input terminal voltage is below a corresponding suitable predetermined threshold voltage for that terminal. These corresponding suitable predetermined threshold voltages can be the same, although upper and lower thresholds for each signal preferably allow for out-of-range parameter detection.
The controller module 142 can be any suitable processor, such as for example and without limitation, an embedded microcontroller circuit, digital logic circuitry and/or discrete analog components. The controller module 142 implements an economizer circuit function by direct control from output 143 of a suitable switch 148 electrically connected in series with the second pull-in solenoid coil winding 150 . The switch 148 can be, for example and without limitation, a suitable signal electro-mechanical relay or a suitable semiconductor device, such as a transistor. The controller module 142 sends relay status information 152 by a suitable communication interface 154 to a power distribution unit (PDU), a main controller or a load management controller 156 (e.g., for a vehicle).
Example 1
A load terminal (A 1 -A 2 ) differential voltage can be about 50 mV to about 175 mV when the separable contacts are closed in the presence of a suitable load current, while the load terminal A 2 can be at about 0 mV when the separable contacts are open.
TABLE 1
V A1-GND
V A2-GND
V A1-A2
V X1-GND
V X2-GND
V X1-X2
Information Deduced
Status
Low
Low
Low
Low
Low
Low
No power on input; Relay commanded open;
No Fault
Relay contact status: undetermined
High
Low
High
Low
Low
Low
Power present at input; Relay commanded open;
No Fault
Relay contact status: open
High
High
Low
Low
Low
Low
Power present at input and output; Relay
Fault
commanded open; Relay contact status: possibly
closed (failed or welded)
High
High
Low
Low
High
High
Power present at input and output; Relay
Fault
command undefined (possible loss of connection
at input); Relay contact status; possibly closed
Low
Low
Low
High
Low
High
No power on input; Relay commanded closed;
No Fault
Relay contact status: undetermined
High
Low
High
High
Low
High
Power present at input; Relay commanded closed;
Fault
Relay contact status: open (failed to close)
High
High
Low
High
Low
High
Power present at input and output (normal power
No Fault
to load); Relay commanded closed; Relay contact
status: closed
High
High
Low
High
High
Low
Power present at input and output; Relay
Fault
commanded open (possible loss of connection
at input); Relay contact status: closed
In Tables 1 and 2:
V A1-GND is voltage at terminal A 1 with respect to ground (e.g. chassis ground); V A2-GND is voltage at terminal A 2 with respect to ground (e.g., chassis ground); V A1-A2 is differential voltage between terminals A 1 and A 2 ; V X1-GND is voltage at terminal X 1 with respect to ground (e.g., chassis ground); V X2-GND is voltage at terminal X 2 with respect to ground (e.g., chassis ground); V X1-X2 is differential voltage between terminals X 1 and X 2 ; Current (Table 2 only) is current flowing between terminals A 1 and A 2 ; Low means that voltage (or current) is below an expected minimum threshold; and High means that voltage (or current) is above an expected minimum threshold.
FIG. 9 shows another relay system 240 in which the four terminal voltages for (A 1 , A 2 , X 1 and X 2 ) of relay 241 are sensed with respect to the vehicle chassis ground 96 . The four discrete logic outputs 242 , 244 , 246 , 248 from the voltage sensing circuits 20 , 50 or 60 of FIG. 2, 4 or 5 are processed by the relay controller module 142 to determine the relay state in a similar manner as that of the relay system 140 of FIG. 8 . It will be understood, however, that any suitable combination of direct differential sensing and/or ground referenced sensing may be employed, depending on the needs of the particular application.
FIG. 10 shows another relay system 340 including a relay 341 in which the dual input/dual output indirect or direct differential terminal voltage sensing circuits 90 or 110 of FIG. 6 or 7 are employed. The dual input differential terminal voltage sensing circuits 90 or 110 detect differential voltage with respect to ground 96 and the dual outputs 342 , 344 and 346 , 348 of each of the sensing circuits 90 or 110 are processed by the relay controller module 142 .
Example 2
The disclosed concept replaces a relay auxiliary circuit with voltage sensing electronics. A suitably low voltage between the load terminals (A 1 -A 2 ) of the relay allows the elimination of a conventional relay auxiliary circuit and provides a status to a PDU, a main controller or a load management controller, such as 156 , which needs to know which relays of a power distribution system are on. Further, if the terminal set X 1 -X 2 is high and the terminal set A 1 -A 2 is low, then suitable electronics can be employed to transfer from the pull-in coil to the hold coil. This combines “coil control electronics” or a “cut-throat circuit” function with auxiliary switch functions. This eliminates various mechanical adjustments of the relay, and reduces the cost of the auxiliary switch and the cost of the coil control electronics.
Relays often use the circuit of FIG. 1 to switch between the pull-in and hold coils. The disclosed concept determines when there is a suitable high voltage (e.g., without limitation, 28 V) between the coil terminals and a suitable low voltage between the load terminals. Hence, the auxiliary circuit of the relay can be eliminated, which provides a significant cost and mechanical adjustment savings. Furthermore, if that is done, then these two signals can be used to “replace” the circuit of FIG. 1 that controls the coil. For example, if the relay has closed (as determined by the low voltage between the load terminals A 1 -A 2 ) and the coil voltage shows that it had closed (as determined by the high voltage between the coil terminals X 1 -X 2 ), then the relay controller module 142 ( FIGS. 8-10 ) can switch to the “hold coil”.
Example 3
Additionally, the disclosed voltage sensing circuits 20 , 50 , 60 , 90 , 110 and relay systems 140 , 240 , 340 can employ a current sensor 400 (shown in phantom line drawing in FIGS. 8-10 ) structured to sense current flowing through the load terminals (A 1 -A 2 ), then the relay can provide detailed load management information as shown in Table 2, which shows diagnostics with both voltage and current sensing. The term “I High” means that the sensed current is above a corresponding suitable predetermined threshold current, and the term “I Low” means that the sensed current is below a corresponding suitable predetermined threshold current. These corresponding suitable predetermined threshold currents can be the same, although upper and lower thresholds for each signal preferably allow for out-of-range parameter detection.
Suitable unique current and voltage thresholds can be employed to establish functional health limits for load current and voltage based upon insulation and/or contamination across the separable contacts.
TABLE 2
V A1-GND
V A2-GND
V A1-A2
V X1-GND
V X2-GND
V X1-X2
Current
Information Deduced
Status
Low
Low
Low
Low
Low
Low
Low
No power on input; Relay commanded open;
No Fault
Relay contact status: undetermined
Low
Low
Low
Low
Low
Low
High
Relay commanded open; Possible sensor failure;
Fault
Relay contact status: closed (possible failure or welded)
High
Low
High
Low
Low
Low
Low
Power present at input; Relay commanded open;
No Fault
Relay contact status: open
High
Low
High
Low
Low
Low
High
Power present at input; Relay commanded open;
Fault
Possible sensor failure; Relay contact status:
undetermined
High
High
Low
Low
Low
Low
Low
Power present at input and output; Relay commanded
Fault
open; Relay contact status: possibly closed (failed
or welded)
High
High
Low
Low
Low
Low
High
Power present at input and output; Relay commanded
Fault
open; Relay contact status: closed (failed or welded)
Low
Low
Low
High
Low
High
Low
No Power on input; Relay commanded closed;
No Fault
Relay contact status: undetermined
Low
Low
Low
High
Low
High
High
Relay commanded closed; Possible sensor failure or
Fault
source voltage collapse; Relay contact status:
undetermined
High
Low
High
High
Low
High
Low
Power present at input; Relay commanded closed;
Fault
Relay contact status: open (failed to close)
High
Low
High
High
Low
High
High
Relay commanded closed; Possible sensor failure;
Fault
Relay contact status: undetermined (possible high
resistance)
High
High
Low
High
Low
High
Low
Power present at input and output (normal power to
Fault
load); Relay commanded closed; Relay contact status:
closed; Load no drawing current (possible load fault)
High
High
Low
High
Low
High
High
Power present at input and output (normal power to
No Fault
load); Relay commanded closed; Relay contact status:
closed
Example 4
Non-limiting examples of current sensors, such as 400 , include Hall effect sensors for DC applications; current transformers for AC load imbalance and ground fault detection; and shunts on, for example, a 270 VDC contactor with corresponding thermal measurement for linear compensation. Current sensors can be placed, for example and without limitation, on terminals or lugs, around conductors, or within contactor buss bars (e.g., Hall effect: shunt).
Example 5
The disclosed concept can be employed in connection with the following features: (1) determination of contactor “open/close” state and communication of the same to remote systems, such as 156 of FIGS. 8-10 (e.g., without limitation, electronic or solid state auxiliary contacts; coil and plunger sealing redundancy (e.g., the current profile of the coil can be monitored to ensure that the plunger seals the magnetic path)); (2) determination of contactor “on/off” response time (e.g., without limitation, this time can be employed to indicate contactor health; coil performance; change in response time over the life of the product; change in performance as compared to other indicators, such as on resistance); (3) contactor “on resistance” (e.g., without limitation, this resistance can be saved and/or used to evaluate initial factory build performance; heat generation versus wear; performance versus number of electrical cycles (e.g., without limitation, typical relays are rated for 50,000 or 100,000 cycles; depending upon the application, the wear versus number of electrical cycles may need to be de-rated, load de-rated, or the contactor size may need to be increased if the device does not meet failure/quality criteria); impact on contactor performance when subjected to in-rush loads, capacitive loads, or a rupture fault current; also, this resistance can be employed to alert the user of potential reliability concerns, advice for contactor replacement, and/or re-torque of the contactor mounting mechanism); (4) contactor “in-rush current limit” (e.g., without limitation, this value can be used to indicate a potential issue with a downstream load, such as a three-phase motor wearing out and causing a much higher than expected starting in-rush current; this value can be used as a warning only for early diagnostics, such as a warning only for early diagnostics, such as a pump load wearing out or being in need of service); (5) contactor “over current” (e.g., this value (I 2 T) can be used to provide protection and replace in-line fuses in power distribution units; protection against relatively large feeder short circuit faults); (6) contactor “over temperature” (e.g., without limitation, this temperature can be used to provide a nearly linear I 2 T trip curve on a contactor by compensating for changes in resistance with changes in temperature and current; can be used as an input to a processor (e.g., a microcontroller) when sensing current using a shunt: can be taken on the contactor coil to provide a health measurement (e.g., checking for shorted coil windings; checking for a pull-in coil staying on as a result of, for example, a bad cut-throat circuit)); (7) contactor “power factors” (e.g., without limitation, the values can be employed to monitor power conditions on an aircraft and regulate the power within the power distribution unit delivering clean power to other aircraft systems/loads); (8) contactor “bounce” (e.g., without limitation, this parameter can be used to indicate contact wear; contamination; spring wear; misadjusted wear allowance; contactor nearing the end of useful life); (9) relay pull-in voltage; and (10) relay drop-out voltage.
Example 6
Relay separable contacts, such as 10 , usually start with a contact voltage drop (CVD) of about 50 mV to about 60 mV between A 1 and A 2 when fully closed at rated current. Typical relay specifications allow a change of CVD over life to about 100 mV, 125 mV or 150 mV. Loading on the separable contacts during use is usually about 50% of rating up to about 100% continuous; this concerns how relays or contactors are designed into systems and how they are typically loaded with current as compared to the maximum device rating. A relatively lower contact force corresponds to a relatively higher CVD. The load terminal voltage is essentially zero when the contacts are open. By monitoring the relay timing, when the A 1 -A 2 voltage changes state to the CVD, resulting from the X 1 -X 2 voltage, the voltage for pick-up and drop out and the relay timing can be determined. The ability to compare the A 1 -A 2 voltage versus the X 1 -X 2 voltage and timing allows the relay manufacturer to optimize the coil size, permits determining when to transfer from the pick-up coil to the hold coil, and permits determining the contact open or closed status.
As a result, a mechanical switch and/or a resistor-capacitor circuit are not needed for timing from the X 1 -X 2 input to the state change of the relay separable contacts. The mechanical link from the main separable contacts to the auxiliary switch is one of various error-prone adjustments along with switching from the pull-in coil to the hold (or “release”) coil. For example, the mechanical switch is usually spring actuated, which provides another force that the coil must “overcome”. Because of the lack of “precision” across broad environmental and voltage constraints, the “hold” timing is much broader than it “needs” to be and the coil has to be able to withstand the longer times.
In the disclosed concept, “coil control” electronics or timing circuits are used instead of mechanical adjustments. Mechanical wear would indicate/create a need for a relatively higher pick-up voltage to close the relay. As a result, a threshold can be set for when the pick-up voltage change is outside an acceptable range or trending to show wear.
Similarly, the drop-out voltage can be monitored. If more friction occurs, then this can be observed since the relay will hold closed at a relatively lower voltage. Also, the relay timing will change. As a result, a threshold can be set for when the drop-out voltage change is outside an acceptable range or trending to show wear.
While the example terminal voltage sensing circuits of FIGS. 2 and 4-7 include comparators and other similar circuits to generate a logic output indicative of the presence (or absence) of voltage with respect to a predetermined threshold, they do not provide an analog value that a processor may utilize to measure actual coil pick-up, drop-out or contact drop voltage levels. However, this functionality could be easily employed by providing selected analog signals generated internally in some of the circuits presented directly to the processor. For example, if the processor were implemented using a microprocessor, the microprocessor could employ an integral analog-to-digital (A/D) converter which could sample the analog signals from the sensing circuit to determine the actual terminal voltages for use in performing diagnostic functions. In the circuit of FIG. 5 , an analog voltage of the output signal 82 at the output of operational amplifier 66 is essentially a voltage proportional to the differential voltages sensed at the input terminals 62 , 64 . In the circuit of FIG. 6 , the analog voltages present at the non-inverting inputs of comparators 92 , 94 are also proportional to sensed terminal voltages and could be sampled by an A/D converter. A similar approach could be employed with the circuit of FIG. 7 .
In addition to determining wear by monitoring changes in operational voltages over a relay's life, changes in timing of the logic signals may also be used as indication of mechanism wear. For example, if the time period between detection of voltage application to the coil control terminals X 1 ,X 2 and the detection of appropriate voltages at relay terminals A 1 ,A 2 indicating contact closure increases, then this may be indicative of jamming or drag in the relay mechanism. A suitable predetermined maximum duration for this period may be determined for allowable relay performance, beyond which the relay may need to be inspected, serviced or replaced.
A thermistor or other suitable temperature sensor can be added to account for temperature effects. For example, the resistance of copper changes with temperature. The thermistor measures the temperature of the copper as an input to provide a linear signal when measuring current for over-current protection.
While specific embodiments of the disclosed concept have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof. | A relay includes a first terminal, a second terminal, a third terminal, a fourth terminal, separable contacts electrically connected between the first and second terminals, an actuator coil comprising a first winding and a second winding, the first winding electrically connected between the third and fourth terminals, the second winding electrically connected between the third and fourth terminals, a processor, an output, a first voltage sensing circuit cooperating with the processor to determine a first voltage between the first and second terminals, and a second voltage sensing circuit cooperating with the processor to determine a second voltage between the third and fourth terminals. The processor determines that the separable contacts are closed when the first voltage does not exceed a first predetermined value and the second voltage exceeds a second predetermined value and responsively outputs a corresponding status to the output. | 7 |
BACKGROUND AND SUMMARY
The invention relates to fluid filters, including oil filters, gasoline filters and water separating fuel filters for internal combustion engines. The invention provides a fluid retention cup cooperating with the filter to catch fluid spills during loosening and removal of the filter from the engine.
An internal combustion engine has a threaded stud to which an oil filter is mounted. The filter has an end facing the engine and sealed thereto by an outer circumferential gasket concentric to the stud. When changing engine oil and replacing the filter, the filter is unscrewed from the stud. During loosening and removal of the filter, oil typically spills from around the gasket. This oil spill may run down the side of the filter, the hand of the user, the filter wrench, or down the side the engine block, requiring cleanup.
The present invention provides a simple yet effective retention cup for catching oil spills from around the filter gasket. The invention has application to various fluid filters of the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view partially in section of an oil retention cup in accordance with the invention.
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a side view partially in section of an alternate embodiment of an oil retention cup in accordance with the invention.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a side view partially in section of another alternate embodiment of an oil retention cup in accordance with the invention.
FIG. 6 is an end view of the oil retention cup of FIG. 5.
FIG. 7 is a top view of the oil retention cup of FIG. 5.
DETAILED DESCRIPTION
FIG. 1 shows a portion of the engine block 2 of an internal combustion engine having a threaded stud 4 to which an oil filter 6 is mounted. Filter 6 is conventional, and has a top end 8 facing annular seating disk 10 of the engine and sealed thereto by an outer circumferential gasket 12 concentric to stud 14. Filter 6 has a top recessed plate 14 with an aperture 16 through which stud 4 extends. The central portion of plate 14 is of increased thickness and is internally threaded to receive stud 4, or an internally threaded separate member 18 is affixed to the top or bottom side of the central portion of plate 14 for receiving the stud. Stud 4 is hollow, and engine oil is circulated through the stud into the filter, and the oil then flows through return holes 20 in plate 14 back to the engine, all as is well known.
An oil retention cup 22 is provided by a cylindrical canister 24 having an open top end 26, a closed bottom end 28, and a cylindrical side wall 30 therebetween. Canister 24 is slid axially upwardly onto and around filter 6. Open top end 26 of the canister has an outer circumferential edge 32 forming a lip concentric to gasket 12 and spaced radially outwardly from the filter to form an annular gap 34 therebetween. Cylindrical side wall 30 of the canister has a plurality of inner filter-gripping portions 36, 37, 38, 39, 40 gripping filter 6 such that filter 6 may be removed from stud 4 by gripping the outer surface of canister 24 such that inner filter-gripping portions 36-40 grip filter 6, and then turning canister 24 such that canister 24 and filter 6 turn together. Filter 6 is initially pre-loosened on stud 4 by a standard filter wrench to enable turning by hand, whereafter canister 24 is slid onto the filter and gripped and turned by hand to continue loosening filter 6 from stud 4 and remove the filter from the stud. During loosening and removal of the filter, oil spilling from around gasket 12 falls into canister 24 through annular gap 34. After removal, filter 6 is retained in canister 24. Both the canister and the filter can be disposed of, or the filter can be removed from the canister, and the canister retained for further use.
The bottom 28 of the canister has a central raised portion 42 limiting the axial depth of insertion of filter 6 into canister 24 as the canister is slid onto the filter. This spaces the bottom end 44 of the filter from the bottom 28 of the canister, to provide a reservoir 45 at the bottom of the canister for collecting the spilled oil. FIG. 3 shows a further embodiment of the canister of FIG. 1 and uses like reference numerals with the postscript "a" where appropriate to facilitate clarity. A separate spacer element 42a is provided at the bottom 28a of canister 24a to space the bottom 44a of filter 6a above the bottom of the canister, to provide a reservoir 45a at the bottom of the canister for collecting the spilled oil.
Referring to FIGS. 1 and 2, filter-gripping portions 36-40 of the canister are formed by inner radial projections extending from cylindrical side wall 30 radially inwardly to engage filter 6 and grip the latter for removal from stud 4. Projections 36-40 also serve to space cylindrical side wall 30 of the canister from filter 6 to provide the noted annular gap 34, such that spilled oil flows downwardly through such annular gap and between projections 36-40. Canister 24 is preferably a semiflexible plastic member sized to provide a slight interference fit on filter 6 as the latter is engaged by the inner tips of projections 36-40. The projections are tapered at their upper ends, as shown at 46, to facilitate axial sliding of the canister onto the filter. Outer circumferential edge 32 of the canister is flared radially outwardly and has a greater diameter than cylindrical side wall 30 of the canister. Lip edge 32 is substantially radially coplanar with gasket 12.
FIG. 5 shows an alternate embodiment of an oil retention cup 50 formed by a relatively rigid plastic tray 52 having a lower collection chamber 54, a forward lip 56 extending from the collection chamber, and an upper cylindrical band 58 slid axially onto and around filter 60 such that the forward lip 56 of the tray extends beneath the gasket 62 at the interface between the engine block 64 and filter 60. Oil retention cup 50 is better suited to an internal combustion engine with a horizontal stud, shown in dashed line at 66; whereas oil retention cup 22 of FIG. 1 is better suited to a vertical stud 4.
Band 58 loosely engages filter 60 such that the filter can be turned to loosen and remove the filter from stud 66 without turning tray 52, whereby the tray remains in place while the filter is loosened. During turning of the filter, tray 52 is supported on the filter by band 58, with collection chamber 54 beneath the filter and depending from band 58. Oil spilling from around gasket 62 falls into collection chamber 54 as guided by lip 56. After removal of filter 60 from stud 66, the filter is held and retained on the tray by band 58. Filter 60 is then slid axially out of band 58 and disposed of. The oil in collection chamber 54 is disposed of by pouring same out lip 56.
A handle 68 is integrally formed with the plastic tray at the rear end, opposite lip 56. Handle 68 extends upwardly from collection chamber 54 and is axially spaced rearwardly from filter 60 by a distance sufficient to allow filter 60 to be turned and axially moved out of threaded connection with stud 66.
Lip 56 and collection chamber 54 are formed by a receptacle 70 having side walls 72 and 74, FIGS. 6 and 7, and an open top 76. Band 58 is attached to the receptacle by a bridge member 78 spanning and sonically welded to side walls 72 and 74 at open top 76. Band 58 is attached to bridge member 78 by sonic welding. Lip 56 includes a sloped ramp portion 80 extending from collection chamber 54 forwardly beneath bridge member 78 and gasket 62 to a forward edge 82 beyond the gasket.
It is recognized that various equivalents, alternatives and modifications are possible within the scope of the appended claims. | For an internal combustion engine (2, 64) having a fluid filter (6, 60), a fluid retention cup (22, 50) is disposed around the filter and extends beneath the interface (12, 62) of the filter and the engine to catch fluid spills when the filter is loosened and removed from the engine. The cup has a filter-engaging portion (36-40, 58) engaging the filter and holding an retaining the filter after removal of the filter from the engine, a lip portion (32, 56) proximate and spaced from the interface of the filter and engine, and a reservoir portion (45, 54) communicating with the lip portion and collecting spilled fluid. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application 60/555,141 filed Mar. 22, 2004, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention relates to an electrically variable transmission with a torsional damper assembly having a hydraulically balanceable lock-out clutch assembly.
BACKGROUND OF THE INVENTION
Automobile engines produce torsionals or vibrations that are undesirable to transmit through the vehicle transmission. To isolate such torsionals, torsional dampers can be implemented into the vehicle transmission. These dampers rest between the engine crankshaft and the input shaft or turbine shaft of the transmission to substantially counteract the unwanted torsionals generated by the engine. Dampers are configured with springs that have the capacity to carry maximum engine torque plus some margin above.
One premise behind hybrid automobiles is that alternative power is available to propel the vehicle, thus reliance on the engine for power can be decreased, thereby increasing fuel economy. Since hybrid vehicles can derive their power from sources other than the engine, hybrid engines typically operate at lower speeds more often and can be turned off while the vehicle is propelled by the electric motors. For example, electrically variable transmissions alternatively rely on electric motors housed in the transmission to power the vehicle's driveline. Engines in hybrid vehicles are therefore required to start and stop more often than engines in non-hybrid systems. Compression pulses are generated by the engine during starts and stops that can produce undesirable vibration in hybrid vehicles such as those having an electrically variable transmission. Therefore, greater functionality is desirable in the damper assembly to aid the electrically variable transmission in canceling these compression pulses.
Lastly, since the torsional damper assembly is securable to the engine crankshaft the torsional damper revolves at high annular speeds. Where hydraulic fluid is used to govern the torsional damper, the fluid is subjected to centrifugal loading as a result of these annular speeds.
SUMMARY OF THE INVENTION
The present invention provides a means of hydraulically balancing the actuator (or piston) driving a lock-out clutch for the torsional damper assembly of an electrically variable transmission (or EVT). The invention includes two separate hydraulic circuits transferring a hydraulic fluid to opposing sides of the piston when necessary to balance the piston. The need for this balancing depends upon the centrifugal loading placed on the hydraulic fluid resulting from the annular speed of the damper assembly.
In one embodiment of the present invention, each circuit is in parallel with two pumps (one motor driven and the other engine driven) to assist in supplying the hydraulic fluid to the intended areas of the torsional damper assembly.
More specifically, the present invention provides an electrically variable transmission with at least one electric motor and a rotatable torsional damper assembly. The torsional damper assembly includes a torsional spring operable to eliminate or reduce compression pulses and torsionals. A clutch assembly is further provided, having a hydraulically operable piston for selectively locking out the torsional spring; whereas at least one electric motor cancels out compression pulses when the torsional spring is locked out. Also included is a hydraulic fluid applicable to opposing sides of said piston to sufficiently hydraulically balance the piston so as to prevent the clutch assembly from locking out the torsional spring at least partially in response to centrifugal forces resulting from the rotational speed of the damper.
Also provided is a method of operating a rotatable hydraulically actuated torsional damper of an electrically variable transmission in the start, stop and drive modes. The method includes hydraulically locking out the torsional damper during the start and stop modes with hydraulic fluid; and hydraulically counter balancing the lockout piston of the torsional damper to prevent the hydraulically locking out of the torsional damper during drive mode.
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of an electrically variable transmission with parts broken away to show selected transmission components and an auxiliary pump mounted to the transmission;
FIG. 2 is a fragmentary cross-sectional view of the torsional damper assembly taken along one side of the centerline of the front portion of the electrically variable transmission with two hydraulic circuits shown schematically;
FIG. 3 is a graph indicating the piston charging pressure as a function of the damper assembly speed (line A) and the damper vessel volume required to balance the piston (line B).
FIG. 4 a is a schematic sectional view of the perforated thrust washer of FIG. 2 isolated from the transmission; and
FIG. 4 b is a schematic front view of the perforated thrust washer of FIG. 2 isolated from the transmission.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIGS. 1 through 2 , wherein like characters represent the same or corresponding parts throughout the several views there is shown in FIG. 1 a side view of an electrically variable transmission 10 . Fundamentally, the present invention is implemented in an electrically variable transmission 10 with at least one electric motor (A or B) and a rotatable torsional damper assembly 26 , as shown in FIG. 2 . The torsional damper assembly 26 includes a torsional spring 32 operable to eliminate or reduce compression pulses and torsionals. A clutch assembly (or lock-out clutch 33 ) is further provided, having a hydraulically operable piston 50 for selectively locking out the torsional spring 32 ; thereby enabling one or both of the electric motors (A or B of FIG. 1 ) to cancel out engine compression pulses. Also included is a hydraulic fluid which is applicable to the piston cavity 58 and the damper vessel 34 , which are on opposing sides of the piston 50 , to sufficiently hydraulically balance the piston 50 so as to prevent the lock-out clutch 33 from locking out the torsional spring 32 as a result of centrifugal forces from the rotation of the torsional damper 26 .
More specifically, FIG. 1 displays selected components of an electrically variable transmission 10 including the input housing 12 and main housing 14 with dual electric motors (A and B), which are indirectly journaled onto the main shaft 19 of the transmission 10 through a series of planetary gear set (not shown). The motors (A, B) operate with selectively engaged clutches (not shown) to rotate the output shaft 20 . The oil pan 16 is located on the base of the main housing 14 and is configured to provide oil volume for the transmission 10 and its components. The main housing 14 covers the inner most components of the transmission such as the electric motors (A, B), planetary gear arrangements, the main shaft 19 and two clutches (all of which are mentioned for exemplary purposes and not all are shown). Finally, the input housing 12 is bolted directly to the engine block rear face of the engine 24 (schematically represented in FIG. 2 ) and encases the transmission components that mechanically interface with the engine 24 . Namely, the input housing 12 covers the torsional damper assembly 26 (shown better in FIG. 2 ). The input housing 12 also supports an auxiliary pump 27 (as shown in FIG. 1 ), which is mounted to the base of the input housing 12 and secured nestably adjacent the oil pan 16 .
The torsional damper assembly 26 , as shown in FIG. 2 , generally functions to isolate the transmission 10 from unwanted torsionals generated by the engine 24 during operation and also to selectively aide the transmission electric motors (either A or B) in canceling engine compression pulses during starts and stops. The torsional damper assembly 26 consists of an engine side cover 28 , which is affixed to the engine crankshaft 29 . The engine side cover 28 is welded to the transmission side cover 30 at 31 and houses the damper springs 32 . The two covers ( 28 and 30 ) define a vessel 34 , which encloses the lock-out clutch 33 and a piston 50 . The torsional damper assembly 26 further houses a damper flange 38 with hub portion 40 that mates to the input shaft 18 at complementary splines 42 . The engine side cover 28 of the torsional damper assembly 26 is affixed to an engine flexplate 44 . The flexplate 44 functions to transmit to the transmission the torque produced by the engine 24 and also to absorb any thrust loads generated by the damper assembly 26 . The torsional damper assembly 26 consists of a series of damper springs 32 running annularly or circumferentially between the engine side cover 28 and transmission side cover 30 . The damper springs 32 absorb and dampen the unwanted torsionals produced by the engine 24 during normal or drive mode operation (i.e., speeds above 600 rpm). The torsional damper assembly 26 has a torque capacity equal to the maximum torque capacity of the engine plus some margin. The torsional damper assembly 26 may be configured, in part, similarly to the structure disclosed in commonly owned, U.S. Pat. No. 5,009,301, which is hereby incorporated by reference in its entirety.
The electrically variable transmission 10 is equipped with two electric motors (A and B as shown in FIG. 1 ). Electric motor A creates a torque during start and stop that effectively cancels out the engine compression pulses caused when the engine is operating at speeds below 600 rpm (or in start and/or stop mode). The damper springs 32 of the torsional damper assembly 26 can be locked out by applying the clutch plates 36 and 37 (of the lock-out clutch 33 ) when the engine 24 is operating within a predetermined speed range. In the preferred embodiment, the torsional damper assembly 26 is effectively locked out when the engine is operating at speeds less than or equal to 600 rpm. This mode of operation is desirable because in an electrically variable transmission either electric motor (A or B) can be used to actively cancel out engine compression pulses generated during start or stop. The lock-out clutch 33 , located inside the torsional damper assembly 26 , consists of two reaction plates 37 connected to the damper flange 38 , two friction plates 36 connected to the transmission side cover 30 , a backing plate 46 and a snap ring 48 that is attached to the damper flange 38 at arm 61 . The lock-out clutch 33 is adjacent a hydraulic piston 50 which moves against the reaction plates 37 forcing them to engage the friction plates 36 . The piston 50 moves in response to oil fed into cavity 58 from an oil circuit 57 . The load is reacted at the backing plate 46 and snap ring 48 and contained by the damper flange 38 . Adjacent the piston 50 and affixed to the damper flange 38 is the damper hub 40 of the torsional damper assembly 26 , which has a cross-drilled channel 56 to define a radially extending aperture 52 that allows oil from circuit 57 to pass through. The oil extends through a cross-drilled aperture 55 in the input shaft 18 through aperture 53 , into the channel 56 to the front side of the piston 50 . The piston 50 is restricted from engaging with the lock-out clutch 33 and held in the disengaged position by a return spring 54 . As oil is fed through channel 56 of the damper hub 40 , the pressure inside the piston cavity 58 increases creating a load sufficient to overcome the spring force and stroke the piston 50 thereby engaging the lock-out clutch 33 . The vessel 34 is also filled with oil from the hydraulic circuit 59 , through aperture 51 , into the inner diameter of tube 35 , which is fitted in the input shaft 18 , through a grooved thrust washer 41 (or bushing), into cavity or spacing 43 and to the interior of vessel 34 . The oil thus received in vessel 34 is on the right side of the piston 50 , as shown in FIG. 2 , to counter balance the oil fed into cavity 58 on the other side of the piston 50 .
The hydraulic circuits 57 and 59 , as shown in FIG. 2 , supply oil to the piston cavity 58 and damper vessel 34 respectively; governing the lock-out clutch 33 and commanding it to engage and disengage under certain predetermined conditions. The first circuit 57 delivers hydraulic fluid to the piston cavity 58 . The second circuit 59 is regulated at a lower pressure and ultimately sends oil to the vessel 34 located on another side of the piston 50 . The piston 50 inside the torsional damper assembly 26 responds to the sufficiently higher pressure resulting from the oil fed through the first circuit 57 by stroking and engaging the lock-out clutch 33 to effectively lock out the damper springs 32 . When the lock-out clutch 33 is engaged the torsional damper springs 32 are deactivated or locked out so that the engine 24 is directly coupled to the input shaft 18 of the transmission 10 . This condition is only preferred for engine starts and stops (i.e., start and/or stop modes where engine speeds are within the predetermined speed range: between 0 and 600 rpm).
The transmission 10 can operate in electric mode where the engine 24 is completely turned off. When the engine is off the main pump 62 , which derives its power from the engine, is inoperable. Since the damper vessel 34 is unsealed the oil inside drains from the damper vessel 34 to approximately half full when the main pump 62 and the auxiliary pump 27 are not in operation. As the engine is restarted, the remaining oil is forced to the perimeter of the torsional damper assembly 26 by the centrifugal loading resulting from the revolution of the input shaft 18 and torsional damper assembly 26 . Likewise, the oil remaining in the damper hub 40 is forced into the piston cavity 58 (i.e., its perimeter). Since the oil in the damper flange 38 is concentrated in the piston cavity 58 the oil in the piston cavity 58 weighs on the piston 50 . At high speeds the centrifugal loading on the oil (or hydraulic fluid) in the piston cavity 58 may overcome the force of the return spring 54 and stroke the piston 50 . To stroke the piston 50 the pressure difference between the piston cavity 58 and the damper vessel 34 must be greater than or equal to 4 psi to overcome the return spring and greater than or equal to 60 psi to acquire full capacity on the clutch 33 . Line A of FIG. 3 illustrates the increased pressure differential of the oil in the piston cavity 58 as a function of the speed of the torsional damper assembly 26 . The x-axis represents the speed of the torsional damper assembly 26 and the y-axis represents the charging pressure on the piston 50 . As the torsional damper assembly speed approaches 4000 rpm the charging pressure resulting from the hydraulic fluid in the piston cavity 58 is approximately 60 psi—enough to have full torque design capacity on the clutch 33 . Inappropriate engagement of the lock-out clutch 33 and effectively locking out of the torsional damper assembly 26 can lead to additional wear on transmission components causing premature failure or reduced cycle life. However, as demonstrated by the intersection of lines A and B in FIG. 3 , when using the provided pumps ( 27 and 62 ) to fill the damper vessel 34 the piston 50 can be hydraulically balanced prior to reaching a charging pressure of 60 psi. Though either pump is capable of supplying oil into the damper vessel 34 , the auxiliary pump 27 is responsible for sending oil to the vessel 34 or other side of the piston 50 when the transmission is operating in electric mode (or when the engine is off).
One of the technical advantages of the present invention is that the hydraulic circuits, 57 and 59 as shown in FIG. 2 , and pumps 27 and 62 are configured to balance the hydraulic piston 50 in preparation for engine operation. To balance the piston 50 at least 0.36 liters of oil must be inside the damper vessel 34 as shown by line B in FIG. 3 . When the auxiliary pump 27 is operating it pulls oil from a sump and sends oil in parallel to the control module 64 and the priority regulator 70 (as shown in FIG. 2 ). The priority regulator 70 regulates the pressure at which the auxiliary pump 27 operates (which is 60 psi in the preferred embodiment) and directs all excess oil to the thermal exchanger 68 which returns oil to the transmission 10 , through the lube regulator 72 and into hydraulic circuit 59 . The control module 64 , under certain predetermined conditions (or in start and/or stop modes of operation in the preferred embodiment), will supply oil to hydraulic circuit 57 to pressurize the oil in the piston cavity 58 up to 110 psi. When the engine is on and turning the main pump 62 pulls oil from the sump and sends it in parallel to the control module 64 and main regulator valve 66 . From the main regulator 66 , oil passes through the priority regulator 70 , flows through the thermal exchanger 68 to lube regulator 72 and into hydraulic circuit 59 .
In the preferred embodiment, the lube regulator 72 ensures that the pressure of the oil in the damper vessel 34 does not exceed 30 psi. The control module 64 maintains oil pressure in the hydraulic circuit 57 to 2 psi. Therefore, the piston 50 cannot stroke to apply the clutch 33 with the oil in the piston cavity 58 at 2 psi, the oil in the damper vessel 34 at 30 psi, and the return spring 54 applying an adverse load. The piston 50 is thereby hydraulically balanced or prevented from engaging the lock-out clutch 33 . However, when desirable (or in start and/or stop modes of operation), the auxiliary pump 27 can apply the clutch 33 by supplying high-pressure oil to the piston cavity 58 overcome the 30 psi in the damper vessel 34 and the adverse force of the return spring 54 .
The two circuits ( 57 and 59 ) are isolated by a set of rotating seal rings 74 and a steel tube 35 fitted within the input shaft 18 of the transmission 10 . A grooved thrust washer 41 , as better shown in FIGS. 4 a and 4 b , facilitates oil travel from the inner diameter of the tube 35 to the damper vessel 34 . The thrust washer 41 has grooves 76 in its perimeter to facilitate oil travel through the washer 41 and into the damper vessel 34 .
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. | The present invention relates to a torsional damper for an electrically variable transmission. The torsional damper is equipped with a hydraulically actuable lock-out clutch to selectively directly couple the engine to the input shaft of the transmission. The electric motors provided with the electrically variable transmission can serve to effectively cancel out engine compression pulses when the springs of the torsional damper are locked out. During higher speeds the centrifugal loading placed on oil in the torsional damper increases, which may cause the lock-out clutch to inappropriately engage. The present invention hydraulically balances the hydraulic actuator (or piston) driving the lock-out clutch to appropriately regulate lock-out clutch engagement. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 15/266,535, filed on Sep. 15, 2016, which is a continuation of U.S. patent application Ser. No. 14/931,060, filed on Nov. 3, 2015 (now U.S. Pat. No. 9,450,410), which is a continuation of International Application No. PCT/US2015/035305, filed on Jun. 11, 2015, which claims benefit of U.S. Provisional Patent Application No. 62/010,746, filed on Jun. 11, 2014, the disclosures of all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a surge suppression system for medium and high voltage systems of a power grid.
BACKGROUND AND SUMMARY
[0003] Current surge suppression systems have been developed to protect equipment from voltage transients on one side of a three-phase power supply bus used in industrial settings such as in plants, factories, or other large scale systems. In one known voltage surge suppressor, three single-phase transformers are provided with terminals that are each connected through a fused disconnect to a respective single-phase power supply on the power-supply bus. This surge suppressor protects against voltage transients, which can severely damage or destroy equipment connected to the effected three phase circuit or can cause power outages throughout the plant. The surge suppressor circuit operates as a surge and fault protector for any equipment on the power bus. This surge suppressor system is usable with 480 volt distribution systems powered by a 2000 to 3000 kVA ungrounded delta power transformer that feeds approximately 1000 ft of bus duct, so as to generally have about 1 to 3 Amperes of charge current. This charge current may generally be just over 2 Amperes by actual amperage determined by readings in the field, wherein the variations are due to the lengths of the feeder cable and bus duct as well as the number and size of the electric motors and power factor correction capacitors operating at any given time. More typically, resistance grounding circuits constantly bleed this charge to ground to help prevent grounding problems. The known surge suppressor is connected to the bus bars and does not bleed this energy to ground, but uses this charge energy to help stabilize and balance the phase voltages to ground.
[0004] This known surge suppressor is installed in and protects equipment connected to a power supply bus at the facility level. However, there is a need for a surge suppressor system for medium and high voltage electrical systems on the grid located outside of and remote from an industrial bus bar power supply system.
[0005] A power grid is comprised of many components that are generically described as generators, transformers, transmission and distribution wires and controls. Generators are driven by many forms of energy such as coal, natural gas, nuclear fission, hydro, solar and even wind to name a few. Once power is created at a relatively low voltage around 6,000 volts it is stepped up to high voltage (often in the hundreds of thousands) using large power transformers (LPTs) which allow the electricity to be more effectively delivered over miles of high tension (transmission) wires. Once the electricity reaches the general area where it will be used it is then stepped back down closer to the final voltage at sub/distribution stations. Distribution lines carry near-low voltage electricity on roadside power poles or underground to the final transformer before being delivered into buildings for use.
[0006] The present invention is a surge suppressor system that improves upon existing phase adder circuit products, is designed to provide grid-level protection to residences and industrial facilities prior to delivery of the power to these structures so they can withstand higher voltages, provide monitoring and communication from remote settings, and provide more robust installation platforms, and configures the system of surge protection devices in parallel to protect grid level applications on both sides of a power system where the need exists to step power either up or down.
[0007] On a medium or high voltage system, the current invention would be configured to handle large and rapid energy “drain offs”, prevent interference from high voltage/high magnetic flux, allow remote performance maintenance, and increase protection, as required, from physical attacks and severe over voltages. When the invention is installed in parallel with critical grid infrastructure, the components of the grid are protected against:
[0008] Transients: An impulsive transient is what most people are referring to when they say they have experienced a surge or a spike. Many different terms, such as bump, glitch, power surge, and spike have been used to describe impulsive transients. Causes of impulsive transients include lightning, poor grounding, the switching of inductive loads, utility fault clearing, and Electrostatic Discharge (ESD). The results can range from the loss (or corruption) of data to physical damage of equipment. Of these causes, lightning is probably the most damaging. The surge suppressor devices of the current invention provide grid-level protection against such transients.
[0009] Interruptions: An interruption is defined as the complete loss of supply voltage or load current. The causes of interruptions can vary but are usually the result of some type of electrical supply grid damage, such as lightning strikes, animals, trees, vehicle accidents, destructive weather (high winds, heavy snow or ice on lines, etc.), equipment failure, or a basic circuit breaker tripping. While the utility infrastructure is designed to automatically compensate for many of these problems, it is not infallible.
[0010] Sag/Under-voltage: A sag is a reduction of AC voltage at a given frequency for the duration of 0.5 cycles to 1 minute's time. Sags are usually caused by system faults and are also often the result of switching on loads with heavy startup currents.
[0011] Swell/Over-voltage: A swell is the reverse form of a sag, having an increase in AC voltage for a duration of 0.5 cycles to 1 minute's time. For swells, high-impedance neutral connections, sudden (especially large) load reductions, and a single-phase fault on a three-phase system are common sources.
[0012] Frequency Variations: There are all kinds of frequency issues from offsets, notching, harmonics, and inter-harmonics; but these are all conditions that occur largely in the end user's power system. These variations happen because harmonics from loads are more likely in smaller wye type systems. The high frequency variations that may lead to massive interconnected grid failure would come from the sun or enemy attack. Damage to only a few key infrastructure components could result in prolonged blackouts and collateral damage to adjoining devices. Solar flares are natural occurrences that vary in severity and direction. This “solar weather” is sent out from the surface of the sun throughout our solar system in all directions. These flares contain large amounts of magnetic energy and depending on how they hit the earth can cause component damage on the surface or by temporarily changing the properties of the planet's magnetic core. Either way, a direct hit of large proportion could cause equipment failure and black out entire regions. Electromagnetic Pulses (EMP) can be used in similar fashion but directed by enemy combatants in the form of a high altitude nuclear explosion. A well-executed detonation over Cincinnati, Ohio could black out 70% of the American population. Damage to large power transformers or generators could take months to repair. The high frequency disturbance of nuclear explosions can destroy unprotected components much like an opera singer's voice can break a glass. The magnitude of each disturbance may depend on the source but each can be mitigated effectively through the use of a phased voltage stabilization system such as the invention.
[0013] Current surge suppression technology may attempt to address these disturbances on the facility side of the power distribution system, so as to directly protect equipment in a facility, and also at a grid level but these technologies possess drawbacks in protecting against these disturbances.
[0014] As one example of a known surge suppression technology, capacitors are thin conductors separated by even thinner layers of insulation. Capacitors have a design rating for current and voltage. If this rating is not exceeded they will typically operate for 10 to 15 years. One high voltage spike may (and generally will) cause catastrophic failure of capacitors. In factories with 4,000 power factor correction capacitors, it is not uncommon to have 300 to 500 capacitors fail each year due to high harmonic current or high voltage spikes.
[0015] In another example, SPD (Surge Protective Devices) are solid state devices constructed in various sizes. Like capacitors, their ratings are also in current and voltage. When the MOV (Metal Oxide Varistor) is hit with many low-level voltage spikes it degrades, and the “clamping voltage” will rise as the MOV breaks down, allowing the clamping voltage to continue to rise until it no longer protects the equipment it was installed to protect. When a voltage spike hits the MOV above the rated voltage, it starts to conduct thousands of amps to ground, causing noise on the ground system and very high heat within the SPD. If the event is longer than a few millionths of a second, the MOV could be destroyed, and therefore would no longer protect the equipment it was installed to protect.
[0016] Further, Faraday cages have been used for many years to house and protect computer hardware and sensitive data in factories, as well as some government and military buildings. They recently have been touted as a solution to solar flares, lightning and EMP pulse issues. However, most buildings are not built within a metal enclosure and it is difficult and expensive to properly design and build these enclosures. Most automobiles, trucks, trains and planes are totally enclosed by metal, but they offer no protection from any of these events. By design, the metal enclosure must have a suitable solid ground connection as it relies heavily on enclosing and shielding the sensitive electrical equipment and removing the energy by draining it to ground. The power company uses the Faraday cage design in some of their grid tie substations. They are extremely large and expensive.
[0017] The greatest threat to the grid/LPTs is the presence of an electromagnetic pulse (EMP) or geomagnetic disturbance (GMD), the latter would originate as a solar flare and the prior would be from enemy weaponry. Either threat could cause an overworked LPT to be saturated with power and cause the transformer to burn out. With an EMP, saturation could happen in less than a second so detection systems are worthless.
[0018] GMD is slower to cause damage so detection systems could reduce the load on a transformer which could allow it to ride out the GMD incident. This brown out or temporarily blacked out condition could last minutes, hours or days depending on the severity of the solar storm. In the case of the 1869 Carrington Event the Earth was pummeled with solar magnetic energy for nearly a month. While the grid could survive such an event if properly managed it would hardly be well received by citizenry to be without power that long.
[0019] Simply, Large Power Transformers cannot be protected with old technology like Faraday Cages. The hundreds of miles of wire that connect the LPT to sub stations way down the line act like antennae and harvest EMP with such efficiency that the Faradays would have no value. Surge protecting devices are not fast enough to arrest an EMP which occurs in a millionth of a second or handle the massive electron flow that occurs at the transmission level without allowing current bleed through to the LPT which would ultimately have the same effect as an unprotected system. Grounding systems would try to route surplus current from an EMP to earthen ground probes or mats but that excess energy would likely find its way back into the power system through the ground bus and result in burnout as well.
[0020] The present invention relates to a system of surge suppressor units connected at multiple locations on the grid to provide grid level protection against various disturbances before such disturbances can reach or affect facility level equipment. The effect of the invention is significant for protecting grid level applications. With the unique application and design of the present application, the surge suppressor units of the present invention would effectively prevent major voltage and current spikes from impacting the grid. In addition, the surge suppressor units included various integration features which provide diagnostic and remote reporting capabilities required by most utility operations. As such, the surge suppressor units protect the grid level components from major events such as natural geomagnetic disturbances (solar flares), extreme electrical events (lightning) and human-generated events (EMPs) and cascading failures on the power grid. The invention also provides significant protection against arc flashes and reduces voltage harmonics that exists in “normal” grid operations.
[0021] The reporting features of the inventive surge suppressor unit are also unique to protecting medium and high voltage systems that are often in remote or isolated settings. Unlike devices designed to protect local low voltage equipment and infrastructure, real time diagnostic reporting from the surge suppressor unit is critical to ensure it is working effectively and providing the continuous protection needed to protect power systems like the US power grid.
[0022] As discussed, various known technologies (such as MOVs, Faraday cages, even similar devices designed with fused disconnects) attempt to also correct voltage imbalances. These devices either do not provide the scalability to the voltage requirements at the grid level or “burn out” when significant voltage is applied. These technologies also do not provide reporting, remote diagnostics, or protection from ancillary dangers such as arc flashes or localized voltage overflow. The surge suppressor system of the present invention provides each of these benefits and is also completely scalable for various grid level applications.
[0023] Other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1A is a diagrammatic view of power grid interfaces with a system of surge suppressor units connected thereto at various locations on the electrical supply grid.
[0025] FIG. 1B is an enlarged partial view of FIG. 1A showing the transmission grid.
[0026] FIG. 1C is an enlarged partial view of FIG. 1A showing the distribution grid.
[0027] FIG. 2 illustrates typical fault conditions.
[0028] FIG. 3 diagrammatically illustrates a protection scenario ( 20 ) for grid level components (e.g. substations) at a grid level.
[0029] FIG. 4 illustrates a surge suppression unit ( 30 ) comprised of shunt-connected three phase transformer banks that is referenced as complete units ( 21 , 22 , and 23 ) on FIG. 3 .
[0030] FIG. 5 illustrates a remote monitoring system.
[0031] FIG. 6 is a graph showing test results of a surge suppressor unit installed on a three phase circuit when subjected to an E1 EMP pulse component.
[0032] FIG. 7 is a graph showing test results of a surge suppressor unit installed on a three phase circuit when subjected to an E2 EMP pulse component.
[0033] FIG. 8 is a graph showing test results of a surge suppressor unit installed on a three phase circuit when subjected to an E3 EMP pulse component.
[0034] FIG. 9 is a graph showing test results of a surge suppressor unit installed on a three phase circuit when subjected to an E3 EMP pulse component with the threat pulse removed.
[0035] Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words “upwardly”, “downwardly”, “rightwardly” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the arrangement and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
DETAILED DESCRIPTION
[0036] Referring to FIGS. 1A-1C , a generalized power distribution system 10 is shown which discloses various power system components at the grid level which supply power to individual consumers at the facility level. For purposes of this disclosure, the facility level includes industrial and factory facilities and the like, as well as residential facilities such as homes and apartment buildings. These structures include various types of power consuming devices or power consumers such as various types of equipment, motors and appliances. Stand-alone power consuming devices are also supplied by the power grid, such as street lighting, traffic signals, and other power consumers.
[0037] More particularly, the power distribution system 10 includes a transmission grid 11 at high voltage levels and extra high voltage levels, and a distribution grid 12 at medium voltage levels, which in turn supplies lower power at the facility level to residences, factories and the like. FIG. 1B shows various power supply sources which generate power at extra high voltages such as a coal plant, nuclear plant and a hydro-electric plant. These may supply power through step-up transformers 13 to an extra-high voltage transmission grid 14 . This grid 14 may in turn connect to a high voltage grid 15 through a network of transformers 16 , which grid 15 is connected to various grid facilities such as an industrial power plant, factory, or a medium sized power plant through respective networks of transformers 17 . Generally, medium voltage refers to the range of 10 kV-25 kV or higher which is typically carried in the distribution grid and may include generation voltages, high voltage refers to the range of 132 kV-475 kV as might exist in the transmission grid, and extra high voltage is in the range of 500 kV-800 kV, which also is typically carried in the transmission grid. These grid level voltages are significantly higher than the low voltages present within a facility or other similar structure.
[0038] The transmission grid 11 may in turn connect to a medium voltage distribution grid 12 ( FIG. 1C ) through a network of transformers 18 . In turn the residential grid 12 may include various facilities such as city power plants, industrial customers, solar farms, wind farms, agricultural farms, rural networks of residences or city residential networks. Various transformers 18 are provided to interconnect these components of the power distribution system 10 . Generally, the present invention relates to a surge suppressor system which is installed at various locations within the power distribution system 10 to provide grid level surge suppression and thereby protect the various facilities supplied with power from the power distribution system 10 . These various transformers may be of various types and configurations such as step-up and step-down transformers, as well as substation transformers installed in substations or delivery transformers which serve to supply individual customers.
[0039] The invention relates to a system of voltage surge suppressor units 20 that are installed at various locations on the power distribution grid 10 to provide three-phase, grid level protection to various facilities which receive power from or supply power to such grid 10 . FIG. 3 generally illustrates a system of multiple surge suppressor units 20 which are differentiated from each other in FIG. 3 by reference numerals 21 , 22 and 23 . These surge suppressor units 21 , 22 and 23 are sized for the particular installation location and the voltage levels present within the power distribution system 10 at such locations. Generally, the power grid uses various transformers described above, with the representative grid transformer 24 of FIG. 3 being one of the various transformers used in the transmission grid 11 or distribution grid 12 . The transformer 24 includes a primary side coil 24 P which is connected to three power lines 25 A, 25 B and 25 C which supply power, for example, from a generation plant or the like to the grid transformer 24 . The transformer 24 includes a secondary side coil 24 S which connects to transmission lines 26 A, 26 B and 26 C for supplying power to downstream components of the power grid. In this exemplary embodiment, the transformer 24 steps up the power from 6 kV received from the generation side power lines 25 A, 25 B and 25 C to 300 kV as supplied to the grid power lines 26 A, 26 B and 26 C. It will be understood that voltages for the primary and secondary sides of the transformer 24 can vary depending upon the location within the power grid, wherein the voltage levels can be medium or high voltages.
[0040] The surge suppressor unit 21 connects to the generation power lines 25 A, 25 B and 25 C and the primary side coil 24 P to protect against the various transient conditions described above which thereby protects the primary coils 24 P and the upstream power generators and any upstream grid components and equipment. The surge suppressor unit 22 in turn connects to the grid or transmission power lines 26 A, 26 B and 26 C and the secondary side coil 24 S to protect against the various transient conditions described above which thereby protects the secondary coils 24 S as well as the downstream transmission lines 26 A, 26 B and 26 C as well as any connected grid equipment and components. Also, the surge suppressor unit 23 may be a 480V unit or other suitable voltage level suitable to protect system circuitry and logic.
[0041] Referring to FIG. 4 , each surge suppressor unit 21 , 22 and 23 can generally use the design of the surge suppressor unit design 20 ( FIG. 4 ) that comprises a series of shunt-connected three phase transformer banks 31 , 32 and 33 that are designed to correct phase neutral voltage imbalances by feeding them back onto themselves and/or draining the imbalances off to the integrated resistor bank that is wired to the secondary side of the system as also shown in FIG. 4 . Each transformer bank 31 , 32 and 33 includes primary coils 31 P, 32 P and 33 P which connect to and receive power from one of the power transmission lines L 1 , L 2 and L 3 of the system, which may be at the medium or high voltages present in the power grid. The primary coils 31 P, 32 P and 33 P also connect to ground 34 . The lines L 1 , L 2 and L 3 may for example be connected to transmission lines 26 A, 26 B, 26 C ( FIG. 3 ) and supplied by power generator and mega transformers shown in FIG. 4 , or lines 25 A, 25 B, 25 C in the example of FIG. 3 .
[0042] Each transformer bank 31 , 32 and 33 also includes secondary coils 31 S, 32 S and 33 S which connect in series together and have a resistor 35 connected in series therewith. The series connected resistor 35 provides both noise filtering and a discharge path for energy during a power down whether intentional or caused by a natural occurrence. The resistor 35 also helps to drain system energy to prevent an arc-flash since an arc flash is a series phenomenon. By holding up the remaining phases during a fault, voltage buildup cannot form and simply allows circuit protection to open the circuit without a flashing event. This enhanced stability ensures cleaner electron flow and renders the flow safer for components and personnel alike. In other words the surge protection unit 30 balances the voltage on the “load” side. Since the flash is inherently on the “source” side, the voltage across the arc is minimal and the arc will be suppressed.
[0043] Each surge suppressor unit 20 utilizes a circuit breaker 36 governing power from each of the lines L 1 , L 2 and L 3 that can be programmed to rapidly reset and can be made scalable to medium and high voltage requirements. The circuit breaker 36 also may be manually operated for installation and replacement of the surge suppressor unit 20 , or another switch device could be included to provide manual switching of the surge suppressor unit 20 . Depending of the requirements of the utility organization, added protection, in the form of Metal Oxide Varistors, can be series piped in as a secondary circuit as severe over voltage occurs.
[0044] With this construction, the surge suppressor unit 20 thereby balances phase voltages with respect to ground by pushing clean phase shifted current into the phase with the lowest phase voltage. The components preferably are matched single phase transformers 31 , 32 and 33 and in this permanent solution are sized to the voltage class and kVA in which the particular surge suppressor unit 20 will be employed. The voltage specification determines the appropriate turn ratios needed to properly size each surge suppressor unit 30 to its installation location. All three transformers 31 , 32 , and 33 are spaced from one another by IEEE standards to prevent arcing or magnetic flux between each phase. Depending on the specific requirements, the surge suppressor units 20 of the invention may utilize underground installation with oil/coolant immersed resistor banks 35 and oil cooled transformers 31 , 32 , 33 . These options would allow for closer spacing (smaller footprint) and require less mechanical or free air cooling. These options would also remove equipment from line of sight hostilities.
[0045] During installation, each surge suppressor unit 20 is wired in parallel to the power system, for example, as seen in FIG. 3 . Further, a surge suppressor unit 20 such as unit 22 in FIG. 3 may protect from the secondary side 24 S of a power transformer 24 to the primary side of the downstream transformer to provide extended protection extending from the surge suppressor units 20 to other power components connected thereto. For example, a surge suppressor unit 20 may protect from the secondary side of an LPT down to the primary windings of the next step down transformer. Additional surge suppressor units 20 would be installed on the next portion of the stepped down power system beginning with the secondary of that distribution transformer down to the primary on the next transformer and so on. Each surge suppressor unit 20 would be engineered and constructed to operate with the hookup voltage and the VA rating of the transformer it is designed to protect, such that different sized and rated surge suppressor units 20 would be installed in the power grid depending upon the location of installation. This extended protection is also true from the generation source to the primary side 24 P on the initial transformer 24 which is protected by the surge suppressor unit 21 in FIG. 3 . All connected components would be protected, and the surge suppressor unit 20 of the present invention would stabilize imbalances whether caused by downstream activity or directly on line.
[0046] Further, no power system would need to be turned off to connect the surge suppressor units 20 . The circuit breaker 36 or other suitable disconnect device 36 A can be manually operated such that utility linemen could hot tap the surge suppressor devices 20 into the system and then engage each surge suppressor unit 30 by using the disconnect switch 36 A.
[0047] This system of surge suppressor units 20 provides power factor correction (PFC) by optionally introducing power regulating products (e.g. capacitors 37 ) to help streamline the power current making the energy more efficient.
[0048] Preferably, the surge suppressor unit 20 ( FIG. 4 ) also includes one or more appropriate sensors 38 , which preferably include a current sensor. The sensor 38 connects to a control system 39 for detecting and monitoring the sensor 38 . The control system 39 may also include remote (web-based) diagnostic and reporting features such as that shown in the data display 40 of FIG. 5 . The data display 40 may be located remote from the various surge suppressor units 40 for monitoring by utility personnel, such as through a computer terminal. The data display 40 preferably shows information regarding faults (imbalances) that are proactively communicated and can be monitored from off-site locations. The data display 40 includes several display graphs 41 , 42 , 43 and 44 which can display various types of data. This real time status reporting would provide significant information and data including but not limited to:
[0049] Voltage by phase
[0050] Amps by phase
[0051] Harmonics by phase
[0052] Oil/Coolant Temperature
[0053] Ground fault indicator (by phase and the severity of each occurrence).
[0054] The control system 39 may include alarms for every data point, which alarms could be customizable so as to trigger utility response to multiple remote locations. This is critical with grid level power substations that are often un-manned and/or in remote settings. Every data point can be captured, stored, and maintained with data storage means within the control system 39 for historical tracking and reference so as to allow for both historical trend analysis and specific search capability.
[0055] Focusing on voltage allows the invention to address each of the 5 Common Power Issues discussed above. Transients are the brief voltage spikes that occur regularly and may last only a few cycles. The inventive system would take the surplus voltage in the same waveform and electromagnetically feed it back on itself with the same intensity through the transformers 31 , 32 and 33 . Even with a power analyzer one could see that disturbances placed directly on line are completely mitigated.
[0056] Interruptions have many causes but the damage occurs in the brief moments as a system loses power and motors which wind down turn into mini generators sending inappropriate voltages to connected loads. The system of the invention would not prevent sustained power losses but would prevent damage to loads by allowing a softer landing should an outage occur due to the interaction of the transformers 31 , 32 and 33 and the resistor 35 .
[0057] The invention will also reduce the harmful effects of voltage instability like sags and swells or under/over-voltage at a grid level. The primary sides 31 P, 32 P and 33 P of the transformers 31 , 32 and 33 and their adjoining secondary sides 31 S, 32 S and 33 S constantly stabilize the voltage discrepancy. If there is a sustained swell, the excess power is harmlessly drained off to the integrated resistor bank 35 that is series wired on the secondary side of the system.
[0058] Waveform and frequency variations might best be described as noise on the line from massive magnetic forces. These magnetic hits to the grid can cause damage to generators, transformers, auto tapping devices, and connected loads throughout. High frequency noise from hostile EMPs change the normal 60 Hz flow of electrons which may wreak havoc on infrastructure. Depending on the severity or proximity to such hostilities, damage could range from loss of end user electronic devices to the overheating of the stators on utility generation plants or power transformers. The surge suppressor units 20 of the present invention would act as a gatekeeper, suppressing any frequency above or below the 60 Hz range. Damage to grid components could occur in an instant without the system of the present invention but since it operates only on 60 Hz waveforms it routs the inappropriate waveform to the integrated resistor bank 35 at the exact speed of the infraction. The invention, therefore, rectifies disturbances that are out of specification and harmonizes everyday activity.
[0059] The system of the present invention provides significant advantages over prior surge suppressor devices. For example, the system of the present invention is designed for medium and high level voltages with a targeted application for grid system protection. Many prior surge suppression devices were designed for low voltage systems such as an industrial or residential setting that are self-contained which have no “cascading” issues or additional sources of power to be concerned about. The present invention can accommodate the unique requirements of the power grid.
[0060] Further, each surge suppressor unit 20 does more than protect a single device. Rather each of the surge suppressor units 20 is wired in parallel at appropriate locations on the power grid to protect both sides of grid level substations, power delivery systems, and generation plants. FIG. 3 provides an exemplary illustration of the extended protection provided by individual surge suppressor unit.
[0061] Further, the provision of a circuit breaker 36 and disconnects 36 A in the surge suppression units 20 allows the invention to be scaled to medium and high voltage grid systems and facilitates hot tapping of each unit 20 during installation or replacement. The surge suppressor unit 20 also allows for the inclusion of Metal Oxide Varistors, which can be series piped in as a secondary circuit, to add specific grid level protections for severe over-voltages.
[0062] More particularly, a surge suppressor device according to this design has been tested at defined voltage levels under conditions representing an EMP of varying wavelength/shape and frequencies directly on line through injection. This testing was conducted with resistive and inductive loads using Mil-spec 188-125-1 and Mil-Std-2169 test standards and equipment to represent grid level protection. Thousands of volts were injected into a surge suppressor unit designed according to surge suppressor unit 20 described above and a connected power system wherein threat pulses were identified, clamped and drastically reduced every time through multiple individual test events. FIGS. 6-9 illustrate test data from such tests.
[0063] Generally as to an EMP such as a nuclear generated EMP, such pulses are considered to include three pulse components commonly designated as E1, E2 and E3. The E1 component is considered to be the quickest and can induce high voltages in an electrical system. The E2 component is an intermediate pulse beginning at a short time after initiation of the electromagnetic pulse and ending soon thereafter. This pulse is considered to be similar to a lightning strike but of a lesser magnitude. The E3 pulse component is longer and slower and is considered most similar to a solar flare. The E3 pulse component is the most troublesome component to deal whether it is generated by a nuclear EMP or a solar flare, and current technologies do not handle the E3 pulse component and suitably protect grid systems.
[0064] In EMP testing of the present invention, the surge suppressor unit 20 has shown to handle and protect against all three pulse components, namely E1, E2 and E3. The surge suppressor quickly clamps on EMP pulse threats within millionths of a second and reduces the severity of the threat to safe levels. For example, the unit mitigated the E1 pulse instantaneously and eliminated the threat within 1.3 μsecs, the unit mitigated the E2 pulse instantaneously and returned the phases to “normal” within 0.002 seconds, and the unit also mitigated the E3 pulse instantaneously and returned the phases to “normal” within 0.002 seconds. The same device continued to operate throughout all tests and suffered no damage such that it can be installed and performs through multiple EMP events.
[0065] FIG. 6 illustrates a graphical representation of the test results for the three phases and their reaction to the injected E1 pulse which was injected under test conditions recreating such a pulse component. This graph compares the kAmps detected in the system phases against the time measured in μseconds with pulse initiation at time 0. FIG. 6 shows the E1 pulse injection test from time −1.0 to 3.5 μsecs. The surge suppressor unit was connected to a three phase circuit wherein the system under normal operating conditions was a 480 v operating system with 6000 watts of load. The test injected 20,000 volts at 1500 Amps to simulate an E1 waveform. The height of the threat pulse 80 maxes out at nearly 1500 Amps (1.5 kA) on a single phase and lasts for over 1.9 micro seconds. The threat pulse 80 is injected onto the operating system, and the pulse is shown with a sudden spike with a diminishing tail. The darker Phase A load 81 and the lighter colored Phase B load 82 create an immediate dip to help correct the imbalance or resultant E1 spike on the Phase C load 83 . The Phase C carried the wave from the injected load, but mitigates the impact by pushing the load back on to Phases A and B. Phases A, B and C of the surge suppressor unit have compensated for the threat pulse by correcting the wave against itself or in other words balances the pulse against the other two phases creating a real time correction that can be seen in the graphs. As a result, the surge suppressor unit immediately mitigates the surge and begins reducing the magnitude and width within 0.1 μsec. The threat is kept to less than 500 amps at its peak as is reduced to below 250 Amps within 0.2 microseconds (70% reduction in amplitude). By reducing the height (magnitude/amplitude) and the width (duration) by such a wide margin, the surge suppressor renders the E1 threat harmless to the grid components. The threat is completely eliminated by 1.3 μseconds.
[0066] FIG. 7 shows the graphical results of the surge suppressor unit responding to an injected E2 threat. The threat pulse is shown as graph line 90 wherein the threat pulse is injected onto Phase C shown by line 91 at approximately 5 kV with a 6 kw load being present. The pulse is shown as a sudden spike with a diminishing tail. The Phase A load 92 and Phase B load 93 create an immediate dip to help correct the imbalance on the Phase C load 91 which exhibits a spike. Phase C 91 is already mitigating the impact by pushing the load back onto Phase A 92 and Phase B 93 . Phase C 91 peaks at 109 Amps compared to the 260 Amp peak of the threat 90 . All three phases are corrected and back in phase within 0.002 seconds from the initial threat being injected on the line. All three phases 91 , 92 and 93 are in alignment prior to the threat 90 being injected at time 0. All three phases are back in phase very quickly from the initial E2 threat being injected on the line. Therefore, the surge suppressor unit also can readily handle the E2 pulse component or a pulse exhibiting similar characteristics.
[0067] The surge suppressor unit was also tested under an E3 pulse component which is shown in FIGS. 8 and 9 . FIG. 8 shows the graphical results with the threat pulse 100 injected onto Phase C 101 at approximately 2 kV with a 6 kw load. The threat pulse is clearly shown in FIG. 8 with a sudden spike and corresponding waves. Due to the scale of the graph in FIG. 8 , the reaction of the phases is not entirely clear. As such, FIG. 9 is provided with the threat pulse 100 omitted so that the scale of the system phases can be increased for clarity. As seen in FIG. 9 , Phase C 101 has an immediate spike. However, the Phase A load 102 and the Phase B load 103 create an immediate dip to help correct the imbalance on the Phase C load 101 . Phase C already mitigates the impact of the threat pulse 100 by pushing the load back on to Phase A 102 and Phase B 103 . Phase C 101 peaks at 109 Amps compared to the 1710 Amp peak of the threat pulse 100 . All three phases 101 , 102 , and 103 are corrected and back in phase within 0.002 seconds from the initial threat pulse 100 being injected on the line. All three phases are in alignment prior to the threat pulse 100 at time zero, and back in alignment within 0.002 seconds, such that the surge suppressor can readily handle the E3 pulse component.
[0068] As such, the inventive surge suppressor system can prevent the need to shed load in the presence of E3 activity or solar flare activity on the grid by correcting the flattening of the AC waveform. By maintaining 3 perfectly balanced phases where the vectors are 120 degrees out of phase, the surge suppressor eliminates the need to reduce LPT loads to prevent overheating and damage from half cycle saturation.
[0069] Preferably, the surge suppressor unit never routes surplus energy from these electromagnetic forces to ground, and instead, said energy is thrown against the incoming surge at the speed of the infraction. Much like a mirror instantaneously rebounds a beam of light, the surge suppressor system rebounds pulse threats to mitigate the inrush of power regardless of the magnitude.
[0070] The surge suppressor system can be installed nearly anywhere within the power distribution grid and still protect the entire portion of the circuit. This means a surge suppressor unit could be installed midway between the LPT and the next step down transformer which eliminates the need for a new piece of equipment in an already crowded space at the power source.
[0071] Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A system of surge suppressor units is connected at multiple locations on a power transmission and distribution grid to provide grid level protection against various disturbances before such disturbances can reach or affect facility level equipment. The surge suppressor units effectively prevent major voltage and current spikes from impacting the grid. In addition, the surge suppressor units include various integration features which provide diagnostic and remote reporting capabilities required by most utility operations. As such, the surge suppressor units protect grid level components from major events such as natural geomagnetic disturbances (solar flares), extreme electrical events (lightning) and human-generated events (EMPs) and cascading failures on the power grid. | 7 |
RELATED APPLICATIONS
[0001] This is a continuation in part of co-pending U.S. patent application Ser. No. 09/096,443 filed on Jun. 11, 1998 in the name of Robert T. Kulakowski, Robert Marshall and George J. Rogers for Wireless System for Broadcasting, Receiving and Printing Packets of Information, U.S. patent application Ser. No. 09/096,444 filed on Jun. 11, 1998 in the name of Robert T. Kulakowski, Robert Marshall and George J. Rogers for Wireless System for Broadcasting, Receiving and Selectively Printing Packets of Information Using Bit-String Selection Means, and U.S. patent application Ser. No. 09/095,820 filed on Jun. 11, 1998 in the name of Robert T. Kulakowski, Robert Marshall and George J. Rogers for Printer Appliance for Use in a Wireless System for Broadcasting Packets of Information.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a wireless system for broadcasting, receiving and selectively printing packets of information such as redeemable coupons, forms, messages or any other packet of information consisting of text or graphics, or a combination thereof, and, more particularly, to such a system which comprises a method and apparatus for selectively broadcasting such messages through conventional pager network to a network of printer appliances that are adapted to convert such messages to a readable permanent format such as, for example, a printed copy. In its broadest form the subject system in essence creates a universal delivery system for virtually any type of information packet that is currently delivered using conventional means such as the United States Postal Service or overnight delivery service such as Federal Express, etc. One particularly unique application for such system is the broadcasting and generation of redeemable consumer coupons in printed format that can be redeemed by consumers at retail outlets, although it should be appreciated that the system of the present invention has applicability in generating virtually any type of printed message.
[0004] 2. Description of the Prior Art
[0005] The dispatch of packets of printed information, such as consumer coupons, to individual households is well known. Individuals are accustomed to receiving such printed messages from a variety of different sources including the mail, overnight delivery services, house to house door-hanger crews, private runner services, the print media and the like. Conventional methods for dispatching and delivering such printed messages to a large number of individual households are limited severely by the need for manually handling and delivering the printed copy. While these vehicles are capable of handling large volumes of messages on a daily basis, the need to manually deliver such messages imposes certain constraints on the system in terms of both cost and delivery time.
[0006] Telecommunications systems for conveying and delivering messages have improved rapidly over the past decade. For example, facsimile systems have become a common method for the distribution of printed messages and other communications. The speed and cost of such facsimile systems are quite favorable when compared with the conventional methods described above. Facsimile transmissions are, however, severely limited in terms of wide distribution and, generally speaking, are inappropriate for mass, broadcast messaging. The appeal and utility of such transmissions is also somewhat limited by the requirement and expense of telephone line connections.
[0007] More recently, the Internet has become a very potent force in delivering printed messages. As with all other forms of delivery systems, however, there are constraints in terms of reach capability, line connection, and the need for a computer and operating software and auxiliary and ancillary systems. Moreover message recipients must be Internet accessible and have a certain degree of computer literacy. Even more importantly, for such a system, the user must assume an active role if the printed messages are to be received.
[0008] With respect to redeemable coupons, the most common form of distribution of such products is through the print media, i.e., either as a freestanding insert or as part of a print advertisement in a newspaper or magazine. In addition, many coupons are distributed by direct mail. Although this distribution method is slow and very costly, it can be targeted at specific recipient groups through the use of selected mailing lists. This contact approach is used extensively by mail-order marketers, telephone companies, magazine publishers, and insurance or financial service providers.
[0009] While the bulk of manufacturer discount coupons were printed and distributed in conventional methods of home delivery, some are now being presented automatically in-store, using relatively advanced communications and computer technology. For example, in one such application, a coupon is dispensed at checkout to an exiting customer for use on the next shopping trip. The particular coupon is targeted to the specific product preferences of the customer through analysis and interpretation of her current purchases. This system is supported by a vast communications network, an extensive computerized database and dedicated in-store computers. The basic purpose of this type of promotion is to encourage a return trip and influence new purchase decisions.
[0010] In another, semi-automated in-store coupon dispensing system application, discrete, electromechanical dispensers are attached directly to shelves adjacent to the product. The consumer can then withdraw a coupon and obtain an instant discount on the purchase at checkout. Such a system is directed more to the “impulse” purchase as the consumer moves through an aisle in the store.
[0011] A third class of automated, in-store coupon distributing systems are the kiosk or booth dispensers. These booths are generally installed in store entryways to increase exposure and take advantage of concentrated traffic. A consumer activates the system through a keyboard, touch screen or by swiping a magnetic strip card. The system then presents images of the currently available promotions and the shopper can choose coupons of interest. Problems with such a system include high initial capitalization costs, complex and high-maintenance technology, difficulty of use, and extended selection time on the part of users.
[0012] For the aforementioned reasons, none of these forms of message delivery offer particularly fast and inexpensive distribution of such messages.
SUMMARY OF THE INVENTION
[0013] Against the foregoing background, it is a primary object of the present invention to provide a system for delivering printed packets of information directly to high visibility and high traffic areas within a retail environment, including but not limited to, on the shelf, on an end-cap (end of aisle) at the checkout, on a freestanding kiosk or display etc. within a designated store. The printer(s) could be located virtually anywhere in a store.
[0014] It is another object of the present invention to provide such a system that is capable of delivering such packets at a low cost when compared to manual delivery systems.
[0015] It is yet another object of the present invention to provide such a system wherein the delivery time of such packets can be controlled and, further, where the packet sequencing and dispatching capability is flexible.
[0016] It is still another object of the present invention to provide such a system which has a broad and rapid audience reach and which is able to deliver packets of information virtually simultaneously to pre-determined but widely diverse recipient groups, including those within the retail environment.
[0017] It is still yet another object of the present invention to provide such a system where the recipient is able to automatically receive a printed copy of the packet of information using a printer appliance.
[0018] It is but another object of the present invention to provide such a system that includes means to store the packet of information being delivered for future printing.
[0019] It is another object of the present invention to provide such a system that includes means of detecting whether the printed packet of information has been removed and printing a new copy of the packet in the event the printed packet has been removed.
[0020] It is but still another object of the present invention to provide such a system in which the packet can be traced to a particular printer appliance, store or store chain/company.
[0021] It is yet another object of the present invention to provide such a system that includes a series of printer appliances that require minimal maintenance and attention.
[0022] It is still another object of the present invention to provide such a system that influence purchase decisions at the time of entry into a store, and/or during the entire shopping trip throughout the store.
[0023] It is but another object of the present invention to provide such a system that reinforces the coupon offer at the shelf or any linked coupon distribution at checkout.
[0024] It is but another object of the present system to provide a system whereby supplemental visual messages draw attraction to the printed information.
[0025] It is yet another object of the present invention to provide a system for supplying audio supplementary audio messages to draw attention to the printed information.
[0026] It is yet another object of the present invention to provide a motion sensing system such that activation of the supplementary systems are triggered or initiated by human presence near the present system (printer).
[0027] It is another object of the present invention to provide method and apparatus to effect the objects and advantages of such system.
[0028] To the accomplishments of the foregoing objects and advantages, the present invention, in brief summary, comprises a new system for originating, transmitting, receiving, storing and printing packets of information directly to retail stores and the like through a network of unique printer appliances. Such information may constitute redeemable coupons, forms, rebate instruments, helpful product information, messages, advertisements, warnings, tickets and the like. Since the techniques are essentially electronic in nature, the system eliminates the need to physically handle or deliver such packets that vastly improves its efficiency in terms of delivery cost and time. The severe reach limitations of the facsimile and Internet systems are eliminated since the system of the present invention can operate in a broadcast mode which is optimal for mass message delivery. With the inclusion of innovative communication filters, the system can limit delivery to a single printer appliance, all printer appliances or a select group of printer appliances.
[0029] The system of the present invention does not require the installation of new telephone line connections, requires virtually no technology literacy or any active participation on the part of the recipient in actually receiving and obtaining printed copies of the information packets being transmitted. Using a novel printer appliance, packets can be delivered to the home, office, store, or automobile or virtually anywhere where electrical power is accessible.
[0030] The present system is characterized by an ability to inexpensively reach a precise target in the marketplace with minimal recipient involvement. The essential transmission methodology is through established national pager networks such as, for example, those operated by PageNet or SkyTel, which are capable of reaching more than 90% of U.S. households. The majority of the remaining audience can be reached by building relays to operators of local pager networks. In addition, the system may work in conjunction with conventional cellular telephone technology such as, for example, Sprint, MCI, etc. as well as with dedicated satellite transmission systems, or from an RF transmitter from within the store, satellite dish tap, remote control or other source. Future versions may employ any current or future wireless broadcast, multicast, or narrow-cast technology for transmission.
[0031] Since the audience is accessed in a virtual parallel mode by a broadcasting system, the number of required transmission channels is minimal. In addition, access/delivery costs are very low, i.e., in the hundredths of a cent for a typical packet, depending upon the size of the audience.
[0032] Although the system employs a broadcast transmission method, the incorporation of blocking filters enables the system to deliver either a specific packet to an individual appliance or to all or substantially all of the printer appliances as well as virtually everything in between.
[0033] One component of the system is a high-performance, upgradable subscriber database such as, for example, those relational type databases provided by Oracle or Informix, containing detailed bibliographic, demographic and other unique subscriber information. Such information could contain specific store and chain/company information as well as information from the customers within each store and/or chain/company. Such information can be obtained from all sources via survey and response to questionnaires. The versatility of this database combined with the selectivity of the blocking filters permits extremely precise message targeting based on definable recipient profiles.
[0034] A strong advantage of the proposed system is the incorporation of the maintenance-free printer appliances used by proposed recipients of such messages. The basic printer device/appliance is a “printed message appliance” (PMA). The enhanced printed appliance, intended for utilization in a retail environment is a “receiver-printer-dispenser” (RPD). With such devices, the recipient does not have to assume an active role in the messaging process. There is no need for even minimal technology or computer literacy since the initial setup and subsequent operation are simple and straightforward. So long as the appliance has power and paper, print messages will be automatically received. It is envisioned that most of the messages will be delivered during the night to take advantage of very low traffic on the pager network at such times. Thus, the incorporation of a printer appliance requiring minimal maintenance and attention is extremely important.
[0035] It is contemplated that the system of the present invention will have particular applicability in the promotion and advertising fields, particularly in the distribution and delivery by packaged-goods manufacturers of redeemable coupons and rebates. The majority of coupons are presently distributed as newspaper inserts or as part of a print advertisement in a newspaper or magazine. However, the device is capable of transmitting, receiving and printing almost any packet of information or graphics.
[0036] Other messages that can be distributed include, for example, forms, for almost any promotional or information gathering purpose, including rebates, surveys, contest announcements and entries, sweepstakes entries etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The foregoing and still other objects and advantages of the present invention will be more apparent from the detailed explanation of the preferred embodiments of the invention in connection with the accompanying drawings, wherein:
[0038] [0038]FIG. 1 is a flow diagram illustrating the information delivery system of the present invention.
[0039] [0039]FIG. 2 is a sample table for the subscriber directory used in conjunction with the information delivery system of the present invention.
[0040] [0040]FIG. 3 illustrates the possible profile bit-string groupings that may be used in conjunction with the information delivery system of the present invention.
[0041] [0041]FIG. 4 is a sample table in which the messages that are stored in the message bank of the present invention.
[0042] [0042]FIG. 5 is an example of a daily message batch created using the message bank of the information delivery system of the present invention.
[0043] [0043]FIG. 6 is a sample of typical message bit-string destination codes that may be used in conjunction with the information delivery system of the present invention.
[0044] [0044]FIG. 7 is a sample table of the message code string used in conjunction with the information delivery system of the present invention.
[0045] [0045]FIG. 8 illustrates the type of data that may be contained in a sample coupon message used in conjunction with the information delivery system of the present invention.
[0046] [0046]FIG. 9 illustrates the manner in which the message identification numbers of the information delivery system of the present invention are created.
[0047] [0047]FIG. 10 is a perspective view of the printer appliance used in the information delivery system of the present invention.
[0048] [0048]FIG. 11 is a flow diagram illustrating the manner in which the printer appliance of the information delivery system of the present invention operates.
[0049] [0049]FIG. 12 is a flow diagram illustrating the method for message content processing in the printer appliance of the present invention.
[0050] [0050]FIG. 13 illustrates the typical eligibility bit-string filter that may be created from the data in the subscriber directory table of FIG. 4.
[0051] [0051]FIG. 14 is a table illustrating the reception eligibility matching of the printer appliance of the present invention.
[0052] [0052]FIG. 15 is a flow diagram illustrating the print processing in the printer appliance of the present invention.
[0053] [0053]FIG. 16 is a flow diagram illustrating another embodiment of the information delivery system of the present invention.
[0054] [0054]FIG. 17 is a flow diagram illustrating the manner in which the receiver-printer-dispenser appliance of the information delivery system of the present invention operates.
[0055] [0055]FIG. 18 is a perspective view of the receiver-printer-dispenser appliance used in the information delivery system of the present invention.
[0056] FIGS. 19 - 22 illustrate the various types of dispenser configurations for the receiver-printer-dispenser appliances.
[0057] [0057]FIG. 23 is a sample floor plan illustrating the placement of the various types of dispenser configurations for the receiver-printer-dispenser appliances.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] Referring to the drawings, FIG. 1 is a flow diagram describing the information delivery system of the present invention which includes eight major components: (1) a subscriber directory 10 ; (2) a system control center 20 ; (3) a message bank 30 ; (4) a database manager 40 ; (5) a transmission sequence compiler 50 ; (6) a bank of modems 60 ; (7) a transmitter network 70 ; (8) and a network of printer appliances or receiver-printer-dispensers 80 . It should be appreciated that the subscriber directory 10 , the system control center 20 , the message bank 30 , the database manager 40 and the transmission sequence 50 compiler are software modules that may be maintained on one or a plurality of separate but interconnected or networked computer systems. Such computer systems can be microcomputers to mainframes. Certain software functions of certain modules may be incorporated into any of the appliances.
[0059] The subscriber directory 10 is a database and maintains records of all system subscribers, i.e., those individuals, entities, stores or retail establishments who will receive the messages through the printer appliances or receiver-printer-dispensers 80 . The subscriber directory 10 is preferably maintained in a conventional database program such as, for example, Oracle, dBase, Paradox. While flat file database programs may be used, relational databases such as the ones described above are preferred.
[0060] The subscriber directory 10 maintains the serial numbers of all the printer appliances or receiver-printer-dispensers 80 that have been released to the market place. The appliance serial number for such appliances is very significant because it serves as a message destination code or address for directing messages using the system. Through the database manager 40 , the serial number can be linked to detailed household or retail location information including geographical address and subscriber profile data. The appliance serial number is always printed on all delivered messages. If a message also serves as a discount coupon or other voucher, the identification of the issuing source can be identified upon redemption. This would, for example, enable a promotion sponsor to track the event and obtain information on the respondents for inclusion in his customer database. A printer appliance owner, including a store, would have the option to deny use of any personal or confidential information for any use for privacy reasons.
[0061] Other data that can be maintained by the subscriber directory 10 includes bibliographic, geographic, and specific store location information.
[0062] A sample table illustrating the subscriber directory is shown in FIG. 2 and, includes, for example, information relating to the subscriber's name, address, and geographical region. It should, of course, be appreciated that virtually any type of information concerning the subscriber may be maintained depending upon the particular application.
[0063] The information contained in the subscriber directory 10 can be outputted in print form similar to a regular telephone directory and used by senders in compiling their message lists. A hard-copy directory might be used, for example, by the chain headquarters, the promoter/advertiser, or others to follow-up on activity or performance with personnel in individual stores. Large-scale users such as major grocery chains, national retail chains or mass merchants, may be allowed secured direct access to the directory or provided with magnetic tape, diskette or ROM forms for assigning serial number usage within their in-house loyalty/frequency programs.
[0064] The subscriber directory 10 , when affiliated with an in-store loyalty program, potentially has a high commercial value because of the consumer information content and, if desired, may be rented to or shared with manufacturers, direct mail or telephone marketers, per published privacy policies and in accordance with governing laws and proper notification to users.
[0065] The data contained in the subscriber directory 10 is, in a preferred embodiment, maintained in bit-string format which facilitates the ability to sort such data and subsequently match the data to corresponding requirements in the printer appliances 82 upon broadcast.
[0066] A sample of possible bit-string groupings is included in FIG. 3 in which multiple digit numbers are assigned to a particular field and data. For example, bits between 000 and 100 may be assigned to the geography and zip code of the subscriber (store); bits 101 - 130 may be assigned to household or store composition data; bits between 131 - 160 to the type of home or store; 161 - 170 to the family income or store traffic patterns by day; 171 - 200 ; and above 200 to brand usage or product movement cycles or even product or store/chain competitive information, etc. It is anticipated that up to 1000 bits may be used in this regard although this number may be increased or decreased if necessary.
[0067] The system control center 20 may be run on most current CPU's including microcomputers and main frame computers and provides overall management and administration for the entire information delivery system. It is composed of a computer and associated input/output peripherals incorporating software modules that perform functions such as:
[0068] a. Collecting and accepting new system information such as the serial numbers of additional printer appliances or receiver-printer-dispensers, new messages, and new and updated subscriber profile data.
[0069] b. Relaying and entering new information to the appropriate repositories, e.g., new serial numbers to the subscriber directory 10 , messages to the message bank 30 and profile information to the database manager 40 .
[0070] c. Editing, updating and generally maintaining the subscriber directory 10 , message bank 30 , and database manager 40 .
[0071] d. Providing support to the database manager 40 and transmission sequence compiler 50 in posting and dispatching messages, and tracking sender volumetrics for billing.
[0072] Basic utilities to support the above functions generally exist within the management system of modem database products.
[0073] The message bank 30 is a table in a database of the type such as, for example, Oracle, dBase, Paradox, etc. The message bank 30 serves as a vast repository for collecting and storing messages pending distribution. It would preferably have a highly versatile data reception capability to permit messages to be received electronically, recovered from storage media such as disk, ROM, swipe cards or tape, optically scanned from hard copy by barcode or optical character readers or, as a last resort, entered by keyboard.
[0074] Upon entry into the message bank 30 , the messages are stored in table format of the type illustrated in FIG. 4. The message bank 30 contains the date that the message is to be delivered, the priority of delivery (e.g., urgent), the type of message, (e.g., coupon, warning, advertisement, etc.), the text and graphic of the message, the destination criteria (e.g., national, specific subscribers or stores, selected groups of subscribers or stores, etc.) and whether the message needs to be broken into parts due to its length.
[0075] The message bank will, on a daily basis, process those messages that are to be delivered during such day. FIG. 5 illustrates the manner in which a sample batch of message may be processed for a particular day. The messages are initially sorted by the date on which they are to be delivered and then by priority. Thus, all urgent messages or time sensitive promotions (e.g., priority 1) would be delivered before increasingly less urgent messages (e.g., priorities 2-0). Messages of a particular priority, e.g., 1 would be delivered in the order that they were initially received by the system.
[0076] Bits conforming to the bit-string sequence of the subscriber table identify the destination criterion identified in the message bank table. For example, FIG. 6 illustrates the application of the bit-string procedure discussed previously concerning the subscriber bank 10 with reference to a group of messages. Note, in particular, that by using the bit-string procedure heretofore discussed, it is possible to quickly and specifically target a group or groups of individuals or stores. For example, the coupon may be directed to a specific geographical area, a specific type of household or store and a specific income level or product or store competitive situation by simply identifying the applicable bit-string for the targeted groups.
[0077] The database manager 40 is a sophisticated system, preferably of the Oracle or Informix genre, due to its need to handle multiple databases including the subscriber directory 10 , the message bank 30 , and schedule the transmission of messages or packets of information.
[0078] The transmission sequence compiler 50 is a dedicated component with the responsibility for readying message batches so that they can be relayed to the pager network 70 in a controlled and efficient manner. Required tasks for the transmission sequence compiler 50 include sorting and sub-dividing the daily batch into sub-batches for optimal loading to the different modems and prioritizing within these sub-batches to ensure that the messages within the sub-batches are sequenced in accordance with urgency of delivery requirements. An important priority would be, for example, to ensure that early time-zone messages are queued early in the relay process.
[0079] [0079]FIG. 7 is a sample of the format in which a group of messages ready for transmission would be organized and FIG. 8 provides some examples of data that may be contained in such a table. Note that the messages are sorted by priority and then by message sequence number (MSN). The Destination Code String indicates whether the printer appliances are to receive data based on the individual PMA number or, alternatively, on the bit string code. For example, if the message is intended to be processed only by a particular PMA or RPD, the identification number of the targeted PMA or PMA's or RPD's will be indicated. In such manner, the destination Code String would be “0”. Note that one or a multiplicity of PMA or RPD identification numbers can be provided.
[0080] Where, however, the message is intended to be processed by “groups” of subscribers based on criteria identified in the bit-string codes, the Destination Code String would read “1” or “2” depending upon whether the message was “public” or “private.” If public, that is, if it is intended to be an unsecured message, the Destination Code String would be “1” and the Bit Code String would be provided. Thus, if the message was intended to be processed by a particular group of subscribers, the bit-string of such group would be identified in the Bit String Code.
[0081] The system of the present invention has the ability to deliver private, secure messages to be printed on printer appliances containing a “private” key. In this manner, the Destination Code String would read “2” and both the PMA or RPD number and a Private Key Number unique to that printer appliance or receiver-printer-dispenser would be transmitted as part of the Destination PMA or RPD Code. Secure messages in a store environment may include reports, summaries, and individual unique store communications.
[0082] The transmission sequence compiler 50 assigns a unique Message Identification Number (“MIN”) to each message for subsequent audit tracking. The MIN number represents that number of the batch in which the message was transmitted, e.g., 00001, followed by the Message Sequence Number and the year. Thus, the MIN for Message Sequence Number 152001 which was transmitted in the first batch in the year 1998 would be “0000115200198”. The assignment of such a MIN permits the system to automatically track the transmission of each message delivered to the system. It further serves to facilitate tracking of production efficiency, volumetrics, and quality control measures.
[0083] The bank of modems 60 is the primary channel for telecommunication messages to the pager network 70 . Conventional off-the-shelf modems such as, for example those provided by U.S. Robotics, Hayes or other conventional modems may be used. The capabilities of everyday modems are improving rapidly with standard transmission rates currently at least 56 KB. The bank of modems may be replaced by a dedicated cable TV link as the system grows.
[0084] Batches of messages from the sequence compiler 50 are telecommunicated by the message bank to the wireless pager network 70 by regular modem-modem interconnection. Such communications are buffered at the network head-end and broadcast as traffic permits. They may be maintained by the network in buffer storage and then transmitted in batches along with other messages or interlaced between other messages. This permits more efficient and convenient transmission and at lower costs than transmission at peak rates.
[0085] In certain applications, it may be necessary to install a dedicated traffic monitor, with message storage and retrieval modules, between the bank of modems 60 and wireless pager network 70 . This utility is intended to efficiently integrate the high volume of lengthy print messages into the regular, pager transmission activity.
[0086] Major providers of pager networks are PageNet, SkyTel, ComCast and others. In addition to the foregoing, there are a host of regional pager networks including, for example, Page 2000 by the Southern New England Telephone Company.
[0087] It should, of course, be appreciated that the pager network system may constitute virtually any form of wireless broadcast or narrowcast system now known or developed in the future.
[0088] In a typical pager network, the messages are transmitted by the modem bank 60 to the wireless pager network 70 where they are amplified and transmitted to a teleport for uplink to the receiving satellite receiver. The messages are then re-broadcast to a plurality of receiver/re-transmitter towers which, again, amplify the signals and re-transmit the messages to the network of printer appliances or receiver-printer-dispensers 80 .
[0089] The network of printer appliances or RPD's 80 consists of a plurality of individual printer appliances or RPD's 82 , each having a unique serial number for identification purposes. These appliances include normal pager components and circuitry, combined with a thermal printer and enclosed in a case with a lid allowing easy access for paper placement.
[0090] A possible rendition of a printer appliance or RPD 82 is illustrated in FIG. 10 and a flow diagram of the function of the printer appliance or RPD 82 is shown in FIG. 11.
[0091] The printer appliance or RPD 82 includes a ferrite core antenna 83 , a receiver 84 , a decoder 85 , filter or format generator 86 , microprocessor 87 including random access memory 87 A, write only memory 87 B and an EPROM 87 C, a power supply 88 and a printer 89 , preferably of the thermal type although, in future years as the prices come down, it may be possible to use inkjet or other computer type printers. A multiplicity of microprocessors 87 , random access memory 87 A or EPROMS 87 C may be required for volume and packet size options to be utilized within each printer.
[0092] It is preferred that the thermal paper be stored in a fan-folded manner rather than a spool or roll although it should be appreciated that a spool or roll may be utilized in some applications. The use of fan-fold paper enhances the design efficiency of the unit. Fan-fold paper provides higher residual paper storage density than roll paper. In addition, by perforating the paper, it facilitates separation of the message paper slips. It also folds and lays flat on delivery with minimal curing that is a serious problem with spooled thermal paper. Since the messages to be delivered using the information delivery system of the present invention are fixed format messages, such formats lend themselves to the use of fan-fold paper.
[0093] In a preferred embodiment, the receiver 84 of the printer appliance 82 is a standard pager receiver POCSAG Format, 2400 Baud and the decoder 85 is an off-the shelf POCSAG unit. Other formats than can be used include FLEX and GOLAY. The use of the FLEX format would provide a significant advantage in terms of providing back channel capability for message reception confirmation and is also much more power efficient than the POCSAG format.
[0094] A destination code eligibility-matching filter 86 and a basic microprocessor 87 , preferably an 8031 or 8051 chip, are also included in the preferred embodiment, but advances in technology and improvements in economics may make RISC or other newer technology more desirable. 1 Kbytes of RAM 87 A is typically sufficient along with at least 128 bytes of EPROM 87 B, however more or less may be incorporated within various applications. The incorporation of write-only memory 87 B is important to permit storage of the subscriber bit string eligibility filter, allowing subsequent matching with the messages being transmitted. In addition, a conventional consumer appliance type power supply 88 is preferred.
[0095] It should be appreciated that printers draw considerable wattage so that there is need for a dedicated power supply 88 . Such a power supply 88 would preferably be a stand-alone module due to design and operation restrictions as well as economics. The main unit would be fitted with an LED power-on indicator 90 as shown in FIG. 10 so that a user may quickly see that the appliance is in an active mode.
[0096] The printer appliance or RPD 82 utilizes established POGSAG technology that is sufficient for most applications. Future versions of the appliance may incorporate a Motorola Flex receiver/decoders if improvements in performance criteria or economics become more attractive or are required. Most of the other components such as the 8051 processor, RAM and EPROM are mass produced devices available at low cost.
[0097] The components of the printer appliance or RPD 82 represent the initial preferred embodiment of such device. The printer appliance or RPD 82 has inherent processing capabilities beyond simply providing the basic tasks. With additional components and control software, extended functionality can be readily incorporated.
[0098] The printer appliance or RPD 82 may also include, for example, an RS232 port (not shown) to permit transfer of messages to or from an auxiliary system such as a personal organizer, a laptop or desktop computer, smart card appliances etc. Relay to a personal computer permits messages to be archived, reformatted and the likes as well as offering a host of other print options. It should be appreciated that the printer appliance may also be upgraded to render it compatible with a cable television delivery system of messages such as the one, for example, described in U.S. Pat. No. 5,500,681 which issued on Mar. 19, 1996 to Charles P. Jones for Apparatus and Method for Generating Coupons in Response to Televised Offers, the disclosure of which is hereby incorporated herein by reference thereto.
[0099] Similarly, the incorporation of an input port would permit the printer appliance to function as a utility printer to print, for example, e-mail messages (including communications store to store, from headquarters etc.) thereby rendering the printer appliance 82 a centralized message source.
[0100] The incorporation of an IR port (not shown) may also be of particular interest because it may be addressed by an intelligent remote control. See, for example, U.S. Pat. No. 5,500,681 that describes a method for transmitting promotional messages via cable television, except print on demand in the current application is triggered by a remote control type device for selectively triggering the printing of stored information. Communication within the store may be from a central communication device to the individual printers via RF.
[0101] Incorporation of a display 90 for the printer appliance or RPD 82 , preferably a LCD, may also serve to facilitate the user interface. It may, for example, flash urgent messages, allow the user to scroll and review messages and provide prompts for error conditions. With additional memory and software upgrades, the recipient may have the choice of visually reviewing the message and selectively printing only those messages that it selected in much the same manner they currently choose which e-mail messages to print.
[0102] As a transfer medium, the inclusion of a magnetic stripe or smart card reader/writer (not shown) into or as an optional attachment to the printer appliance or RPD 82 would also allow portability of the stored message, with subsequent printing done at the user's convenience. It is possible that, for example in the case of discount coupon messages, printers would be available at the retail establishment where the purchase is to be made. Apart from the portability aspect, limiting printing to only specifically authorized printers may add another layer of security to the process. In future generations of the system, it is possible that coupon messages would never have to exist in print form. Discount coupons stored on the transfer media may be read at the store checkout station or at an in-store kiosk or display incorporating the appliance and the card reader/writer attachment and the savings applied if the appropriate purchase was made.
[0103] In addition, confirmation means (not shown) can be incorporated into the printer appliance or RPD 82 . In conventional paging network systems using POCSAG technology, there is no back-channel capability. Thus, the broadcaster does not receive any confirmation that the message has actually been delivered. In order to increase the reception probability, it is common to employ a redundancy process where repeat message packets are transmitted at different time intervals, but only printing from any printer appliance or RPD a single time.
[0104] Each message may be transmitted 2 or 3 times over a course of minutes to insure that they are received. The PMA is able to identify duplicate transmissions and reject the redundant transmission. The receiver has in-built sensing capabilities and ignores repeat receptions. This 110 methodology has worked exceedingly well and will accommodate the vast majority of messages. Reception confirmation may be an issue in those cases where the message has a significant monetary value, as for airline or event tickets.
[0105] SkyTel has recently introduced a paging service that guarantees message reception and does incorporate back channel, confirmation capability. Their system is based on a new Flex component that does have response capability. Prior to actual message transmission, the particular receiver is polled by the network to determine whether the unit is in an active mode. If a “ready and able” response is echoed, the message is relayed repeatedly until the “AOK” reception confirmation is returned. This modern technology may be utilized when the underlying economics are more favorable for deployment in a high volume consumer appliance or within the store environment.
[0106] The entire system is practical and economically viable only if a large number of printer appliances or RPD's 82 are installed. Factors that will influence mass acceptance are price, design appeal, available distribution channels, ease of use, minimal user responsibility, and ready message display.
[0107] While the system of the present invention is designed to operate in a continuous message-dispatching mode, it is much more efficient if messages are handled in a batch mode. In this manner, a batch would consist of all messages that were due for delivery on any particular day. These daily batches would be transmitted during the late hours of the prior day and early hours of the due date to take advantage of the low network traffic conditions that exist during sleeping hours.
[0108] A unique feature of the system of the present invention resides in the security features of the system, which are intended to prevent fraud and counterfeiting. While some messages contain only information, others such as coupons or tickets have a defined monetary value and are likely candidates for fraud through unauthorized duplication. The present system employs at least five reproduction inhibition techniques: (1) chemically treated paper; (2) color printed edges; (3) reverse side printing; (4) incorporation of a high-resolution pattern; and (5) serial number printing.
[0109] In this regard, the printer appliances or RPD's 82 may employ special, coated thermal paper having a production identification so as to verify the paper source. Similarly, pre-printed color edges may be used on the paper to require color-replicating equipment for duplication. Specific markings may also be printed on the reverse side of the paper that can be automatically sensed using opto-electronic means which can not only assist in alerting the recipient that the appliance is out of paper or there is a paper jam but, also, will serve as a deterrent to unauthorized duplication.
[0110] Other deterrents that can be employed to prevent counterfeiting include the incorporation of a high-resolution pattern on the reverse side of the paper. Thus, reproduction may only be accomplished with sophisticated and expensive copy equipment. Finally, the printer appliance or RPD 82 would print its serial number on every outputted message which, in addition to providing a unique trace to origin, would serve as a further deterrent to counterfeiting since it is a declaration of identify. In the event that any replication activity was even suspected, a serial number erasure message may be transmitted to immediately disable the particular printer appliance or RPD. Alternatively, messages to a specific printer appliance may be eliminated by the system control center 20 or by a flag or field set into the subscriber directory 10 or even in the database manager 40 .
[0111] With reference to FIG. 1, operation of the information delivery system of the present invention is as follows. The subscriber directory 10 would include the most relevant and current data for a given subscriber. As previously noted, the subscriber directory 10 would include all applicable bibliographic, demographic and user-characteristic information. It is anticipated that the information in the subscriber directory 10 would be updated on a regular basis as new members or stores are added or deleted, additional printers are added or deleted within a store, and as the information relating to a particular member or store changes. Such data can be inputted either manually or electronically.
[0112] It should be noted that for ease of distribution, it is advisable to assign bit-strings to the data contained for a particular subscriber. In this manner, messages can be broadcast for processing only by one or a number of specific appliances or, alternatively, by those appliances that have characteristics that match the criteria in the message. The use of bit-strings substantially reduces the amount of data that needs to be processed by the system when determining the potential recipients of a particular message.
[0113] Simultaneously, messages that are to be delivered are inputted into the message bank 30 with specific information concerning the message and delivery instructions, e.g., intended recipients, priority, time and date of delivery, etc.
[0114] Upon entry of the appropriate message or messages into the message bank 30 and the subscriber information into the subscription directory 10 , the system control center 20 and the database manager 40 then reviews all messages stored in the message bank 30 and segregates them based on the date or dates on which they are to be delivered. Those messages that are to be delivered on a particular date or for a very limited time, like special “event” type promotions would be identified and segregated. A sample batch of typical messages to be delivered on a particular date is illustrated in FIG. 5.
[0115] The database manager 40 then assigns bit-string destination codes for the data contained in the batch of messages using the criteria previously identified in FIG. 6.
[0116] The message is then formatted by the inclusion of detailed text and graphics if so instructed. It is contemplated that the database manager 40 will include a vast store of graphic templates such as, for example, prior coupon images, invoice and appointment reminder layouts, logos, simple product pictures, clip-art and a wide variety of text fonts. The database manager 40 would also incorporate a dedicated publisher module with access to the template files and a general capability for semi-automatically designing the printed-message layout. The publisher module would assist in the generation of publisher quality material and would include standards logos, clipart and photographs that would be included in the message. In this manner, the message may simply reference a logo or piece of artwork contained in the publisher module that would then substitute the stored artwork or photographs for incorporation into the message.
[0117] In the case of manufacturer discount coupons, the industry guidelines require that the coupon be bar-coded using a standard UPC Coupon Code format which permits a retailer to automatically scan the coupon at the checkout register. Basic code information identifies the issuing manufacturer, classifies product type with a group family code, and denotes the coupon value. An appendix code has recently been endorsed in UPC/EAN format that can carry additional information such as offer number, expiration date and household identification. The publisher may include a subsystem that would automatically generate the numbers for the bar codes and embed them in the coupon message.
[0118] Prior to release for relay, the message images might require some manual editing in order to optimize the esthetic presentation of the image.
[0119] The compiler 50 then compiles all applicable messages for a particular date, puts then in priority order and then readies them for broadcast.
[0120] Where a specific message such as, for example, a message reminder, is to be transmitted to a single appliance, the message would include the specific serial number of the appliance to which the message is to be directed. Similarly, where messages are to be distributed to all appliances, the message would include a default number common to all active appliances, e.g., 99999.
[0121] When messages are to be delivered to a profiled group of recipients, the Database Manager 40 would search the database, extract subscribers from the Subscriber Directory 10 matching the specific profile criteria, and then extract the serial numbers of the appropriate appliances from the Subscriber Directory for dissemination to such appliances. It is also possible, especially in the case of promotion or advertising messages that the sender will want delivery to as many recipients as can be reached on his particular roster. This would require that the Database Manager 40 to overlay the customer or store roster with the Subscriber Directory 10 , and extract those serial numbers of the common entries.
[0122] Similarly, where the message is to be delivered to a group of subscribers, the bit-string code described above would be part of the message transmitted.
[0123] The final process in preparing the daily batch for transmission requires that the transmission sequence compiler 50 in FIG. 1 serializes the message code strings in a priority sequence as determined by delivery urgency. Some messages must be delivered the next day, while others may be carried over to the following day without difficulty. This allows for accommodation if the system becomes capacity stressed or slowed by high network traffic. The daily batch would actually be subdivided before sequence so that the smaller batches may be dispersed amongst many modems and messages and relayed in parallel to the head-end of the pager network 70 . Messages will then likely be broadcast by the pager wireless pager network 70 within the normal pager frequency band of 929-932 MHz along with other regular paging message activity.
[0124] Messages are then received by all of the printer appliances or RPD's 82 in the appliance network 80 . Functionally the printer appliance or RPD 82 operates as follows:
[0125] 1. The broadcast messages are sensed by the antenna 83 and fed to the receiver 84 .
[0126] 2. The message signal is then pre-amplified and decoded in the CPU.
[0127] 3. Message acceptance is achieved by the CPU 87 performing a software, password-matching processes. Each particular appliance has at least four levels of passwords, namely: (1) the default appliance serial number (all “9's” to accept and process national messages); (2) the specific appliance serial number (a unique number assigned to each individual appliance); (3) a bit-string eligibility code number (which is derived from the profile of the subscriber); and (4) the private PIN number as defined by the subscriber (for processing of highly secure messages). Each message is codes with one or more of the aforesaid numbers
[0128] 4. RAM memory 87 A is needed by the CPU 87 for performing multiple tasks including, for example, system management, message handling, destination code matching, bar code generation and the like. EPROM 87 C would store security information, and in particular the appliance serial number. Information concerning the characteristics of the subscriber would be stored in the write-only memory 87 B to protect against loss during a power failure.
[0129] [0129]FIG. 12 illustrates the critical, message eligibility process that the CPU in the local printer appliance 82 must perform. To determine whether a message is being addressed to a particular printer appliance 82 ; the CPU interrogates the destination code header. If the Destination Code String is “0” indicating that the message may only be processed by a specific printer appliance or RPD or appliances, it then determines whether there is a match with the PMA or RPD number being transmitted with that of the appliance. If there is a match, the message is processed. If not, the process is aborted.
[0130] Similarly, if the Destination Code String is “1” indicating that only appliances with a particular bit-string code may process the messages, it then compares the bit-string of the appliance with that of the message. If there is a match to all or a predetermined percentage, the message is then passed on for processing. If there is no match, the process is aborted.
[0131] Lastly, if the Destination Code String is “2” indicating that the message is being transmitted to a specific appliance or appliances having a private key, it looks to match the PMA or RPD number of the message with that of the appliance. Standard encryption techniques used in RSA and PGP use a public key/private key encryption. An algorithm in the PMA or RPD will decrypt the message, process the decrypted message and print it out. It can only be decrypted by the PMA or RPD with the private key. If there is a match, it then performs a second function by attempting to match the appliance's private PIN number with the PIN number being transmitted. If both match, the message is processed. If not, the process is aborted.
[0132] [0132]FIGS. 13 and 14 illustrate a particular sample of bit-string matching between the destination bit-strings contained within the broadcast message and the eligibility bit-string code number contained in the appliance. Note that there needs to be a complete match between the destination bit-string contained in the message and the bit-string of the appliance. In certain situations, it may be feasible to permit the appliance to process a message where only a predetermined percentage of the bit-strings are matched, e.g., at least 25%.
[0133] [0133]FIG. 15 illustrates the manner in which messages within the appliance may be processed and eventually printed using a message interpretation process. Incoming messages will typically be received in a highly condensed form as the Sequence Compiler has adopted compaction processes such as zipping, zero compression, bit packing and general data compression. The CPU must then decode and decompress the message content.
[0134] As previously discussed, in order for a Pager-Network provider to handle the message in a normal manner, the message must be contained within a specified packet length or, alternatively, will be packetized over multiple packets. Some messages, particularly coupons, will include significant graphic content and the total message may have to be transmitted in the form of a packet series. This necessitates inclusion of a pre-content header indicating the number of parts to the message. A byte indicator packet, for example 1 of 3, would serve to alert the system that the message is not complete until all three parts have been received and that the CPU will need to merge the packet contents and reconstruct the total page prior to generating print code.
[0135] A particular application of the subject invention involves using the wireless system to broadcast coupons to an array of in-store receiver-printer-dispenser units. FIG. 16 illustrates such a coupon distribution system, in which the components are described as: (1) reservation system 100 , (2) promotion control center 110 , (3) graphics design module 120 , (4) modems 130 , (5) pager network ( 140 ) and (6) in-store arrays of receiver-printer-dispenser units 150 . It should be appreciated that the reservation system 100 corresponds to the message bank 30 , the modems 130 correspond to the bank of modems 60 , the pager network 140 corresponds to the wireless pager network 70 and the in-store arrays of receiver-printer-dispenser units correspond to the network of printer appliances 80 . The promotion control center 110 incorporates the system control center 20 , subscriber directory 10 , database manager 40 and transmission sequence compiler 50 . The addition of the separate graphics design module 120 is designed to facilitate the incorporation of graphical images into the coupons generated by the system.
[0136] The in-store array of receiver-printer-dispenser units 150 consists of a plurality of individual receiver-printer-dispenser (RPD) units 151 , each having a unique serial number for identification purposes. A flow diagram of the function of the RPD units 151 is shown in FIG. 17.
[0137] The RPD unit 151 includes a ferrite core antenna 152 , a receiver 153 , a decoder 154 , format generator 155 , a reprint sensor 156 , microprocessor 157 including random access memory 157 A, flash memory 157 B and an EPROM 157 C, a power supply 158 and a printer 159 . The functionality of the RPD unit 151 is significantly enhanced by the addition of the flash memory 157 B and the reprint sensor 156 , as well as by the addition of a visual display 166 , audio component 168 and motion detector (not shown). On the assigned distribution date, the promotion control center 110 codes the detailed offer information into a format compatible with pager network 140 transmission requirements. These coded signals are relayed to the pager network 140 via a modems 130 . In turn, the pager network 140 broadcasts the coupon offer signals which are detected by the RPD units 150 arranged in various configurations within a store. The antenna 152 senses the coupon signal as broadcast by the pager network 140 . A receiver 153 , such as a Motorola POCSAG demodulates and amplifies this signal and relays it to the decoder 154 and format generator 155 so that the coupon can be printed. The coupon signal is also stored in flash memory 157 B for later printing. An emitter-detector pair in the reprint sensor 156 detects removal of a coupon and orders a fresh coupon to be printed from the originally transmitted image as stored in flash memory 157 B. This action would also activate a counter so that the volume of coupons distributed can be recorded.
[0138] The E-Prom 157 C contains a unique serial number identifying each individual RPD unit 151 . Every transmitted message has a destination header containing the serial number of the particular RPD unit 151 eligible to receive the message. A matching operation is performed prior to full decoding to determine whether an incoming message is eligible for printing.
[0139] A schematic of a basic RPD unit 151 is shown in FIG. 18, and an illustration of a typical shelf RPD unit 151 is shown in FIG. 19. In the preferred embodiment, the physical dimensions of the RPD unit 151 are 8 inches high by 4 wide and 2 inches deep. Such dimensions allow the RPD unit 151 to be placed on a display shelf without obstructing the products unnecessarily, while still being large enough to be visible to a consumer and to print coupons. The RPD unit 151 may include a paper loader 160 for insertion of the paper that coupons 162 are printed upon. A status indicator 164 may consist of an LED that lights when the RPD unit 151 is active or flashes when there is an internal error. In the basic RPD unit 151 shown in FIG. 18, the reprint sensor 156 is of the form of an LED emitter/silicon detector pair.
[0140] The RPD unit 151 may also be fitted with a display 166 for the display of a visual message appropriate for the product or coupon 162 , as well as a speaker module 168 for the broadcast of an audio message relative thereto. The display 166 may include any type of electro-optical signage such LED, LCD, Plasma or CRT, depending upon configuration of the RPD unit 151 and its location in the store. LED or LCD may be more appropriate for smaller configurations such as bulletin boards or shelf units while Plasma or CRT would be more suitable for bigger kiosk or end-cap configurations. The speaker module 168 is composed of a dedicated receiver, controller, voice-chip, speaker and a motion sensor (not shown). As a potential customer comes within range of the coupon dispenser, the motion detector would activate the audio message in order to entice a customer to take the coupon.
[0141] The RPD units 151 can be arranged in a variety of configurations such as bulletin boards, wall displays, entry kiosks, end of aisle stands and shelf displays. The configuration of the RPD units 151 are detailed in a store layout plan in which each array configuration is designated by type, position in the store, and the serial number of each RPD unit in each array.
[0142] A bulletin board dispenser 170 is illustrated in FIG. 20. This configuration is composed of multiple RPD units 151 assembled on a plug-in board 172 with a large display module 174 . The display module 174 may be an LCD or LED display controlled by display controller 176 . The bulletin board dispenser 170 may also include an audio module with speakers 178 . The display module 174 , audio module 178 and RPD units 151 would all be provided power by power supply modules 179 .
[0143] [0143]FIGS. 21 through 24 illustrate various other configurations for the RPD units 151 in store displays. In all the configurations, visual and audio displays could be incorporated to create further interest. FIG. 21 shows an end-cap dispensers 180 configuration wherein an array of RPD units 151 are arranged to attract attention and provide easy accessibility to the dispensed coupons. FIG. 22 depicts a booth or kiosk display 182 with an array of RPD units 151 . FIG. 24 is a sample floor plan showing a variety of different RPD unit 151 displays, including booth displays 182 , end-cap dispensers 180 , shelf dispensers 184 and bulletin board dispensers 170 .
[0144] In an alternate embodiment of the current invention, the RPD units 151 may be programmed locally by a store operator to add promotions directly. Such a facility enables the retailer to run his own promotions on RPD units 151 scheduled for this purpose. The local load out could be done via the pager network or, alternatively, through a dedicated loading module.
[0145] In yet another embodiment of the current invention, software is provided for entering and encoding promotions directly. The software would be installed on the store computer and relay of the promotion would occur via modem to the pager network and on to the addressed RPD units 151 . Alternatively, this software could be installed on a computer at the retailer headquarters which could then control all retail promotions for the complete store/chain roster. This adaptation at the store or headquarters could also be used to interface or integrate the current invention with an in-store loyalty program. Or, this adaptation of the current invention could be used for sending secure/confidential messages throughout the chain or to individual stores. Secure messages in a store environment may include reports, summaries, and individual, unique store communications.
[0146] In still another alternate embodiment, a dedicated piece of hardware including a central processing unit, keyboard, display, memory and a local RF transmitter emulating a normal pager network signal may be used by an operator to configure and address any particular RPD unit 151 and enter a desired promotion.
[0147] It should be appreciated that the RPD units 151 need not be limited to printing coupons. For example, the RPD units 151 could also serve as a dynamic dispenser of rebate claim forms, surveys, contest announcements and entries, sweepstakes entries etc. or any other often-requested forms or printed matter.
[0148] Having thus described the invention with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims. | A system is provided for distributing in a retail environment one or more packets of information selected from the group consisting of redeemable coupons, forms, messages, tickets, warnings and written packets to potential recipients of said packets from a receiver-printer-dispenser at a remote location. The steps included in such a system are: (1) developing a receiver directory containing unique identification information for each of said potential receiver-printer-dispenser within a store or retail environment; (2) creating a packet to be dispatched to at least one of said RPD; (3) identifying the potential RPD's for a particular packet; (4) transmitting said packet through a pager network to all of said potential RPD's; (5) receiving, storing and selectively processing and printing only those packets intended to be processed and printed by said appliance; and (6) detecting whether said printed packet has been removed, and printing another copy of said packet in the event the printed packet has been removed. A variety of audio and visual display components and motion sensors are also provided to enhance the appeal of the RPD's and encourage consumers to accept the printed packet. | 7 |
GENUS AND SPECIES OF PLANT CLAIMED
[0001] Lantana sp.
VARIETY DENOMINATION
[0002] ‘Chapel Hill Gold’
BACKGROUND OF THE INVENTION
[0003] The present invention relates to a new and distinct cultivar of Lantana plant, botanically known as Lantana sp., and hereinafter referred to by the cultivar name ‘Chapel Hill Gold’.
[0004] The new Lantana plant originated as a branch mutation on Lantana sp. ‘Chapel Hill Yellow’ (Plant patent application Ser. No. 11/999,902, filed Dec. 7, 2007, now allowed). The cultivar ‘Chapel Hill Gold’ originated and was discovered in a cultivated environment at Watkinsville, Ga.
[0005] Asexual reproduction of the new cultivar by stem cuttings in Watkinsville, Ga. has shown that all the unique features of this new Lantana, as herein described, are stable and reproduced true-to-type through successive generations of such asexual propagation.
SUMMARY OF THE INVENTION
[0006] Plants of the new cultivar ‘Chapel Hill Gold’ have not been observed under all possible environmental conditions. The phenotype may vary somewhat with changes in light, temperature, soil and rainfall without, however, any variance in genotype.
[0007] The following traits have been repeatedly observed and are determined to be unique characteristics of ‘Chapel Hill Gold’. These characteristics in combination distinguish ‘Chapel Hill Gold’ as a new and distinct cultivar: 1. Low growing, layered and spreading growth habit; 2. Leathery, scabrous dark green foliage; 3. Continuous flowering; 4. Bright golden yellow flower buds and flowers; and 5. Cold hardiness to USDA Hardiness Zone 7.
[0008] Plants of the new Lantana ‘Chapel Hill Gold’ differ from plants of the parent, ‘Chapel Hill Yellow’, primarily in flower color, as plants of ‘Chapel Hill Yellow’ have pale yellow flower buds that open to medium yellow with a darker yellow-orange center.
[0009] Plants of the new Lantana can be compared to plants of the cultivar ‘New Gold’. However, in side-by-side comparisons conducted in Watkinsville, Ga., plants of the new Lantana differed from plants of the cultivar ‘New Gold’ in the following characteristics: 1. Plants of the new Lantana had darker green, thicker, more scabrous foliage than plants of the cultivar ‘New Gold’; 2. Plants of the new Lantana had brighter golden yellow flower buds and flowers than plants of the cultivar ‘New Gold’; and 3. Plants of the new Lantana were consistently cold hardy from year to year, whereas plants of the cultivar ‘New Gold’ lacked consistent cold hardiness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying color photographs illustrate the flower and foliage characteristics and the overall appearance of the new Lantana, showing the colors as true as it is reasonably possible to obtain in color reproductions of this type. Colors in the photographs may differ slightly from the color values cited in the detailed botanical description which accurately describe the colors of the new Lantana.
[0011] FIG. 1 illustrates the overall appearance of a mature plant of ‘Chapel Hill Gold’.
[0012] FIG. 2 illustrates a close-up view of the inflorescences of ‘Chapel Hill Gold’.
[0013] FIG. 3 illustrates a close-up view of the foliage of ‘Chapel Hill Gold’.
DETAILED DESCRIPTION
[0014] In the following description, color references are made to The Royal Horticultural Society Colour Chart, 2001 Edition, except where general terms of ordinary dictionary significance are used. Plants used for the description were grown in 11.8 L containers under outdoor conditions in a nursery in Watkinsville, Ga. Plants were 6 months old when the description was recorded. Colors are described using The Royal Horticultural Society Colour Chart (RHS).
Botanical classification: Lantana sp., cultivar ‘Chapel Hill Gold’. Parentage: — Lantana sp. cultivar ‘Chapel Hill Yellow’ (plant patent allowed). Propagation: Type cutting — terminal cuttings. Time to initiate roots, summer — about 10 days at 32° C. Plant description: Perennial flowering plant; subshrub; low growing, layered and spreading growth habit. Freely branching; two lateral branches potentially forming at every node; pinching enhances lateral branch development.
Root description.— numerous, fine, fibrous and well-branched. Plant height.— about 40 cm. Plant diameter.— about 120 cm. Lateral branches having a length of about 15 cm and a diameter of about 2.5 mm. Shape.— squarish. Internode length.— about 5.5 cm. Strength.— strong, but flexible. Texture.— coarse, pubescent. Color ( young ).—close to 144A. Color ( woody ).—close to 199A.
Foliage description:
Arrangement.— opposite, simple. Length.— about 4 cm. Width.— about 3 cm. Shape.— ovate. Apex.— acute. Base.— cuneate. Margin.— crenate. Texture ( upper surface ).—leathery, moderately waxy, with scabrous pubescence. Texture ( lower surface ).—rough, with hispid pubescence. Venation pattern.— pinnate. Venation color ( upper surface ).—close to 144A. Venation color ( lower surface ).—close to 144A. Fragrance.— pungent, mint-like. Color in developing foliage ( upper surface ).—close to 137A. Color in developing foliage ( lower surface ).—close to 138B. Color in fully expanded foliage ( upper surface ).—close to 137A. Color in fully expanded foliage ( lower surface ).—close to 137C. Petiole length.— about 8 mm. Petiole diameter.— about 2 mm. Petiole texture, both surfaces.— hispid pubescence. Petiole color ( upper surface ).—close to 143A. Petiole color ( lower surface ).—close to 144A.
Flower description: Flower type and habit — small salverform flowers arranged in axillary corymbs; flowers face mostly upward or outward. Flowers are self-cleaning. Freely flowering with potentially two inflorescences per node; typically about 27 flowers per corymb.
Natural flowering season.— spring until frost in the autumn; flowering is continuous. Flower longevity on the plant.— about one week. Fragrance.— faint, pleasant. Inflorescence diameter.— about 3.4 cm. Inflorescence height.— about 1.7 cm. Flower appearance.— Flared trumpet, corolla fused, four-parted; flowers roughly rectangular in shape. Diameter.— about 8 mm by 12 mm. Corolla tube length.— about 1.2 cm. Flower bud length.— about 6 mm. Flower bud diameter.— about 2 mm. Flower bud shape.— oblong. Flower bud color.— close to 17B. Pedicels.— not observed, flowers not stalked.
Petals:
Arrangement/appearance.— Single whorl of four petals, fused into flared trumpet. Petal length from throat.— about 4.5 mm for upper and lower petals and about 3 mm for lateral petals. Petal width.— upper and lower petals are about 7 mm. Lateral petals are about 3.5 mm. Petal shape.— spatulate to somewhat orbicular. Petal apex.— obtuse. Petal base.— fused. Petal margin.— entire. Petal texture, upper and lower surfaces.— smooth, glabrous. Color of petal lobes, when opening and fully opened, upper surface.— close to 17A. Color of petal lobes, when opening and fully opened, lower surface.— close to 17B. Color of throat.— close to 17A. Color of tube.— close to 17B.
Sepals:
Arrangement/appearance.— one sepal per flower at the base of the corolla, leaf-like. Length is about 5 mm. Width is about 1 mm. Shape.— lanceolate. Apex.— acute. Margin.— entire. Texture, upper and lower surface.— scabrous. Color, upper and lower surfaces.— close to 144A.
Peduncles: Length is about 4.3 cm. Diameter is about 2 mm.
Angle.— about 45 degrees from the stem. Strength.— flexible, but strong. Color.— close to 144A.
Stamens:
Quantity/arrangement.— four per flower, adnate to the inside of the corolla tube. Anther shape.— oblong. Anther length.— less than 1 mm. Anther color.— close to 200A. Pollen amount.— none observed.
Pistils:
Quantity.— One per flower. Pistil length.— about 2.5 mm. Stigma shape.— rounded. Stigma color.— close to 145A. Style color.— close to 145A. Ovary color.— close to 145A.
Fruit:
Type/appearance.— drupe. Shape.— round. Diameter.— about 5 mm. Mature color.— 202A. Number per infructescence.— about 5.
Disease/pest resistance: Plants of the claimed Lantana variety grown in the garden have not been noted to be resistant to pathogens and pests common to Lantana. Weather and temperature tolerance: Plants of the new Lantana variety have been observed to be tolerant to rain and wind, and have been observed to be tolerant to temperatures ranging from about 0 degrees C. to about 38 degrees C. and are hardy to about USDA Hardiness Zone 7. | A new and distinct cultivar of Lantana plant named ‘Chapel Hill Gold’, characterized by its low growing, layered and spreading growth habit; leathery, scabrous dark green foliage; continuous flowering; bright golden yellow flower buds and flowers; and cold hardiness to USDA Hardiness Zone 7. | 0 |
RELATED APPLICATIONS
[0001] This application derives benefit from U.S. Provisional Application No. 60/909,474, filed Apr. 1, 2007.
FIELD
[0002] The described devices are spinal implants that may be surgically implanted into the spine to replace damaged or diseased discs using a posterior approach. The discs are prosthetic devices that approach or mimic the physiological motion and reaction of the natural disc.
BACKGROUND
[0003] The intervertebral disc is an anatomically and functionally complex joint. The intervertebral disc is composed of three component structures: (1) the nucleus pulposus; (2) the annulus fibrosus; and (3) the vertebral end plates. The biomedical composition and anatomical arrangements within these component structures are related to the biomechanical function of the disc.
[0004] The spinal disc may be displaced or damaged due to trauma or a disease process. If displacement or damage occurs, the nucleus pulposus may herniate and protrude into the vertebral canal or intervertebral foramen. Such deformation is known as herniated or slipped disc. A herniated or slipped disc may press upon the spinal nerve that exits the vertebral canal through the partially obstructed foramen, causing pain or paralysis in the area of its distribution.
[0005] To alleviate this condition, it may be necessary to remove the involved disc surgically and fuse the two adjacent vertebrae. In this procedure, a spacer is inserted in the place originally occupied by the disc and the spacer is secured between the neighboring vertebrae by the screws and plates or rods attached to the vertebrae. Despite the excellent short-term results of such a “spinal fusion” for traumatic and degenerative spinal disorders, long-term studies have shown that alteration of the biomechanical environment leads to degenerative changes particularly at adjacent mobile segments. The adjacent discs have increased motion and stress due to the increased stiffness of the fused segment. In the long term, this change in the mechanics of the motion of the spine causes these adjacent discs to degenerate.
[0006] Artificial intervertebral replacement discs may be used as an alternative to spinal fusion.
SUMMARY
[0007] Prosthetic intervertebral discs and methods for using such discs are described. The subject prosthetic discs include an upper end plate, a lower end plate, and a compressible core member disposed between the two end plates. The described prosthetic discs have shapes, sizes, and other features that are particularly suited for implantation using minimally invasive surgical procedures, particularly from a posterior approach.
[0008] In one variation, the described prosthetic discs include top and bottom end plates separated by one or more compressible core members. The two plates may be held together by at least one fiber wound around at least one region of the top end plate and at least one region of the bottom end plate. The described discs may include integrated vertebral body fixation elements. When considering a lumbar disc replacement from the posterior access, the two plates are preferably elongated, having a length that is substantially greater than its width. Typically, the dimensions of the prosthetic discs range in height from 8 mm to 15 mm; the width ranges from 6 mm to 13 mm. The height of the prosthetic discs ranges from 9 mm to 11 mm. The widths of the disc may be 10 mm to 12 mm. The length of the prosthetic discs may range from 18 mm to 30 mm, perhaps 24 mm to 28 mm. Typical shapes include oblong, bullet-shaped, lozenge-shaped, rectangular, or the like
[0009] The described disc structures may be held together by at least one fiber wound around at least one region of the upper end plate and at least one region of the lower end plate. The fibers are generally high tenacity fibers with a high modulus of elasticity. The elastic properties of the fibers, as well as factors such as the number of fibers used, the thickness of the fibers, the number of layers of fiber windings in the disc, the tension applied to each layer, and the crossing pattern of the fiber windings enable the prosthetic disc structure to mimic the functional characteristics and biomechanics of a normal-functioning, natural disc.
[0010] A number of conventional surgical approaches may be used to place a pair of prosthetic discs. Those approaches include a modified posterior lumbar interbody fusion (PLIF) and a modified transforaminal lumbar interbody fusion (TLIF) procedures. We also describe apparatus and methods for implanting prosthetic intervertebral discs using minimally invasive surgical procedures. In one variation, the apparatus includes a pair of cannulae that are inserted posteriorly, side-by-side, to gain access to the spinal column at the disc space. A pair of prosthetic discs may then be implanted by way of the cannulae to be located between two vertebral bodies in the spinal column.
[0011] The prosthetic discs may be configured by selection of sizes and structures suitable for implantation by minimally invasive procedures.
[0012] Other and additional devices, apparatus, structures, and methods are described by reference to the drawings and detailed descriptions below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The Figures contained herein are not necessarily drawn to scale. Some components and features may be exaggerated for clarity.
[0014] FIG. 1 shows a method for placement of prosthetic intervertebral discs using a posterior approach.
[0015] FIG. 2 is a perspective view of a variation of my prosthetic disc.
[0016] FIG. 3 is a stylized version of a method for introducing the compressible into the space between the end plates.
[0017] FIG. 4 schematically illustrates a method for implanting the described prosthetic discs.
DETAILED DESCRIPTION
[0018] Described below are prosthetic intervertebral discs, methods of using such discs, apparatus for implanting such discs, and methods for implanting such discs. It is to be understood that the prosthetic intervertebral discs, implantation apparatus, and methods are not limited to the particular embodiments described, as these may, of course, vary. It is also to be understood that the terminology used here is only for the purpose of describing particular embodiments, and is not intended to be limiting in any way.
[0019] Insertion of the prosthetic discs may be approached using modified conventional procedures, such as a posterior lumbar interbody fusion (PLIF) or transforaminal lumbar interbody fusion (TLIF). In the modified PLIF procedure, the spine is approached via midline incision in the back. The erector spinae muscles are stripped bilaterally from the vertebral lamina at the required levels. A laminectomy is then performed to further allow visualization of the nerve roots. A partial facetectomy may also be performed to facilitate exposure. The nerve roots are retracted to one side and a discectomy is performed. Optionally, a chisel may then used to cut one or more grooves in the vertebral end plates to accept the fixation components on the prostheses. Appropriately-sized prostheses may then be inserted into the intervertebral space on either side of the vertebral canal.
[0020] In a modified TLIF procedure, the approach is also posterior, but differs from the PLIF procedure in that an entire facet joint is removed and the access is only on one side of the vertebral body. After the facetectomy, the discectomy is performed. Again, a chisel may be used to create on or more grooves in the vertebral end plates to cooperatively accept the fixation components located on each prosthesis. The prosthetic discs may then be inserted into the intervertebral space. One prosthesis may be moved to the contralateral side of the access and then a second prosthesis then inserted on the access side.
[0021] It should be apparent that we refer to these procedures as “modified” in that neither procedure is used to “fuse” the two adjacent vertebrae.
[0022] FIG. 1 shows a top, cross section view of a spine ( 100 ), sectioned across an intervertebral disc ( 102 ). This Figure depicts a minimally invasive surgical procedure for implanting a pair of intervertebral discs in an intervertebral region formed by the removal of a natural disc. This minimally invasive surgical implantation method is performed using a posterior approach, rather than the conventional anterior lumbar disc replacement surgery or the modified PLIF and TLIF procedures described above.
[0023] In FIG. 1 , two cannulae ( 104 ) are inserted posteriorly, through the skin ( 107 ), to provide access to the spinal column. More particularly, a small incision is made and a pair of access windows created through the lamina ( 106 ) of one of the vertebrae ( 108 ) on each side of the vertebral canal ( 110 ) to access the natural vertebral disc. The spinal cord ( 112 ) and nerve roots are avoided or moved to provide access. Once access is obtained, the two cannulae ( 104 ) are inserted. The cannulae ( 104 ) may be used as access passageways in removing the natural disc with conventional surgical tools. Alternatively, the natural disc may be removed prior to insertion of the cannulae. The cannulae are also used to introduce the prosthetic intervertebral discs ( 114 ) to the intervertebral region.
[0024] The described prosthetic discs are of a design and capability that they may be employed at more than one level, i.e., disc location, in the spine. Specifically, several natural discs may be replaced with my discs. As will be described in greater detail below, each such level will be implanted with at least two of my discs. Kits, containing two of my discs for a single disc replacement or four of my discs for replacement of discs at two levels in the spine, perhaps with sterile packaging are contemplated. Such kits may also contain one or more cannulae having a central opening allowing passage and implantation of my discs.
[0025] Once the natural disc has been removed and the cannulae ( 104 ) located in place, two prosthetic discs ( 114 ) are implanted between adjacent vertebral bodies. The prosthetic discs have a shape and size suitable making them suitable for use with (or adapted for) various minimally invasive procedures. The discs may have a shape such as the elongated one-piece prosthetic discs described below.
[0026] Two prosthetic discs ( 114 ) are guided through the cannulae such that each of the prosthetic discs ( 114 ) is implanted between the adjacent vertebral bodies. The two prosthetic discs ( 114 ) may be located side-by-side and spaced slightly apart, as viewed from above. Optionally, prior to implantation, grooves may be formed on the internal surfaces of one or both of the vertebral bodies in order to engage anchoring components or features located on or integral with the prosthetic discs ( 114 ). The grooves may be formed using a chisel tool adapted for use with the minimally invasive procedure, i.e., adapted to extend through a relatively small access space (such as the tunnel-like opening found in through the cannulae) and to chisel the noted grooves within the intervertebral space present after removal of the natural disc.
[0027] These discs may be used as shown in FIG. 1 or, optionally, they may be implanted with an additional prosthetic disc or discs, perhaps in the position shown for auxiliary disc ( 116 ).
[0028] Additional prosthetic discs may also be implanted in order to obtain desired performance characteristics, and the implanted discs may be implanted in a variety of different relative orientations within the intervertebral space. In addition, the multiple prosthetic discs may each have different performance characteristics. For example, a prosthetic disc to be implanted in the central portion of the intervertebral space may be configured to be more resistant to compression than one or more prosthetic discs that are implanted nearer the outer edge of the intervertebral space. For instance, the stiffness of the outer discs (e.g., 114 ) may each be configured such that those outer discs exhibit approximately 5% to 80% of the stiffness of the central disc ( 116 ), perhaps in the range of about 30% to 60% of the central disc ( 116 ) stiffness. Other performance characteristics may be varied as well.
[0029] This description may describe a number of variations of prosthetic intervertebral discs. By “prosthetic intervertebral disc” is meant an artificial or manmade device that is so configured or shaped that it may be employed as a total or partial replacement of an intervertebral disc in the spine of a vertebrate organism, e.g., a mammal, such as a human. The described prosthetic intervertebral discs have dimensions that permit them, either alone or in combination with one or more other prosthetic discs, to substantially occupy the space between two adjacent vertebral bodies that is present when the naturally occurring disc between the two adjacent bodies is removed, i.e., a void disc space. By “substantially occupy” is meant that, in the aggregate, the discs occupy at least about 30% by surface area, perhaps at least about 80% by surface area or more. The subject discs may have a roughly bullet or lozenge shaped structure adapted to facilitate implantation by minimally invasive surgical procedures.
[0030] The discs may include both an upper (or top) and lower (or bottom) end plate, where the upper and lower end plates are separated from each other by a compressible element such as one or more core members, where the combination structure of the end plates and compressible element provides a prosthetic disc that functionally approaches or closely mimics a natural disc. The top and bottom end plates may be held together by at least one fiber attached to or wound around at least one portion of each of the top and bottom end plates. As such, the two end plates (or planar substrates) are held to each other by one or more fibers that are attached to or wrapped around at least one domain, portion, or area of the upper end plate and lower end plate such that the plates are joined to each other.
[0031] FIG. 2 shows a variation of my prosthetic intervertebral disc ( 200 ). This variation comprises an upper end plate ( 202 ) and a lower end plate ( 204 ) separated by a compressible core ( 206 ) comprising two core members ( 208 ). As discussed below in more detail, the compressible core ( 206 ) may comprise one or more core members ( 208 ) and be bounded by one or more fibers ( 210 ) extending between the upper end plate ( 202 ) and the lower end plate ( 204 ). The upper and lower end plates ( 202 , 204 ) may include apertures ( 212 ), through which the fibers ( 210 ) may pass. Other components (woven or nonwoven fabrics, wires, etc.) may be used in functional substitution for the fibers ( 210 ).
[0032] FIG. 3 provides a summary method for placement of my prosthetic disc. In step (a), a pair of end plates ( 202 , 204 ) optionally having a portion of the fiber windings ( 210 ) included, are placed in the implantation site between an upper vertebra ( 220 ) and a lower vertebra ( 222 ). In step (b), a core member ( 224 ) is inserted between the two end plates ( 202 , 204 ). The core member ( 224 ) may be substantially cylindrical and have a diameter less than its height. In step (b), the core member ( 224 ) may be inserted on its side. In step (c), the core member ( 224 ) is rotated such that the axis of the core member ( 224 ) aligns with the spine axis, or is upright.
[0033] The geometry of the core member ( 224 ) may be modified to ease the step of rotating the core member ( 224 ). For instance, imposing a radius or chamfer on the edge of the cylinder will help with the rotation.
[0034] Additionally, more than one such core member ( 224 ) may be placed between the end plates. The disc ( 200 in FIG. 2 ) is one such variation. Exactly one core member ( 224 ) may also be introduced into the prosthetic disc.
[0035] The end plates may be planar substrates having a length of from about 12 mm to about 45 mm, such as from about 13 mm to about 44 mm, a width of from about 11 mm to about 28 mm, such as from about 12 mm to about 25 mm, and a thickness of from about 0.5 mm to about 5 mm, such as from about 1 mm to about 3 mm. The top and bottom end plates are fabricated or formed from a physiologically acceptable material that provides for the requisite mechanical properties, primarily structural rigidity and durability. Representative materials from which the end plates may be fabricated are known to those of skill in the art and include: metals such as titanium, titanium alloys, stainless steel, cobalt/chromium, etc.; plastics such as polyethylene with ultra high molar mass (molecular weight) (UHMW-PE), polyether ether ketone (PEEK), etc.; ceramics; graphite; etc.
[0036] The discs may also include fibers ( 210 ) wound between and connecting the upper end plate ( 202 ) to the lower end plate ( 204 ). These fibers ( 210 ) may extend through a plurality of openings or apertures ( 209 ) formed on portions of each of the upper and lower end plates ( 202 , 204 ). Thus, a fiber ( 210 ) extends between the pair of end plates ( 202 , 204 ), and extends up through a first aperture ( 209 ) in the upper end plate ( 202 ) and back down through an adjacent aperture ( 209 ) in the upper end plate ( 202 ). The fibers ( 210 ) may not be tightly wound, thereby allowing a degree of axial rotation, bending, flexion, and extension by and between the end plates. The amount of axial rotation generally is in the range from about 0° to about 15°, perhaps from about 2° to 10°. The amount of bending generally has a range from about 0° to about 18°, perhaps from about 2° to 15°. The amount of flexion and extension generally has a range from about 0° to about 25°, perhaps from about 3° to 15°. Of course, the fibers ( 210 ) may be more or less tightly wound to vary the resultant values of these rotational values. The core members (not shown) forming compressible core ( 206 ) may be provided in an uncompressed or in a compressed state.
[0037] My described prosthetic discs may include a compressible core ( 206 ) comprising a larger single elongated core member, a generally circular core member, or two or more generally cylindrical core members. The dual core structure may better simulate the performance characteristics of a natural disc. In addition, the fibers ( 210 ) found in the dual core structure are believed to endure less stress relative to the fibers ( 210 ) found in the single core structure.
[0038] The lateral, or horizontal, surface area of each of the end plates ( 202 , 204 )—i.e., the area of the disc surfaces that engage the vertebral bodies—is substantially larger than the cross-sectional surface area of the core member or members. The cross-sectional surface area of the core member or members may be from about 5% to about 80% of the cross-sectional area of a given end plate ( 202 , 204 ), perhaps from about 10% to about 60%, or from about 15% to about 50%. In this way, for a given compressible core ( 206 ) having sufficient compression, flexion, extension, rotation, and other performance characteristics but having a relatively small cross-sectional size, the core member may be used to support end plates having a relatively larger cross-sectional size in order to help prevent subsidence into the vertebral body surfaces. In the variations described here, the compressible core ( 206 ) and end plates ( 202 , 204 ) also have a size that is appropriate for or adapted for implantation by way of posterior access or minimally invasive surgical procedures, such as those described above.
[0039] FIG. 4 , step (a), shows placement of upper and lower end plates ( 400 , 401 ) into the intervertebral space ( 402 ) between an upper vertebra ( 404 ) and the adjacent lower vertebra ( 406 ). The upper and lower end plates ( 400 , 401 ) have been passed through the cannula ( 410 ) to the implantation site. Any fibrous members have been omitted from the drawing for ease of explanation. The core member ( 412 ) is shown approaching the site of the upper and lower end plates ( 400 , 401 ).
[0040] FIG. 4 , step (b), shows the high profile disc ( 414 ) after expansion, i.e., placement of the core member and rotation of the core member into the final position. The cannula ( 410 ) is then removed.
[0041] Each of the described prosthetic discs depicted in the Figures has a greater length than width. The aspect ratio (length:width) of the discs may be about 1.5:1 to 5.0:1, perhaps about 2.0:1 to 4.0:1, or about 2.5:1 to 3.5:1. Exemplary shapes to provide these relative dimensions include rectangular, oval, bullet-shaped, lozenge-shaped, and others. These shapes facilitate implantation of the discs by the minimally invasive procedures described above.
[0042] The surfaces of the upper and lower end plates, those surfaces in contact with and eventually adherent to the respective opposed bony surfaces of the upper and lower vertebral bodies, may have one or more anchoring or fixation components or mechanism for securing those end plates to the vertebral bodies. For example, the anchoring feature may be one or more “keels,” a fin-like extension often having a substantially triangular cross-section and having a sequence of exterior barbs or serrations. This anchoring component is intended to cooperatively engage a mating groove that is formed on the surface of the vertebral body and to thereby secure the end plate to its respective vertebral body. The serrations enhance the ability of the anchoring feature to engage the vertebral body.
[0043] Further, this variation of the anchoring component may include one or more holes, slots, ridges, grooves, indentations, or raised surfaces to further assist in anchoring the disc to the associated vertebra. These physical features will so assist by allowing for bony ingrowth. Each end plate may have a different number of anchoring components, and those anchoring features may have a different orientation on each end plate. The number of anchoring features generally ranges in number from about 0 to about 500, perhaps from about 1 to 10. Alternatively, another fixation or anchoring mechanism may be used, such as ridges, knurled surfaces, serrations, or the like. In some variations, the discs will have no external fixation mechanism. In such variations, the discs are held in place laterally by the friction forces between the disc and the vertebral bodies.
[0044] Further, each of the described variations may additionally include a porous covering or layer (e.g., sprayed Ti metal) allowing boney ingrowth and may include some osteogenic materials.
[0045] As noted above, in the variations shown herein, the upper end plate and lower end plate may each contain a plurality of apertures through which the fibers may be passed through or wound, as shown. The actual number of apertures contained on an end plate is variable. Increasing the number of apertures allows an increase in the circumferential density of the fibers holding the end plates together. The number of apertures may range from about 3 to 100, perhaps in the range of 10 to 30. In addition, the shape of the apertures may be selected so as to provide a variable width along the length of the aperture. For example, the width of the apertures may taper from a wider inner end to a narrow outer end, or visa versa. Additionally, the fibers may be wound multiple times within the same aperture, thereby increasing the radial density of the fibers. In each case, this improves the wear resistance and increases the torsional and flexural stiffness of the prosthetic disc, thereby further approximating natural disc stiffness. In addition, the fibers may be passed through or wound on each aperture, or only on selected apertures, as needed. The fibers may be wound in a uni-directional manner, where the fibers are wound in the same direction, e.g., clockwise, which closely mimics natural annular fibers found in a natural disc, or the fibers may be wound bi-directionally. Other winding patterns, both single and multi-directional, may also be used.
[0046] The apertures provided in the various end plates discussed here, may be of a number of shapes. Such aperture shapes include slots with constant width, slots with varying width, openings that are substantially round, oval, square, rectangular, etc. Elongated apertures may be radially situated, circumferentially situated, spirally located, or combinations of these shapes. More than one shape may be utilized in a single end plate.
[0047] One purpose of the fibers is to hold the upper and lower end plates together and to limit the range-of-motion to mimic or at least to approach the range-of-motion of a natural disc. The fibers may comprise high tenacity fibers having a high modulus of elasticity, for example, at least about 100 MPa, perhaps at least about 500 MPa. By high tenacity fibers is meant fibers able to withstand a longitudinal stress of at least 50 MPa, and perhaps at least 250 MPa, without tearing. The fibers ( 207 ) are generally elongate fibers having a diameter that ranges from about 100 μm to about 1000 μm, and preferably about 200 μm to about 400 μm. The fibrous components may be single strands or, more typically, multi-strand assemblages. Optionally, the fibers may be injection molded or otherwise coated with an elastomer to encapsulate the fibers, thereby providing protection from tissue ingrowth and improving torsional and flexural stiffness. The fibers may be coated with one or more other materials to improve fiber stiffness and wear. Additionally, the core may be injected with a wetting agent such as saline to wet the fibers and facilitate the mimicking of the viscoelastic properties of a natural disc. The fibers may comprise a single or multiple component fibers.
[0048] The fibers may be fabricated from any suitable material. Examples of suitable materials include polyesters (e.g., Dacron® or the Nylons), polyolefins such as polyethylene, polypropylene, low-density and high density polyethylenes, linear low-density polyethylene, polybutene, and mixtures and alloys of these polymers. HDPE and UHMWPE are especially suitable. Also suitable are various polyaramids, poly-paraphenylene terephthalamide (e.g., Kevlar®), carbon or glass fibers, various stainless steels and superelastic alloys (such as nitinol), polyethylene terephthalate (PET), acrylic polymers, methacrylic polymers, polyurethanes, polyureas, other polyolefins (such as polypropylene and other blends and olefinic copolymers), halogenated polyolefins, polysaccharides, vinylic polymers, polyphosphazene, polysiloxanes, liquid crystal polymers such as those available under the tradename VECTRA, polyfluorocarbons such as polytetrafluoroethylene and e-PTFE, and the like.
[0049] The fibers may be terminated on an end plate in a variety of ways. For instance, the fiber may be terminated by tying a knot in the fiber on the superior or inferior surface of an end plate. Alternatively, the fibers may be terminated on an end plate by slipping the terminal end of the fiber into an aperture on an edge of an end plate, similar to the manner in which thread is retained on a thread spool. The aperture may hold the fiber with a crimp of the aperture structure itself, or by an additional retainer such as a ferrule crimp. As a further alternative, tab-like crimps may be machined into or welded onto the end plate structure to secure the terminal end of the fiber. The fiber may then be closed within the crimp to secure it. As a still further alternative, a polymer may be used to secure the fiber to the end plate by welding, including adhesives or thermal bonding. That terminating polymer may be of the same material as the fiber (e.g., UHMWPE, PE, PET, or the other materials listed above). Still further, the fiber may be retained on the end plates by crimping a cross-member to the fiber creating a T-joint, or by crimping a ball to the fiber to create a ball joint.
[0050] The core members provide support to and maintain the relative spacing between the upper and lower end plates. The core members may comprise one or more relatively compliant materials. In particular, the compressible core members in this variation and the others discussed herein, may comprise a thermoplastic elastomer (TPE) such as a polycarbonate-urethane TPE having, e.g., a Shore value of 50 D to 60 D, e.g. 55 D. An example of such a material is the commercially available TPE, BIONATE. Shore hardness is often used to specify flexibility or flexural modulus for elastomers.
[0051] We have had success with core members comprising TPE that are compression molded at a moderate temperature from an extruded plug of the material. For instance, with the polycarbonate-urethane TPE mentioned above, a selected amount of the polymer is introduced into a closed mold upon which a substantial pressure may be applied, while heat is applied. The TPE amount is selected to produce a compression member having a specific height. The pressure is applied for 8-15 hours at a temperature of 70°-90° C., typically about 12 hours at 80° C.
[0052] Other examples of suitable representative elastomeric materials include silicone, polyurethanes, or polyester (e.g., Hytrel®).
[0053] Compliant polyurethane elastomers are discussed generally in, M. Szycher, J. Biomater. Appl. “Biostability of polyurethane elastomers: a critical review”, 3(2):297 402 (1988); A. Coury, et al., “Factors and interactions affecting the performance of polyurethane elastomers in medical devices”, J. Biomater. Appl. 3(2):130 179 (1988); and Pavlova M, et al., “Biocompatible and biodegradable polyurethane polymers”, Biomaterials 14(13):1024 1029 (1993). Examples of suitable polyurethane elastomers include aliphatic polyurethanes, segmented polyurethanes, hydrophilic polyurethanes, polyether-urethane, polycarbonate-urethane, and silicone-polyether-urethane.
[0054] Other suitable elastomers include various polysiloxanes (or silicones), copolymers of silicone and polyurethane, polyolefins, thermoplastic elastomers (TPE's) such as atactic polypropylene, block copolymers of styrene and butadiene (e.g., SBS rubbers), polyisobutylene, and polyisoprene, neoprene, polynitriles, artificial rubbers such as produced from copolymers produced of 1-hexene and 5-methyl-1,4-hexadiene.
[0055] One variant of the construction for the core member comprises a nucleus formed of a hydrogel and an elastomer reinforced fiber annulus.
[0056] For example, the nucleus, the central portion of the core member, may comprise a hydrogel material. Hydrogels are water-swellable or water-swollen polymeric materials typically having structures defined either by a crosslinked or an interpenetrating network of hydrophilic homopolymers or copolymers. In the case of physical crosslinking, the linkages may take the form of entanglements, crystallites, or hydrogen-bonded structures to provide structure and physical integrity to the polymeric network.
[0057] Suitable hydrogels may be formulated from a variety of hydrophilic polymers and copolymers including polyvinyl alcohol, polyethylene glycol, polyvinyl pyrrolidone, polyethylene oxide, polyacrylamide, polyurethane, polyethylene oxide-based polyurethane, and polyhydroxyethyl methacrylate, and copolymers and mixtures of the foregoing.
[0058] Silicone-base hydrogels are also suitable. Silicone hydrogels may be prepared by polymerizing a mixture of monomers including at least one silicone-containing monomer and or oligomer and at least one hydrophilic co-monomer such as N-vinyl pyrrolidone (NVP), N-vinylacetamide, N-vinyl-N-methyl acetamide, N-vinyl-N-ethyl acetamide, N-vinylformamide, N-vinyl-N-ethyl formamide, N-vinylformamide, 2-hydroxyethyl-vinyl carbonate, and 2-hydroxyethyl-vinyl carbamate (beta-alanine).
[0059] The annulus may comprise an elastomer, such as those discussed just above, reinforced with a fiber.
[0060] The fiber may be wrapped around the core member in a variety of different configurations, e.g., wrapping the core member in a random pattern, circumferential wrapping, radial wrapping, progressive polar (or near-polar) wrapping moving around the core, and combinations of these patterns and with other patterns.
[0061] The shape of each of the core members may be cylindrical, although the shape (as well as the materials making up the core member and the core member size) may be varied to obtain desired physical or performance properties. For example, the core member's shape, size, and materials will directly affect the degree of flexion, extension, lateral bending, and axial rotation of the prosthetic disc.
[0062] The annular capsule may be made of an appropriate polymer, such as polyurethane or silicone or the materials discussed above, and may be fabricated by injection molding, two-part component mixing, or dipping the end plate-core-fiber assembly into a polymer solution. The annular capsule may be oblong with straight sidewalls or with one or more bellows formed in the sidewalls. A function of the annular capsule is to act as a barrier that keeps the disc materials (e.g., fiber strands) within the body of the disc, and that keeps potential, natural in-growth outside the disc.
[0063] Where a range of values is provided, it is understood that each intervening value within the range, to the tenth of the unit of the lower limit (unless the context clearly dictates otherwise), between the upper and lower limit of that range and any other stated or intervening value in that stated range is described. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges is also described, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also described.
[0064] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the medical devices art. Although methods and materials similar or equivalent to those described here may also be used in the practice or testing of the described devices and methods, the preferred methods and materials are described in this document. All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.
[0065] It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
[0066] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual variations described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of this disclosure. For example, and without limitation, several of the variations described here include descriptions of anchoring features, protective capsules, fiber windings, and protective covers covering exposed fibers for integrated end plates. It is expressly contemplated that these features may be incorporated (or not) into those variations in which they are not shown or described.
[0067] All patents, patent applications, and other publications mentioned herein are hereby incorporated herein by reference in their entireties. The patents, applications, and publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that contents of those patents, applications, and publications are “prior” as that term is used in the Patent Law.
[0068] The preceding merely illustrates the principles of the invention. It will be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles otherwise described here and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended to aid the reader in understanding the described principles of my devices and methods. Moreover, all statements herein reciting principles, aspects, and variation as well as specific examples thereof, are intended to encompass both structural and functional equivalents. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. | The described devices are spinal implants that may be surgically implanted into the spine to replace damaged or diseased discs using a posterior approach. The discs are prosthetic devices that approach or mimic the physiological motion and reaction of the natural disc. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to security systems for doors, and more particularly to an improved security system for use with an electrically operated door locking mechanism, which security system is operative to provide a preset delay following an effort to exit through the controlled door before actuating the door locking mechanism to unlock the door and allow egress.
Security doors have evolved over the years from simple doors with heavy duty locks to sophisticated egress and access control devices. In bygone times, heavy duty chains and locks were the norm on security doors which were not generally used, or which were used to prevent theft or vandalism. However, fire codes have made such relatively simple door locking systems obsolete, at least in most developed countries. Emergency exit doors are required by law to be provided in all commercial buildings, and such doors must be operative in the event of a fire, earthquake, or other emergency.
These exit doors are typically provided with heavy horizontal push bars, which unlock the door upon actuation and which may provide an alarm of some sort. The early alarms on such doors were either mechanical in nature, such as wind-up alarms contained on the push bar mechanism, or completely separate electrical circuits actuated by a switch opened as the door was opened. Accordingly, egress from such doors was immediate, and, although egress was accompanied by an alarm, typically the person leaving through the door was long gone by the time security personnel arrived.
Many stores suffer great losses through emergency doors, with thieves escaping cleanly through the emergency doors with valuable merchandise. In addition, industrial companies also suffer pilferage of valuable equipment and merchandise through such emergency exit doors. While one solution is to have a greater number of security personnel patrolling the emergency exit doors, to do so is also an expensive solution.
As might be expected, the art reflects a number of devices which attempt to solve this problem. A series of such devices is found in U.S. Pat. No. 4,257,631, in U.S. Pat. No. 4,328,985, in U.S. Pat. No. 4,354,699, in U.S. Pat. No. 4,652,028, and in U.S. Pat. No. 4,720,128, all to Logan, Jr. or Logan, Jr. et al. The Logan, Jr. patents begin with the Logan, Jr. '631 patent, which describes a system activated by a push bar which, upon depression, moves a switch carried by the door to sound an alarm and start a timer delay. After the delay, the door is unlocked.
The Logan '985 patent teaches a hydraulic system for accomplishing the delay prior to unlocking the door, and the Logan '699 patent describes a retrofit locking device of the same type, but usable with any door latching system. The Logan et al. '028 patent and the Logan, Jr. et al. '128 patent both teach an electromagnet mounted on a door jamb, an armature on the door held by the electromagnet to retain the door in the closed position, and a switch used to indicate when the door is being opened or tampered with. The Logan, Jr. et al. '128 patent adds a set of contacts to confirm that the armature properly contacts the electromagnet.
U.S. Pat. No. 4,439,808, to Gillham, describes another system which also uses an armature on a door and an electromagnet on the door jamb. The armature has shoulders to retain the door in the closed position even if someone exerts enough pressure on the door to otherwise slide the armature off of the electromagnet. U.S. Pat. No. 4,439,808, to Gillham, is hereby incorporated herein by reference.
Two other patents are relevant, particularly since they are both assigned to the assignee of the present invention. Specifically, these patents are U.S. Pat. No. 4,609,910 and U.S. Pat. No. 5,000,497, both to Geringer et al. The Geringer et al. '910 patent teaches a system with an armature on a door, an electromagnet on a door jamb, and a switch used to tell when an attempt is made to open the door. The Geringer et al. '497 patent teaches a novel door-mounted armature and door jamb-mounted electromagnet. U.S. Pat. No. 4,609,910 and U.S. Pat. No. 5,000,497 are both hereby incorporated herein by reference.
While these references represent a substantial improvement in the state of the art to date, there are still several disadvantages and problems inherent in the art. For example, in an emergency, someone trying to get out will find that the door does not immediately open, and may panic and leave the door prior to it opening after a delay. In addition, the present devices may not fully comply with safety regulations, and thus may no longer be commercially competitive.
It is accordingly the primary objective of the present invention that it provide a security system which, when actuated by someone trying to open the door, will provide information about the delay imposed before the door will be opened. Such information must serve to inform the individual that the door will be opened following a short delay. It is also desirable that the exact period of the delay be made known to the individual.
It is also an objective of the present invention that the security system taught therein operate to unlock the door after a preset period of time, with that preset period being adjustable in duration. In addition, it is an objective that the system operate to ensure that the lock will operate in a fail-safe mode in the event of a fire or another bona fide emergency, operating all doors in the affected area. Also, it is an objective that the system allow immediate egress or access to a security officer. It is an additional objective that the system provide information on its operation to a single remote location.
The security system apparatus of the present invention must also be of a construction which is both durable and long lasting, and it should also require little or no maintenance to be provided by the user. In order to enhance the market appeal of the security system of the present invention, it should also be of inexpensive construction to thereby afford it the broadest possible market. Finally, it is also an objective that all of the aforesaid advantages and objectives of the present invention be achieved without incurring any substantial relative disadvantage.
SUMMARY OF THE INVENTION
The disadvantages and limitations of the background art discussed above are overcome by the present invention. With this invention, any type of electrically operated door locking system may be controlled to delay egress or access through the door. The system of the present invention will set off an alarm, and begin a countdown to the time when the door will be unlocked. The time remaining till the door is opened is prominently displayed on the control unit, which is mounted on the door in a housing which resembles a push bar and which functions as a trigger switch used to actuate the system.
The door-mounted control unit is supplied with power from a remote location. Inputs from one or a series of fire or smoke alarms are also supplied to the door-mounted control unit; whenever the fire or smoke alarms indicate that there in an emergency situation, the door-mounted control unit will immediately enable the electrically operated lock to open, thereby allowing egress or access through the door. Like most of the locks described above in the cited art, the security system of the present invention causes the electrically operated lock to lock whenever a voltage is supplied from the door-mounted system to the locking mechanism. Thus, in an emergency, if the power is cut, the locking mechanism will automatically open.
The security system is microprocessor actuated, with the microprocessor being located within the housing of the door-mounted control unit. In the preferred embodiment, when the door-mounted housing is pushed, a switch which comprises the system trigger is actuated. Thus, when an individual attempts to open the door by pushing on the push bar (the housing), the system trigger will operate to initiate the operation of the security system to allow egress or access through the door.
The microprocessor in the door-mounted control unit begins a countdown when the system trigger is operated to demand egress or access. Unlike the systems of the prior art, the security system of the present invention includes a mechanism to inform the individual who operated the trigger switch to demand egress or access just how long it will be until the door is unlocked. This time period is programmable in the individual door-mounted control unit to allow different doors to have different delay times until egress or access is allowed.
In the preferred embodiment, the mechanism to inform the individual demanding egress or access how long until the door will be unlocked includes a visual display which counts down the time until the door will be opened. A two segment numeric display is mounted on the housing of the door-mounted control unit. This two digit display is sufficiently large to allow it to be easily viewed. For example, a one-inch high, two digit, seven segment LED display may be utilized.
The preferred embodiment also includes a secondary mechanism to inform the individual demanding egress or access how long until the door will be unlocked in addition to the visual display. An audible warning system is included in the door-mounted control unit to provide this additional information to the individual. This audible warning system is in the preferred embodiment an electronic speech synthesizer, which will provide instructions as to the delay until the door is unlocked. In the preferred embodiment, several languages may be programmed into the device, with a choice of one or more languages being selectable.
Other features included in the door-mounted control unit include a key-operated switch to allow immediate egress or access through the door to authorized individuals. Use of the key to gain immediate egress or access will rearm the system after a short delay, which may be programmed as desired. The key-operated switch may also be used to deactivate the system. The LED display may be used to indicate whether the system is armed or disarmed.
A door switch input may also be provided to the door-mounted control system. This input will prevent the lock from being armed until the door is closed. The entire system may also be controlled from a master console at a remote location. Thus, the door-mounted system may be armed, disarmed, or locked out from the remote location by the master console. The status of the door-mounted control unit is in the preferred embodiment indicated by a series of LED's located on the master console at the remote location. The system may also be set up so that events occurring at one door may control a series of other doors.
It may therefore be seen that the present invention teaches a security system which, when actuated by an individual trying to open a secured door, will provide visual and/or audible information about the delay before the door will be unlocked to the individual trying to open the door. Such information will serve to precisely and definitely inform the individual that the door will be opened following a brief delay. In fact, the exact delay will be presented by the preferred embodiment device in both visual form and in audible form to the individual seeking egress or access through the door.
The security system of the present invention enables the locking mechanism to operate to open the door after a preset period of time, with that preset period being adjustable in duration. In addition, the security system of the present invention operates to ensure that the locking mechanism will operate in a fail-safe mode, immediately unlocking the door in the event of a fire or another bona fide emergency, and operating all doors in the affected area. Also, the security system of the present invention allows immediate egress or access to a security officer. It also provides information on its operational status to a single remote location.
The security system apparatus of the present invention is of a construction which is both durable and long lasting, and which will require little or no maintenance to be provided by the user. In order to enhance the market appeal of the security system of the present invention, it is of relatively inexpensive construction to thereby afford it the broadest possible market. Finally, all of the aforesaid advantages and objectives of the present invention are achieved without incurring any substantial relative disadvantage.
DESCRIPTION OF THE DRAWINGS
These and other advantages of the present invention are best understood with reference to the drawings, in which:
FIG. 1 is a functional schematic block diagram of the preferred embodiment delayed egress locking system of the present invention, showing the various controls used to operate the system;
FIG. 2 is a schematic front perspective view of an electromagnetic door lock system which can be used with the present invention, showing an electromagnetic door lock device installed in a doorway, with an armature shown therebelow which armature is for mounting on the top of a door;
FIG. 3 is a perspective view of a door and a door frame, showing a door-mounted version of the control system illustrated in FIG. 1 for the delayed egress locking system of the present invention, and also showing the electromagnetic door lock system shown in FIG. 2 installed on a door and a door frame;
FIG. 4 is a perspective view of a door and a door frame, showing a door-mounted version of the control system illustrated in FIG. 1 for the delayed egress locking system of the present invention embodied in a push bar deadbolt lock system; and
FIG. 5 is a functional schematic block diagram of the delayed egress locking system of the present invention used on three doors, and also shows the remote master console and five fire alarm switches which are activated in the event of a fire at the alarm switch locations.
FIG. 6 is s typical status display of the delayed egress locking system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is illustrated in FIG. 1, which shows a number of components which are included in a door-mounted control unit 20, a number of additional components which are included in a remote master console 22, and a number of additional components mounted on a door (not shown), as well as other inputs supplied to the door-mounted control unit 20 from a remote location. It is important to understand that while the system illustrated schematically in FIG. 1 is but an example of the preferred implementation of the present invention using a specific lock hardware implementation, the door-mounted control unit 20 and the remote master console 22 may be used with any of a wide variety of different electrically operated lock hardware implementations.
Note that the heart of the door-mounted control unit 20 is microprocessor-based control circuitry 24, which is used as the controller for the system. The microprocessor-based control circuitry 24 is supplied with power by a power supply 26, which receives an input voltage from a voltage source (not shown). The input voltage supplied to the power supply 26 may be either 12 Volts D.C. or 24 Volts D.C.; the power supply 26 is a regulated and filtered power supply, which protects the circuitry of the door-mounted control unit 20 from damage due to power fluctuations.
The power supply 26 also provides power to a fire alarm interface 28, which normally receives a high input (a digital "1") from one or more fire alarm stations (not shown). Since the system of the present invention is a fail-safe system, the presence of a high signal from the fire alarm station(s) is used to indicate that there are no emergency conditions. The absence of a high signal (a digital "0") from the fire alarm station(s), whether caused by an actual fire condition or by a fault in the system, will be interpreted by the system as an emergency condition. Note that the fire alarm interface 28 could also use signal(s) from one or more smoke detectors instead of fire alarm station(s), or a combination of both.
The power supply 26 also provides power to a lock controller 30. The lock controller 30 receives an input from the microprocessor-based control circuitry 24, and a second input from the fire alarm interface 28. Both of these inputs are normally high (each would be a digital "1"), so the absence of either high input (a digital "0") represents a situation in which it is necessary to unlock the door (not shown). The absence of a high signal (a digital "0") from the fire alarm interface 28 indicates that an emergency condition is occurring, as indicated by the inputs to the fire alarm interface 28 from the fire alarm station(s). The absence of a high signal (a digital "0") from the microprocessor-based control circuitry 24 indicates that the microprocessor-based control circuitry 24 has executed an instruction to unlock the door.
The lock controller 30 may be of conventional design, and will vary depending on what type of electrically operated locking mechanism is used. In FIG. 1, the locking mechanism is of the type using an electromagnetic door locking mechanism. The lock controller 30 drives a lock coil 32, typically mounted on a door jamb (not shown), with the lock coil 32 attracting and holding an armature 34 mounted on the door (also not shown). The lock controller 30 may use hardware as simple as a relay to cleanly disconnect the lock coil 32 from the power supply 26, but in the preferred embodiment the lock controller 30 also includes additional degaussing circuitry to ensure a quick release of the armature 34 from the lock coil 32. Such circuitry is known to those skilled in the art, and is shown, for example, in the Gillham patent incorporated by reference above.
A door position switch 36 is used to indicate whether or not the door (not shown) is closed. The door position switch 36 is necessary, since it is undesirable to energize the lock coil 32 until the door is closed and the armature 34 is in position to properly contact the lock coil 32. The door position switch 36 may be a stand-alone device such as a mechanical switch, mounted either on the door (not shown) or on the door jamb (also not shown). Alternately, the door position switch 36 may be a magnetic switch, mounted for example on the door jamb, in which case a door switch actuator 38 is required to be mounted on the door. The door switch actuator 38 would be a small magnet if it was used with a door position switch 36 which was a magnetic switch.
The door-mounted control unit 20 includes a system trigger 40, which is typically a switch built into the door-mounted control unit 20. When an individual presses on the door-mounted control unit 20, the system trigger 40 will signal the microprocessor-based control circuitry 24 that egress or access has been demanded. Thus, the system trigger 40 is used to indicate that someone has tried to open the door (not shown).
When the system trigger 40 is operated, the microprocessor-based control circuitry 24 will sound an alarm (as will be explained in detail below), and will begin timing a preset delay time. Upon the conclusion of the preset delay time, the microprocessor-based control circuitry 24 will cause the lock controller 30 to deenergize the lock coil 32, unlocking the door (not shown) and allowing egress or access.
In the preferred embodiment, the door-mounted control unit 20 also includes a remote arm/disarm switch 42 connected to the microprocessor-based control circuitry 24. The remote arm/disarm switch 42, which is typically a key-operated single-pole, double throw switch, is mounted on the door-mounted control unit 20 in a position accessible from the outside thereof. By turning the remote arm/disarm switch 42 in one direction, the system is armed (or, if it was already armed, is reset).
Following arming or resetting, the microprocessor-based control circuitry 24 will cause the lock controller 30 to deenergize the lock coil 32 for a preset interval referred to as the activation delay time to allow authorized personnel egress or access through the door (not shown). By turning the remote arm/disarm switch 42 in the opposite direction, the system is disarmed.
Three elements operated by the microprocessor-based control circuitry 24 and also included in the door-mounted control unit 20 are quite novel. Output control circuitry 44 is driven by the microprocessor-based control circuitry 24 whenever the system trigger 40 is actuated to demand egress or access. In the most advanced devices prior to the present invention, the components used instead of the lock controller 30 would merely sound an alarm. The novel function of the output control circuitry 44 is that it provides information to an individual who has demanded egress or access, including how long it will be until the door is unlocked.
Thus, the output control circuitry 44 is used to drive a status display 46 whenever the system trigger 40 has been actuated to demand egress or access. The status display 46 of the preferred embodiment is a two digit, seven segment LED display mounted in the door-mounted control unit 20 where it is visible from the exterior thereof. FIG. 6 illustrates a typical status display which might include a LED display 45 which, in association with the lettering 47, provides information as to the time remaining until the door is unlocked. Upon actuation of the system trigger 40, the microprocessor-based control circuitry 24 will drive the output control circuitry 44 to cause the status display 46 to count down the interval prior to the door (not shown) being opened. Thus, the number of seconds remaining until the door is opened will be visible on the status display 46. When demand for egress or access has not been made, the status display 46 is used in the preferred embodiment to indicate whether or not the system is armed, which may be done by lighting all or some of the segments.
In addition, the output control circuitry 44 is used to drive a voice/alarm output 48 whenever the system trigger 40 has been actuated to demand egress or access. Upon actuation of the system trigger 40, the microprocessor-based control circuitry 24 will drive the output control circuitry 44 to cause the voice/alarm output 48 to produce either a synthesized speech output, an alarm, or, in the preferred embodiment, both outputs in an alternating fashion. In the preferred embodiment, the voice/alarm output 48 will produce a synthesized speech output informing the individual who has demanded egress or access that the door will open in a certain amount of time, as well as certain other information.
For example, the voice/alarm output 48 may announce, "This door will be unlocked in 60 seconds. Security has been informed that you are attempting to exit through this door." Following the warning announcement, the same the voice/alarm output 48 will then produce an alarm signal. The warning announcement may be alternated with the alarm signal until the egress delay time has ended, and the door (not shown) is opened.
Several other optional switches may be used to vary the operation of the system, all of which are DIP switches in the preferred embodiment. A language switch 50 may be used to choose which language the announcement will be made in. Alternately, the language switch 50 may be used to select two languages, with the warning announcement being given in first one language and then the other. An egress delay time switch 52 may be used to select the delay between actuation of the system trigger 40 and the microprocessor-based control circuitry 24 ultimately causing the lock controller 30 to unlock the door (not shown). Finally, an activation delay time switch 54 may be used to select the activation delay time following system rearming or resetting. Upon rearming or resetting, the microprocessor-based control circuitry 24 will cause the lock controller 30 to deenergize the lock coil 32 for the activation delay time to allow authorized personnel egress or access through the door.
The remote master console 22 includes both control switches used to operate the door-mounted control unit 20, and status indicator LED's. A system reset switch 56 is used to reset the door-mounted control unit 20 from the remote master console 22 following an alarm. An authorized egress switch 58 is used to allow authorized personnel egress or access through the door (not shown) for a period of time equal to the activation delay time. Finally, a system lockout switch 60 is used to cause the microprocessor-based control circuitry 24 to keep the door locked. This switch disables the system trigger 40 from allowing the door to be opened, even after the egress delay time. Following activation of the system lockout switch 60, only a fire alarm station signal can cause to door to be opened.
Eight status indicator LED's are also included on the remote master console 22. A power status LED 62 is used to confirm that the microprocessor-based control circuitry 24 is powered; if so, the power status LED 62 is lit. A lock secure LED 64 is used to indicate whether or not the lock controller 30 is energizing the lock coil 32; the lock secure LED 64 is lit when the lock coil 32 is energized. A door position LED 66 is used to indicated whether the door (not shown) is closed or not; if the door position switch 36 is activated, indicating that the door is closed, the door position LED 66 is lit.
A bond sensor LED 68 is used to confirm that the electromagnetic door locking mechanism components are engaging properly. If the armature 34 is engaging the portion of the electromagnetic door locking mechanism containing the lock coil 32, a pair of electromagnetic door locking mechanism bond contacts 70 located on the armature 34 and the portion of the electromagnetic door locking mechanism containing the lock coil 32 will make contact, and the bond sensor LED 68 will be lit. Such contacts are illustrated in U.S. Pat. No. 4,720,128, to Logan, Jr. et al., which patent is hereby incorporated herein by reference.
An authorized egress LED 72 is lit whenever the authorized egress switch 58 or the remote arm/disarm switch 42 has been used to allow authorized personnel access, and the activation delay time is in process. An alarm status LED 74 is lit whenever the door-mounted control unit 20 is armed. A system lockout LED 76 is lit whenever the system lockout switch 60 has been activated. Finally, an alarm output LED 78 is lit whenever the system is armed and the system trigger 40 has been activated to initiate an alarm output from the output control circuitry 44, until the system is reset or disarmed.
Referring next to FIG. 2, an electromagnetic door locking mechanism similar to that in the above incorporated by reference Geringer '497 patent is illustrated. The portions of the electromagnetic door locking mechanism containing the lock coil 32 and the armature 34 are illustrated. The lock coil 32 is disposed in a rectangular metallic housing 80, and is connected to the microprocessor-based control circuitry 24 (not shown in FIG. 2) by an electrical conduit 82 passing through the housing 80.
The housing 80 is held in place in the underside of the top of a door frame 84 (where it forms part thereof) by a pair of L-shaped brackets 86 and 88 secured to opposite sides of the housing 80 and to the door frame 84 by screws 90. A flat vertical plate 92 is secured between the L-shaped bracket 86 and the housing 80 by the screws 90. The flat vertical plate 92 extends below the bottom of the housing 80 and the L-shaped bracket 86, and there is a slot 94 centrally located in the bottom edge of the flat vertical plate 92. Similarly, a flat vertical plate 96 is secured between the L-shaped bracket 88 and the housing 80 by the screws 90. The flat vertical plate 96 also extends below the bottom of the housing 80 and the L-shaped bracket 88, and there is a slot 98 centrally located in the bottom edge of the flat vertical plate 96.
The armature 34 is rectangular, and has centrally located protrusions 100 and 102 extending from the ends thereof at the top thereof. The armature 34 is formed of a magnetically attractable material, and is connected to the top surface of a door (not shown) by a pair of screws 104. The screws 104 each have a head vertically seated in a loose pocket in the armature 34. Accordingly, the armature 34 will be able to move vertically upward from a position on the top of the door when attracted to the lock coil 32. When the armature 34 is in this position, the protrusion 100 of the armature 34 will be received in the slot 94 in the flat vertical plate 92, and the protrusion 102 of the armature 34 will be received in the slot 98 in the flat vertical plate 96. In this position, the door will be retained in a locked position.
Referring next to FIG. 3, a door 106 is shown mounted in the door frame 84. The housing 80 containing the lock coil 32 is mounted in the door frame 84, and the door switch actuator 38 is mounted on the door frame 84. The armature 34 is mounted on the top of the door 106, and the door position switch 36 is mounted on the door 106. The door-mounted control unit 20 is shown mounted on the door 106, with the remote arm/disarm switch 42 and the status display 46 mounted on the door-mounted control unit 20.
Referring next to FIG. 4, another door frame 108 and door 110 are shown with a variation 120 of the door-mounted control unit 20. The door-mounted control unit 120 is a push bar deadbolt lock system, with a deadbolt 122 extending from the side of the door-mounted control unit 120. A latch member 124 is shown mounted on the side of the frame 108. The door-mounted control unit 120 contains the remote arm/disarm switch 42 and the status display 46, and operates similarly to the door-mounted control unit 20 described above.
Referring finally to FIG. 5, a central control unit 130 is shown connected to three door-mounted control units 20, each of which is mounted on a door 106. Four fire alarm switches 132 are connected together to provide the fire alarm stations input to the door-mounted control units 20. The door-mounted control units 20 can be set up to alarm individually, or as a group, if desired. Other aspects of multiple units are readily apparent to those skilled in the art.
It may therefore be appreciated from the above detailed description of the preferred embodiment of the present invention that it teaches a security system which, when actuated by an individual trying to open a secured door, will provide visual and/or audible information about the delay before the door will be unlocked to the individual trying to open the door. Such information will serve to precisely and definitely inform the individual that the door will be opened following a brief delay. In fact, the exact delay will be presented by the preferred embodiment device in both visual form and in audible form to the individual seeking egress or access through the door.
The security system of the present invention enables the locking mechanism to operate to open the door after a preset period of time, with that preset period being adjustable in duration. In addition, the security system of the present invention operates to ensure that the locking mechanism will operate in a fail-safe mode, immediately unlocking the door in the event of a fire or another bona fide emergency, and operating all doors in the affected area. Also, the security system of the present invention allows immediate egress or access to a security officer. It also provides information on its operational status to a single remote location.
The security system apparatus of the present invention is of a construction which is both durable and long lasting, and which will require little or no maintenance to be provided by the user. In order to enhance the market appeal of the security system of the present invention, it is of relatively inexpensive construction to thereby afford it the broadest possible market. Finally, all of the aforesaid advantages and objectives of the present invention are achieved without incurring any substantial relative disadvantage.
Although an exemplary embodiment of the present invention has been shown and described with reference to particular embodiments and applications thereof, it will be apparent to those having ordinary skill in the art that a number of changes, modifications, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. All such changes, modifications, and alterations should therefore be seen as being within the scope of the present invention. | A security system for use on doors which have an electrically operated door locking mechanism is disclosed, which security system is operative to provide a preset egress time delay following an effort to exit through the controlled door before actuating the door locking mechanism to unlock the door and allow egress. During the egress time delay, the system provides a visual input of the time remaining until the door locking mechanism will unlock the door to allow egress or access therethrough. In the preferred embodiment, a speech synthesizer and digital display is also utilized to inform the individual demanding egress or access of the delay, and to provide other information as desired. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/790,117, filed Mar. 15, 2013, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the field of orthopedic implants, more specifically, a polymer PEEK (polyether ether ketone), carbon fiber PEEK, PEAK or hybrid (polymer and metal) based spinal rods which are used for deformity corrections with growth preservation in early-onset scoliotic patients and for the 8fusion of two or more vertebrae in degenerative spinal disease or deformity. This invention also relates to a mechanism for the minimally invasive distraction of such a rod.
[0003] Surgical techniques for the treatment of early-onset scoliosis are aimed at deformity correction with preservation of growth. The most common approach includes the use of distraction-based growth rods. A typical growth rod fixation has two foundations, namely, proximal and distal, where limited fusion is performed. Pedicle screws, hooks, wires, and other retaining structures may be used at each foundation to anchor the rods with the bony structure. Each foundation has a rod spanning toward the other end, which are connected to each other near the thoracolumbar junction. The rods are connected using a domino, which helps in distraction for serial surgeries until a final fusion is performed.
[0004] In a single growth rod technique, the rods span only one side (the concave side) of the spinal deformity curve. In a dual growth rod technique, the rods span both (both the concave and convex sides) of the spinal deformity curve. For the dual growth rod technique, the region of the rod near the foundation can have a crosslink connecting the rods of both sides.
[0005] In a typical growing rod implant surgery, the rods are attached along one or both sides of the spine above and below the spinal deformity curve using the pedicle screws or other retaining structures. The rod is then extended to correct the spinal deformity curve until the surgeon feels enough compression in the rod to stop the adjustment. The spinal deformity curve can usually be corrected by fifty percent at the time of the initial surgery. During the first operation, the patient usually undergoes invasive surgery. Regular construct lengthening is typically scheduled approximately every six months to a year thereafter. The lengthening procedure usually includes exposing the domino connectors through a small midline incision, loosening either the cranial or the caudal domino-connector setscrews, and distracting across the two rods within the connector. This lengthening process is frequently continued for a period of five to ten years after implantation.
[0006] Although known spinal and growth rod structures and installation procedures have functioned satisfactorily, several potential limitations have been determined. First, current spinal rods are made out of metallic materials, such as stainless steel, cobalt-chromium, or titanium. As a result, these metal spinal and growth rods are very rigid. The high level of rigidity of these metal spinal and rods may restrict the micro-motion of intervertebral disc in the spine, which can cause spontaneous fusion at the intervertebral junction. Spontaneous fusion is an undesirable clinical complication because the aim of the growth rod surgery is to delay or limit spinal fusion so as to allow the spine to grow. Second, current spinal rods are known to experience a relatively high rate of breakage. The material used to form the rod is an important consideration because it is a construct bearing load for a longer duration without spinal fusion, and its durability is vital. Third, the current surgical technique exposes the patient to a chance of infection because of the midline exposure of the tissue during subsequent distraction surgeries. Even though the use of minimally invasive techniques may reduce the chance of infection, none of the current mechanical distraction systems are simple enough for distraction, and some have many sub-units. Therefore, it would be desirable to avoid all of these potential problems.
SUMMARY OF THE INVENTION
[0007] This invention relates to a flexible growth rod system that militates against spontaneous fusion at the intervertebral junction, and which also militates against adjacent level degeneration polymer such as PEEK, PEAK, and other medical grade polymer or hybrid (both metal and polymer) rod, which would provide better deformation during physiologic loads and will reduce the incidence of rod breakage due to higher demand for flexibility is innovated. Further the rod has novel minimal invasive mechanisms attachments which would avoid big open reoperations to distract the rod during regular intervals, thereby preventing pain, infection, and morbidity of patients.
[0008] This invention includes a polymer, where a preferred embodiment is one of PEEK, PEAK, carbon fiber PEEK, and other medical grade polymers or hybrid (polymer and metal) spinal rods.
[0009] Polymer (such as PEEK, PEAK, or other medical grade polymers) or hybrid (such as PEEK, PEAK, or carbon fiber with a nitinol core) spinal rods could be made for use in any growth rod technique and with any generic instruments, such as pedicle screws, hooks, dominoes, etc). The hybrid rod can be of two types, namely: (1) a composite rod with hollow outer cylinder made of nitinol and inner rod of the polymer (such as PEEK, PEAK, carbon fiber, or any other medical grade polymer), wherein the outer metal may have serrations to increase the flexibility, or (2) a composite rod with hollow outer cylinder (having a circular, oval, or other desired cross sectional shape) made of polymer (such as PEEK, PEAK, carbon fiber, or any other medical grade polymer) and inner rod of the nitinol.
[0010] Minimally invasive distractible growth rods could be assembled using a compact domino that connects and houses the two ends of the rods at the thoracolumbar junction. The mechanism incorporated within the compact domino may include two spur gears, each for the distraction mechanism of proximal and distal rods. The rod region within the domino may have a special rack-like surface that uses the rotary motion of the spur gear to translate the rod along its central axis. The rod could be made out of metal or polymer or composite materials. The spur gear may be connected to the domino such that it allows the rotation of the gear. Two screw heads can be used as closings to secure and compress the spur gears inside the domino. The compression of the spur gears with the screw head closings retracts the rotation of the gears. Since the spur gears and the associated rods have dependent motion, the rods also stay fixed due to compression on the spur gears. The domino, screw head closings, and the spur gears may be made out of any desired material or materials including, for example, metals such as titanium or stainless steel.
[0011] An in-series distractible growth rod can alternatively be made using a screw mechanism in which the two rods (proximal and distal) extend within a coupler. The coupler can be rotated using a bevel gear on the top and housed inside a domino. The coupler and bevel gear will be in a compact domino. The rotation of the coupler will push the two rods by virtue of a screw mechanism, thereby causing distraction. This mechanism could operated by a micro-electric motor with a microcircuit that is activated by a remote control.
[0012] Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an elevational view of a first embodiment of a growth rod distraction system in accordance with this invention.
[0014] FIG. 2 is an enlarged elevational view of the first embodiment of the growth rod distraction system illustrated in FIG. 1 with the screw heads removed.
[0015] FIG. 3 is a perspective view of the first embodiment of the growth rod distraction system illustrated in FIG. 2 with the spur gears removed.
[0016] FIG. 4 is a sectional elevational view of the first embodiment of the growth rod distraction system illustrated in FIGS. 1 , 2 , and 3 .
[0017] FIG. 5 is an enlarged perspective view of one of the screw heads for the first embodiment of the growth rod distraction system illustrated in FIGS. 1 through 4 .
[0018] FIG. 6 is side elevational view of the screw head illustrated in FIG. 5 .
[0019] FIG. 7 is an enlarged perspective view of one of the spur gears for the first embodiment of the growth rod distraction system illustrated in FIGS. 1 through 4 .
[0020] FIG. 8 is an enlarged perspective view of an alternative structure for one of the screw heads for the first embodiment of the growth rod distraction system illustrated in FIGS. 1 through 4 .
[0021] FIG. 9 is a sectional elevational view of a second embodiment of a growth rod distraction system in accordance with this invention.
[0022] FIG. 10 is a sectional elevational view of a third embodiment of a growth rod distraction system in accordance with this invention.
[0023] FIG. 11 is a perspective view of a first embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0024] FIG. 12 is a sectional elevational view of the first embodiment of the spinal rod illustrated in FIG. 11 .
[0025] FIG. 13 is a perspective view of a second embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0026] FIG. 14 is a sectional elevational view of the second embodiment of the spinal rod illustrated in FIG. 13 .
[0027] FIG. 15 is a perspective view of a third embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0028] FIG. 16 is a sectional elevational view of the third embodiment of the spinal rod illustrated in FIG. 15 .
[0029] FIG. 17 is a perspective view of a fourth embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0030] FIG. 18 is a sectional elevational view of the fourth embodiment of the spinal rod illustrated in FIG. 17 .
[0031] FIG. 19 is a sectional elevational view of a fifth embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0032] FIG. 20 is a sectional elevational view of a sixth embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0033] FIG. 21 is a sectional elevational view of a seventh embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0034] FIG. 22 is a sectional elevational view of an eighth embodiment of a spinal rod that can be used in any of the embodiments of the growth rod distraction system or for any other spinal surgery for fusion or non-fusion technique in accordance with this invention.
[0035] FIG. 23 is a perspective view of a portion of a fourth embodiment of a growth rod distraction system in accordance with this invention.
[0036] FIG. 24 is a side elevational view of the portion of the fourth embodiment of the growth rod distraction system illustrated in FIG. 23 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] Referring now to the drawings, there is illustrated in FIGS. 1 through 4 a first embodiment of a compact, minimally invasive, and distractible growth rod distraction system, indicated generally at 10 , in accordance with this invention. The growth rod distraction system 10 includes a central domino or housing 11 . In the illustrated embodiment, the domino 11 includes first and second side portions having respective first and second bores 12 and 13 provided therein. Each of the illustrated first and second bores 12 and 13 is generally hollow and cylindrical in shape, having an opened end and a closed end. The illustrated bores 12 and 13 extend generally parallel to one another. However, it will be appreciated that the first and second bores 12 and 13 may have any desired shape or combination of shapes and may be oriented in any desired relationship. In the illustrated embodiment, the domino 11 also includes a central portion that extends between the first and second side portions and that has first and second openings 14 and 15 provided therein. The illustrated first and second openings 14 and 15 are each generally hollow and cylindrical in shape and, as shown in FIGS. 2 through 4 , extend respectively through the domino 11 into the first and second bores 12 and 13 . Respective posts 14 a and 15 a are provided within the first and second openings 14 and 15 for a purpose that will be explained below. The outer ends of the first and second openings 14 and 15 are threaded, as shown at 14 b and 15 b in FIG. 4 , again for a purpose that will be explained below.
[0038] First and second growth rods 16 are respectively disposed within the first and second bores 12 and 13 of the domino 11 , as shown in FIGS. 1 through 4 . The structures of the growth rods 16 are illustrated in detail in FIG. 5 . As shown therein, the illustrated growth rods 16 are each generally cylindrical in shape, preferably corresponding with the shapes of the first and second bores 12 and 13 within which they are respective supported. For example, the growth rods can each define outer diameters of 4.5 mm, 5.5 mm, or 6.35 mm depending upon the particular application. However, it will be appreciated that the growth rods 16 may have any desired shape or combination of shapes. Inner ends of the growth rods 16 are supported within the first and second bores 12 and 13 of the domino 11 for axial movement relative thereto, as will be explained in detail below. The outer surfaces of the inner ends of the growth rods 16 are provided with respective pluralities of recesses 16 a, the purpose of which will also be explained below. The material or group of materials used to form the growth rods 16 will discussed further below.
[0039] First and second spur gears 17 are respectively disposed within the first and second openings 14 and 15 of the domino 11 , as shown in FIGS. 2 and 3 . The structure of one of the spur gears 17 is illustrated in detail in FIG. 5 . As shown therein, the illustrated spur gear 17 has a central opening 17 a and a plurality of outer teeth 17 b. The central opening 17 a is adapted to receive one of the posts 14 a and 15 a therein so as to allow each of the spur gears 17 to be disposed within the first and second openings 14 and 15 . When so disposed, the spur gears 17 are supported for rotation relative to the domino 11 . Also, some of the outer teeth 17 b of the spur gears 17 extend into engagement with some of the recesses 16 a provided in the growth rods 16 . As a result, rotation of the spur gears 17 causes axial movement of the associated growth rods 16 relative to the domino 11 . The purpose for this cooperation between the spur gears 17 and the growth rods 16 will be explained below.
[0040] The spur gears 17 can be retained within the respective openings 14 and 15 of the domino 11 and locked in position relative thereto by respective heads 18 , as shown in FIG. 1 . The structure of one of the heads 18 is illustrated in detail in FIGS. 6 and 7 . As shown therein, the illustrated head 18 is shaped generally in the form of a flat disc, having an outer circumferential surface 18 a that is threaded. The threaded outer circumferential surfaces 18 a of the heads 18 are sized and shaped to cooperate with the threaded outer ends 14 b and 15 b of the first and second openings 14 and 15 , as shown in FIG. 1 , so as to retain the spur gears 17 within the first and second openings 14 and 15 of the domino 11 . Further rotation of the heads 18 cause them to frictionally engage the associated spur gears 17 , thereby preventing the spur gears 17 from to rotating within their respective openings 14 and 15 . This prevents axial movement of the growth rods 16 relative to the domino 11 .
[0041] In use, the heads 18 of the growth rod distraction system 10 are initially loosened or removed so as to not engage the respective spur gears 17 . As a result, the spur gears 17 are free to rotate within their respective openings, allowing free axial movement of the growth rods 16 relative to the domino 11 . The outer ends (not shown) of the growth rods 16 are then anchored to respective bony structures by means of pedicle screws, hooks, wires, or other conventional retaining structures (not shown) as described above. These anchors form the proximal and distal foundations for the growth rod distraction system 10 by attaching the outer ends of the growth rods 16 to the bony structure of spine. After the desired distraction of the bony structure of spine has been achieved by the surgeon, the heads 18 are installed and/or tightened on the domino 11 . As discussed above, the heads 18 are caused to frictionally engage the associated spur gears 17 , thereby preventing the spur gears 17 from to rotating within their respective openings 14 and 15 , and further preventing axial movement of the growth rods 16 relative to the domino 11 .
[0042] FIG. 8 illustrates an alternative structure for one of the screw heads 19 for the first embodiment of the growth rod distraction system illustrated in FIGS. 1 and 6 . The alternative head 19 is shaped generally in the form of a flat disc, having an outer circumferential surface 19 a that is threaded. The threaded outer circumferential surfaces 19 a of the heads 19 are sized and shaped to cooperate with the threaded outer ends 14 b and 15 b of the first and second openings 14 and 15 , as shown in FIG. 1 , so as to retain the spur gears 17 within the first and second openings 14 and 15 of the domino 11 . Additionally, however, the alternative head 19 has an aperture 19 b provided therein that is sized and shaped to receive one of the posts 15 a therein when the head 19 is secured to the domino 11 .
[0043] FIG. 9 illustrates a portion of a second embodiment of a growth rod distraction system, indicated generally at 20 , in accordance with this invention. The growth rod distraction system 20 includes a central domino or housing 21 having a single bore 22 provided therein. In the illustrated embodiment, the domino 21 also includes a single opening 23 having a post 24 provided therein. The outer end of the openings 23 threaded in the same manner as the openings 14 and 15 described above.
[0044] First and second growth rods 25 have respective inner ends that are supported within the bore 22 of the domino 11 for axial movement relative thereto, as will be explained in detail below. The outer surfaces of the inner ends of the growth rods 25 are provided with respective pluralities of recesses 25 a for the same purpose as described above. The material or group of materials used to form the growth rods 25 will discussed further below.
[0045] A single spur gear 26 is disposed within the opening 23 of the domino 21 and includes a central opening 26 a and a plurality of outer teeth 26 b. The central opening 26 a is adapted to receive the post 24 therein so as to allow the spur gear 26 to be disposed within the opening 23 for rotation relative to the domino 21 . Also, some of the outer teeth 26 b of the spur gear 26 extend into engagement with some of the recesses 25 a provided in both of the growth rods 25 . As a result, rotation of the spur gear 26 causes concurrent axial movement of both of the growth rods 25 relative to the domino 21 . The spur gear 26 can be retained within opening 23 of the domino 21 and locked in position relative thereto by a head (not shown) in the same manner as described above. The operation of the second embodiment of the growth rod distraction system 20 is otherwise similar to the operation of the first embodiment of the growth rod distraction system 10 described above.
[0046] FIG. 10 illustrates a portion of a third embodiment of a growth rod distraction system, indicated generally at 30 , in accordance with this invention. The growth rod distraction system 30 includes a central domino or housing 31 . In the illustrated embodiment, the domino 31 includes first and second side portions having respective first and second bores 32 and 33 provided therein. Each of the illustrated first and second bores 32 and 33 is generally hollow and cylindrical in shape, having an opened end and a closed end. The illustrated bores 32 and 33 extend generally parallel to one another. However, it will be appreciated that the first and second bores 32 and 33 may have any desired shape or combination of shapes and may be oriented in any desired relationship. In the illustrated embodiment, the domino 31 also includes a central portion that extends between the first and second side portions and that has first and second openings 34 and 35 provided therein. The illustrated first and second openings 34 and 35 are each generally hollow and cylindrical in shape and extend respectively through the domino 31 into the first and second bores 32 and 33 . Respective posts 34 a and 35 a are provided within the first and second openings 34 and 35 . The outer ends of the first and second openings 34 and 35 are threaded as described above.
[0047] First and second growth rods 36 are respectively disposed within the first and second bores 32 and 33 of the domino 31 . The illustrated growth rods 36 are each generally cylindrical in shape, preferably corresponding with the shapes of the first and second bores 32 and 33 within which they are respective supported. However, it will be appreciated that the growth rods 36 may have any desired shape or combination of shapes. Inner ends of the growth rods 36 are supported within the first and second bores 32 and 33 of the domino 31 for axial movement relative thereto. The outer surfaces of the inner ends of the growth rods 36 are provided with respective pluralities of recesses 36 a. The material or group of materials used to form the growth rods 36 will discussed further below.
[0048] First and second spur gears 37 are respectively disposed within the first and second openings 34 and 35 of the domino 31 . Each of the spur gears 37 has a central opening 37 a and a plurality of outer teeth 37 b. The central opening 37 a is adapted to receive one of the posts 34 a and 35 a therein so as to allow each of the spur gears 37 to be disposed within the first and second openings 34 and 35 . When so disposed, the spur gears 37 are supported for rotation relative to the domino 31 . Also, some of the outer teeth 37 b of the spur gears 37 extend into engagement with some of the recesses 36 a provided in the growth rods 36 . As a result, rotation of the spur gears 37 causes axial movement of the associated growth rods 36 relative to the domino 31 .
[0049] In this embodiment of the invention, a micro-motor 38 or other actuator mechanism is supported within the domino 31 of the growth rod distraction system 30 . The micro-motor 38 is, of itself, conventional in the art and may be controlled by an external remote control structure (not shown) by means of one or more micro-circuits 39 that are also supported within the domino 31 . The micro-motor 38 includes a rotor that engages each of the spur gears 37 . Thus, when the micro-motor 38 is actuated, the rotor is rotated, thereby causing concurrent rotation of the spur gears 37 . The operation of the third embodiment of the growth rod distraction system 30 is otherwise similar to the operation of the first embodiment of the growth rod distraction system 10 described above.
[0050] FIGS. 11 and 12 illustrate a first embodiment of one of the rods 16 , 25 , and 36 that can be used in any of the above-described embodiments of the growth rod distraction system 10 , 20 , and 30 , respectively. In this embodiment of the invention, the rod is formed completely from a solid piece of a flexible polymer material. For example, the rod may be formed from a PEEK (polyether ether ketone), carbon fiber PEEK, PEAK, or similar medical grade polymer material. The rod can be straight or curved as deemed necessary or desirable to correct the particular growth deformity. The rod can be of any desired size or cross sectional shape.
[0051] FIGS. 13 and 14 illustrate a second embodiment of one of the rods 16 , 25 , and 36 that can be used in any of the above-described embodiments of the growth rod distraction system 10 , 20 , and 30 , respectively. In this embodiment of the invention, the rod has a circumferential outer portion that is formed from a flexible polymer material (such as a PEEK, carbon fiber PEEK, PEAK, or similar medical grade polymer material) and an inner core that is formed from a metallic material (such as nitinol, titanium, stainless steel, or similar medical grade metallic material). The rod can be straight or curved as deemed necessary or desirable to correct the particular growth deformity. The rod can be of any desired size or cross sectional shape. The inner core may be formed from one piece of material or may be braided from a plurality of pieces of material.
[0052] FIGS. 15 and 16 illustrate a third embodiment of one of the rods 16 , 25 , and 36 that can be used in any of the above-described embodiments of the growth rod distraction system 10 , 20 , and 30 , respectively. In this embodiment of the invention, the rod has a circumferential outer portion that is formed from a metallic material (such as nitinol, titanium, stainless steel, or similar medical grade metallic material) and an inner core that is formed from a flexible polymer material (such as a PEEK, carbon fiber PEEK, PEAK, or similar medical grade polymer material). The rod can be straight or curved as deemed necessary or desirable to correct the particular growth deformity. The rod can be of any desired size or cross sectional shape.
[0053] FIGS. 17 and 18 illustrate a fourth embodiment of one of the rods 16 , 25 , and 36 that can be used in any of the above-described embodiments of the growth rod distraction system 10 , 20 , and 30 , respectively. In this embodiment of the invention, the rod has a circumferential outer portion that is formed from a metallic material (such as nitinol, titanium, stainless steel, or similar medical grade metallic material), an intermediate portion that is formed from a flexible polymer material (such as a PEEK, carbon fiber PEEK, PEAK, or similar medical grade polymer material), and an inner core that is formed from a metallic material (such as nitinol, titanium, stainless steel, or similar medical grade metallic material). The rod can be straight or curved as deemed necessary or desirable to correct the particular growth deformity. The rod can be of any desired size or cross sectional shape. The inner core may be formed from one piece of material or may be braided from a plurality of pieces of material.
[0054] FIG. 19 illustrates a fifth embodiment of one of the rods 16 , 25 , and 36 that can be used in any of the above-described embodiments of the growth rod distraction system 10 , 20 , and 30 , respectively. In this embodiment of the invention, the rod has a circumferential outer surface or portion having one or more serrations provided therein. The serrations can have any desired size, shape, orientation, and/or combinations thereof. The serrations allow the rod to be more flexible towards the serrated side, giving a surgeon more control of the angulation of the rod during installation.
[0055] FIG. 20 is a sectional elevational view of a sixth embodiment of a rod that can be used in any of the embodiments of the growth rod distraction system in accordance with this invention. In this embodiment of the invention, the rod has a special internal rack region for use with the domino in the general manner described above. The rod and the internal rack region are both formed from a flexible polymer material (such as a PEEK, carbon fiber PEEK, PEAK, or similar medical grade polymer material).
[0056] FIG. 21 is a sectional elevational view of a seventh embodiment of a rod that can be used in any of the embodiments of the growth rod distraction system in accordance with this invention. In this embodiment of the invention, the rod has a special internal rack region for use with the domino in the general manner described above. The rod is formed from a flexible polymer material (such as a PEEK, carbon fiber PEEK, PEAK, or similar medical grade polymer material), while the internal rack region is formed from a metallic material (such as nitinol or similar medical grade metallic material).
[0057] FIG. 22 is a sectional elevational view of an eighth embodiment of a rod that can be used in any of the embodiments of the growth rod distraction system in accordance with this invention. In this embodiment of the invention, the rod has an internal core and a special internal rack region for use with the domino in the general manner described above. The rod is formed from a flexible polymer material (such as a PEEK, carbon fiber PEEK, PEAK, or similar medical grade polymer material), while the internal core and the internal rack region are both formed from a metallic material (such as nitinol or similar medical grade metallic material).
[0058] FIGS. 23 and 24 illustrate a portion of a fourth embodiment of a growth rod distraction system, indicated generally at 40 , in accordance with this invention. In this embodiment of the invention, first and second growth rods 41 and 42 and a coupler gear 43 are supported within the domino (not shown). The ends of the first and second growth rods 41 and 42 have respective helical portions 41 a and 42 a that cooperate with an internal threaded surface 43 a of the coupler gear 43 . As a result, rotation of the coupler gear 43 relative to the domino causes axial movement of the first and second growth rods 41 and 42 in a manner that is similar to that described above. The coupler gear 43 is further provided with an external toothed surface 43 b that cooperates with a bevel gear (not shown) or similar actuator for effecting rotation of the coupler gear 43 (and, therefore, axial movement of the first and second growth rods 41 and 42 ) relative to the domino.
[0059] The major mechanical failure associated with growth rods treatment is rod breakage and screw loosening. It has been found that the parameters of distraction force and distraction frequency can be manipulated to lower the rate of complication by reducing the stresses on rod and load on the screw. The use of electronics would render ease in achieving the required frequency of distraction. It could also be used to set an upper limit on the distraction forces that could results in failure stresses on rod and high loads at screw-bone interface.
[0060] The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. | A growth rod distraction system a domino having first and second bores provided therein. First and second spinal rods are respectively disposed within the first and second bores for movement relative to the domino First and second spur gears are disposed within the domino and respectively cooperate with the first and second growth rods such that rotation of the spur gears causes axial movements of the growth rods relative to the domino The spinal rods may be formed either from a flexible polymer material (such as a PEEK, carbon fiber PEEK, PEAK, or similar medical grade polymer material) or a hybrid combination of such flexible polymer material and a metallic material (such as nitinol or similar medical grade metallic material). The spinal rods can also be used for fusion or non-fusion surgery of the spine to stabilize two or more vertebrae. | 0 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/523,590, filed on Nov. 20, 2003 and U.S. Provisional Application No. 60/523,596, filed on Nov. 20, 2003.
CONTRACTUAL ORIGIN OF THE INVENTION
[0002] The United States Government has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the United States Government and Argonne National Laboratory.
FIELD OF THE INVENTION
[0003] The present invention relates to a method for producing a lithographic pattern using a mask which consists of the same materials as the material to be etched, allowing the pattern to be transferred and the etch mask to be removed in one step and a vector magnetic field sensor defined by a single chip sensor upon which different magnetic reference directions have been established that allows the measurement of the direction and magnitude of an external magnetic field.
DESCRIPTION OF THE RELATED ART
[0004] One of the major steps in the manufacture of nanometer scale devices involves the transfer of a pattern into a multi-layered thin film structure. The most commonly used method of doing this involves several steps. First, an etch mask using a lithographic process is generated and applied to the appropriate substrate. Then the pattern is transferred to the desired substrate, often by directional etching. At this point, in many cases the mask must be removed using a selective chemical etching process. As the material and chemicals used in this step need to be optimized for every material in the multilayered film, choice of suitable reagents can be a formidable task.
[0005] Some of the most sensitive magnetic field sensors available today are spin-valve devices. In such devices a reference magnetic field direction is established through exchange biasing due to the coupling between a ferromagnet and an antiferromagnet. Ordinarily, the reference direction of the exchange biased component is determined during the manufacturing process, either due to magnetic field cooling or due to preparation within a magnetic field, and is unidirectionally fixed for each chip. Therefore in order to measure the different components of a magnetic field, sensors having separate chips with different magnetic reference directions must be used.
[0006] Important objects of the present invention are to provide a method for producing a lithographic pattern using a mask which consists of the same materials as the material to be etched, allowing the pattern to be transferred and the etch mask to be removed in one step and an improved mechanism to measure the different components of a magnetic field.
SUMMARY OF THE INVENTION
[0007] In brief, a method is provided for producing a lithographic pattern using a mask that includes the same materials as the material to be etched, allowing the pattern to be transferred and the etch mask to be removed in one step.
[0008] In accordance with features of the invention, the method includes building up of a layer or layers of material of specific thickness on top of a substrate so that temporal control of an etching process allows formation of the desired pattern.
[0009] In accordance with features of the invention, different exchange bias directions can be established by the use of shape anisotropy for the exchange biased component of the spin valve device. This enables several different magnetic reference directions to be present on a single chip, which allows a more compact magnetic field sensor to be developed. A single chip sensor upon which different magnetic reference directions have been established allowing the measurement of an external magnetic field defines a vector magnetic field sensor of the invention.
[0010] In accordance with features of the invention, different field directions are established on one single chip by using shape anisotropy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention together with the above and other objects and advantages may best be understood from the following detailed description of the preferred embodiments of the invention illustrated in the drawings, wherein:
[0012] FIGS. 1A, 1B , 1 C, 1 D, 1 E, and 1 F illustrate magnetic hysteresis loops of line patterns measured with magneto-optic Kerr effect (MOKE) using an optical cryostat;
[0013] FIGS. 2A, 2B , 2 C, and 2 D and FIG. 3 illustrate calculated hysteresis loops for a theoretical coherent rotation model;
[0014] FIG. 4 illustrates an exemplary etch-mask that mimics layers to be patterned for producing a pattern transfer in accordance with the preferred embodiment;
[0015] FIGS. 5-8 illustrate an experimental demonstration of a method for producing a pattern transfer in accordance with the preferred embodiment and an exemplary demonstration sample for a vector magnetic field sensor in accordance with the preferred embodiment; and
[0016] FIG. 9 illustrates an exemplary design for a vector magnetic field sensor in accordance with the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The magnetic behavior of Fe lines on top of a continuous FeF2 antiferromagnetic layer was investigated as a function of the orientation of the lines with respect to the applied magnetic field and a unidirectional anisotropy established by field cooling. The orientational dependence of the asymmetric loop shift, called exchange bias, shows that the competition between shape and unidirectional anisotropies modifies the exchange bias and the coercivity. Remarkably, in certain cases, exchange bias can be observed even when the applied field is perpendicular to the unidirectional anisotropy. Numerical simulations with a coherent rotation model illustrate a rich phase diagram, which originates from the noncollinearity of the involved anisotropies. Using this phase diagram, exchange bias and coercivity can be predictably tailored. In particular, different preferred magnetization directions can be designed in separately patterned structures of the same sample with identical preparation and magnetic history.
[0018] Although the role of shape anisotropy in homogeneous magnetic materials has been well understood for a long time, it is shown here that adding shape anisotropy to magnetic heterostructures can give rise to an unexpected behavior due to a competition between shape anisotropy and internal interactions of the heterostructure. Examples of heterostructures, which received much attention lately, are ferromagnetic/antiferromagnetic exchange-coupled systems. The coupling between an antiferromagnet and a ferromagnet can give rise to an induced unidirectional anisotropy in the ferromagnet, which is referred to as exchange bias. The main characteristic of this induced anisotropy is a shift of the hysteresis loop of the ferromagnet along the field axis. This unidirectional anisotropy stems presumably from the way the antiferromagnet orders in the proximity of a ferromagnet, but a detailed understanding is still missing. Regardless of the missing microscopic understanding, exchange bias has become important for many magnetoelectronic applications, because it pins the magnetization orientation of one ferromagnetic layer, which then serves as the reference layer in a variety of device structures, such as spin valves and magnetic memory elements.
[0019] For applications, it is often necessary to pattern the heterostructures into a confined geometry. Thus the question of how patterning influences the magnetic behavior arises naturally. Up to now, studies of exchange-biased antiferromagnetic/ferromagnetic wires have been restricted to cases with shape anisotropy either parallel or perpendicular to the applied magnetic field. These studies showed a modified exchange bias similar to nanostructured networks of exchange-bias systems. However, there has been no systematic study of the role of the shape anisotropy orientation and no quantitative understanding of these effects has yet been obtained.
[0020] In this work, the exchange bias of Fe lines on an antiferromagnetic FeF 2 film was studied as a function of line orientation with respect to cooling and applied magnetic fields, but fixed with respect to the FeF 2 crystalline orientations. The main result is that competition and noncollinearity between unidirectional exchange coupling and shape anisotropy can give rise to an unexpected magnetic behavior. This opens up a straightforward pathway to tailor both the magnitude and direction of exchange bias, which can be applied to any exchange-bias system. We compare the experimental results to numerical simulations obtained from a coherent rotation model. The simulations give rise to a surprisingly rich variety of hysteretic behavior. The magnetic behavior depends strongly on the ratio and relative orientation between shape and uniaxial anisotropies. In particular, when the ratio is less than 1, large exchange bias is observed even with magnetic fields applied perpendicular to the unidirectional anisotropy. This permits the introduction of several different preferred magnetization directions in separately patterned structures, independent from material specific parameters, even if they have identical magnetic history.
[0021] Using the new patterning technique, which is described in more detail below, we defined 300-nm-wide polycrystalline Fe lines on top of a continuous quasiepitaxial (110) FeF 2 film grown on a MgO (100) substrate. The FeF 2 and Fe are 90 and 10 nm thick, respectively. The Fe lines have a periodicity of 500 nm and cover several 100×100-μm 2 areas, each with a different direction with respect to the MgO [010] direction. Since all the patterns are on one single chip, it is assured that the local exchange interaction between the Fe lines and FeF 2 film and the magnetic history (i.e., magnitude and direction of the cooling field) are identical for all patterns.
[0022] The magnetic hysteresis loops of the line patterns were measured with magneto-optic Kerr effect (MOKE), using an optical cryostat. The transverse MOKE geometry is used under ˜45° incidence, which allows us to measure the magnetization component Mpar parallel to the applied field. The laser beam is focused down to 50 mm diameter, which enables us to address each of the Fe-line patterns individually. Magnetic hysteresis loops measured at room temperature for the patterned Fe lines along various directions are consistent with a uniaxial shape anisotropy K u =150 Oe.
[0023] FIGS. 1A-1E show hysteresis loops measured with MOKE at 35 K for three patterns with the lines −45° in FIGS. 1A, 1D , 0° in FIGS. 1B, 1E , and +45° in FIGS. 1C, 1F oriented with respect to the applied field during the hysteresis loop measurements. The applied magnetic field is parallel to the cooling field for in FIGS. 1A-1C , while it is perpendicular for in FIGS. 1D-1F . The directions of the applied field and cooling field with respect to the lines are indicated to the right of each plot.
[0024] For measurements in the exchange-biased state, the sample is cooled from room temperature to 35 K in an applied field of 1.5 kOe. FIGS. 1A-1C show magnetic hysteresis loops after field cooling for three patterns with the lines oriented at −45°, 0°, and +45° relative to the cooling and the applied field. The resulting exchange bias is similar (HE ˜475 Oe) for all three patterns and only the shape of the hysteresis loop is somewhat changed by the different shape anisotropies. Furthermore, as expected, the hysteresis loops for the patterns rotated +45° or −45° are essentially identical, see FIGS. 1A and 1C .
[0025] As shown in FIGS. 1D-1F the situation is completely different as soon as the patterns are rotated 90° clockwise after field cooling. The unidirectional anisotropy is now perpendicular to the applied magnetic field and therefore one would naively not expect to observe any exchange bias. Indeed, for the pattern where the cooling field direction is parallel to the lines and thus along the direction of the uniaxial shape anisotropy, the exchange bias is negligible compared to the other cases, see FIG. 1E . On the other hand, for the lines at 45° to both the applied and the cooling fields, there is an exchange bias, see FIGS. 1D and 1F . However, note that the sign of the exchange bias is opposite for the two orientations, even though the magnetic history is exactly the same.
[0026] It is instructive to compare these experimental results with numerical simulations based on a coherent rotation model similar to earlier works. If we assume a homogeneous magnetization in the Fe lines, then the free energy f can be written as:
[0027] f=HM s cos θ− K E cos(θ−θ E )− K u (cos 2 (θ−θ u )
[0028] where H is the applied field, M s is the saturation magnetization, u is the angle of the magnetization with the applied field, K E and K u are the unidirectional exchange coupling and the uniaxial shape anisotropy, and θ E and θ u are the angles between the applied field and these two anisotropy axes, respectively. Hysteresis loops are determined numerically via energy minimization of the above equation. Results are shown in FIGS. 2A-2D for different ratios of K U /K E and fixed values of θ u =90° and θ u =45°, corresponding to the case in FIG. 1D . As one can see, a range of hysteretic behavior can be observed depending on the ratio K U /K E .
[0029] FIGS. 2A-2D show hysteresis loops from the coherent rotation model with θ E and θ u fixed to 90° and 45°, respectively. Shown are the longitudinal (solid line) and transverse (dashed line) magnetizations M par and M perp normalized by the saturation magnetization. The curves are for K U /K E ratios of 0 in FIG. 2A , 0.3 in FIG. 2B , 0.95 in FIG. 2C , and 1.5 in FIG. 2D . The solid symbols in FIG. 2B indicate the average of the two hysteresis branches from FIG. 1D .
[0030] FIG. 3 shows calculated H E (solid line) and Hc (dashed line) normalized by K E /M s and K c /M s , respectively, as a function of K U /K E at fixed θ E =90° and θ u =45°. The regions of different hysteresis behavior are indicated by I, II, and III.
[0031] The exchange bias H E and the coercivity H c values extracted from these simulated loops are plotted as a function of K U /K E in FIG. 3 . One can distinguish three types of behavior. For vanishing K u , H E also vanishes and the magnetization simply rotates reversibly from one direction to the opposite, whereby at remanence the magnetization always points along the unidirectional anisotropy K E , see FIG. 2A . With increasing K u the magnetization still rotates reversibly, albeit asymmetrically, see FIG. 2B . This gives rise to an H E which increases linearly with K u see region I in FIG. 3 . When K U /K E reaches 0.85, the hysteresis loop shows irreversible behavior, see FIG. 2C . Notice that the exact value at which the irreversible behavior becomes important depends on the angle between the uniaxial and the unidirectional anisotropy. For K U /K E larger than 0.85, H c increases and H E decreases, see region II in FIG. 3 until they both become close to K E /2M s near K U /K E =1. For K U /K E <1, the perpendicular component of the magnetization always points along the direction of the unidirectional anisotropy during the magnetization reversal. The situation changes completely at K u =K E . There is a first-order transition in the hysteretic behavior, such that the magnetization reverses in opposite directions during the ascending and descending branches of the hysteresis loop, see FIG. 2D . At the same time H c increases by more than a factor of 2, that H c >K U , and H E changes sign and is significantly reduced in magnitude. Upon further increasing K U , H E vanishes, and H c becomes equal to K U , see region III in FIG. 3 as is expected for a coherent rotation model without additional unidirectional anisotropy.
[0032] It is important to realize that the complexity of this magnetic behavior is due to the noncollinearity of the applied field, the unidirectional exchange-coupling anisotropy established by the field cooling, and the shape anisotropy determined by the geometry. For example, if the unidirectional anisotropy is parallel to the applied field, then the exchange bias is independent of the shape anisotropy, namely, H E =K E /M s , which is exactly the experimental observation, see FIGS. 1A-1C . It should also be pointed out that the calculated hysteresis loops do not require that the uniaxial anisotropy be due to the shape of the ferromagnet. If the ferromagnet has an intrinsic uniaxial anisotropy (i.e., crystalline) then the same effects should be observable. However, unlike crystalline uniaxial anisotropy, shape anisotropy introduces an extra degree of freedom, since different parts of the same sample can be easily designed to have different magnitude and direction of shape anisotropy.
[0033] We can estimate, which region of FIG. 3 corresponds to the samples we measured. The shape anisotropy of the Fe lines can be calculated from demagnetizing factors if one approximates the wires as general ellipsoids. Using M s =1740 emu/cm 3 for Fe and the dimensions of 100 mm length, 300 nm width, and 10 nm thickness results in K U /M s =353 Oe. This compares well with the shape anisotropy determined from room-temperature, hard-axis hysteresis loops, which show an anisotropy field H a ˜300 Oe, corresponding to K u /M s ˜150 Oe. The unidirectional exchange-coupling anisotropy can be determined directly from measurements with the field applied along the field cooling direction FIGS. 1A-1C and is K E /M s =H E =475 Oe. Thus, the samples correspond to region I in FIG. 3 . Therefore the exchange bias should be equal to K u /M s , and in fact the exchange bias in FIGS. 1D and 1F is ±180 Oe, corresponding well to K u /M s =150 Oe, determined from the room-temperature hysteresis loops. Of course, one may notice that the simulation in FIG. 2B does not show any hysteresis in contrast to the experimental data. This is most likely due to the fact that the model ignores more complicated origins of coercivity in exchange-bias systems, such as irreversible losses in the antiferromagnet. These contributions can be removed from the experimental data by averaging the branches of the two hysteresis loops and the result is shown by the solid symbols in FIG. 2B together with the corresponding numerical simulation. The result is remarkable, since without any free parameter, not only the shift of the loop but also the overall shape of the loop are well described.
[0034] In the past, various other approaches have been used successfully to modify exchange bias locally, for example, by ion irradiation. One distinct advantage of the work presented here is that the use of shape anisotropy provides precise control of the magnitude and orientation (i.e., sign) of the exchange bias over a wide range. This means that once the unidirectional exchange-coupling anisotropy is known (i.e., from an unpatterned film), the coherent rotation model can be used to predict quantitatively the resulting exchange bias shifts of the patterned areas.
[0035] In summary, it is proven that this new patterning technique can be used to define lateral structures for multilayers resulting in well defined physical properties. In this particular case it is shown that uniaxial shape anisotropy can give rise to exchange bias in situations where one naively would not expect any. Numerical simulations based on a coherent rotation model show that this effect relies on the noncollinearity of the involved anisotropies. The exchange bias is most pronounced when the uniaxial anisotropy is slightly smaller than the unidirectional exchange-bias anisotropy. Furthermore, as a function of the ratio between the uniaxial and the unidirectional anisotropy K U /K E , the numerical simulations provide a phase diagram with three regions of hysteretic behavior and a change of sign for the exchange bias. Future experiments with varying ratios of K U /K E should be able to explore the full range of predicted hysteretic behavior. Furthermore, the directional selectivity of the exchange bias due to shape anisotropy can be used to establish different preferred magnetization directions in separately patterned structures with the same magnetic history. Similarly, one can expect that the competition between shape anisotropy and internal interactions in other types of magnetic heterostructures can give rise to equally rich varieties of magnetic behavior.
[0036] In accordance with features of the preferred embodiment, an etch-mask in accordance with the preferred embodiment mimics layers to be patterned for producing a pattern transfer.
[0037] Referring to FIG. 4 , there is shown a lift-off step generally designated by the reference character 100 for an exemplary etch-mask 101 that mimics the layers to be patterned in accordance with the preferred embodiment. An etch multilayer step generally designated by the reference character 102 in accordance with the preferred embodiment results in the complete pattern transfer. The etch multilayer step 102 can be an ion-milling operation.
[0038] The etch multilayer step 102 for pattern transfer in accordance with the preferred embodiment also removes the etch-mask 101 , thus eliminating the need for mask stripping of conventional processes.
[0039] Referring now to FIGS. 5-8 , there is shown an experimental demonstration of a method for producing a pattern transfer in accordance with the preferred embodiment.
[0040] Referring first to FIG. 5 , there is shown an initial structure generally designated by the reference character 500 including an MgO substrate(100) 502 , Fe/FeF 2 bilayers 504 , and a Al layer 506 . The Fe layer of the Fe/FeF 2 bilayers 504 is capped by the Al layer 506 to prevent oxidation of the Fe layer. As shown, the Al layer 206 is 4 nm, the Fe layer is 10 nm and the FeF 2 layer is 90 nm.
[0041] Referring to FIG. 6 , there is shown a modified structure generally designated by the reference character 600 including a resist layer 602 , such as, a PMMA layer for electron beam lithography that is deposited on the initial structure 500 , for example, to define lines having a line width, such as, 180-350 nm and a line pitch, such as, 500 nm and covering an 100×100-μm 2 area.
[0042] Referring to FIG. 7 , there is shown a modified structure generally designated by the reference character 700 for a lift-off step. The modified structure 700 includes an etch-mask 702 that is deposited on the PMMA layer 602 that is removed. The etch-mask 702 includes the same materials as those to be etched. The etch-mask 702 includes an array of lines 704 , each line 704 including an Al layer 706 that is 4 nm, a Fe layer 708 that is 10 nm and an Al layer 710 that is 4 nm.
[0043] Referring to FIG. 8 , there is shown a final structure generally designated by the reference character 800 for the etch multilayer step. The modified final structure 800 includes a pair of lines 802 supported by FeF 2 layer of bilayers 504 carried by the MgO (100) substrate 502 . Each line 802 including a Fe layer 804 that is 10 nm and an Al layer 806 that is 8 nm, and the FeF 2 bilayers 504 is 90 nm.
[0044] In accordance with features of the preferred embodiment, different field directions are established on one single chip by using shape anisotropy. In the presented case the patterned systems show still a hysteretic behavior, which would be detrimental for an actual sensor device. Nevertheless, these issues can be easily resolved through a selected combination of ferromagnetic and antiferromagnetic materials. Also the current demonstration is made with materials chosen to answer specific basic science questions. Therefore the exchange bias is only established at low temperatures (<78 K), which is clearly undesirable for practical applications. However an extension of the present idea to room-temperature compatible materials is straightforward.
[0045] Referring now to FIG. 9 , there is shown an exemplary design for a vector magnetic field sensor generally designated by the reference character 100 in accordance with the preferred embodiment. Magnetization of a free layer is a vector and while ordinary or conventional spin-valves measure only one component; the vector magnetic field sensor 900 with two reference directions allow measuring orientation of magnetization vector represented as follows:
ΔR 1 ˜cos(θ−θ 1 ); and
ΔR 2 ˜cos(θ−θ 2 )
Exchange bias is established in the vector magnetic field sensor 900 by applying a magnetic field during preparation and annealing after preparation in the magnetic field applied along a direction, which bisects the long axes of the two spin-valves comprising the sensor. Consequently there is one fixed unidirectional anistropy direction, along the applied magnetic field for the whole sample, that is the single chip defining the vector magnetic field sensor 100 . Combined with the shape anisotropy, which is uniaxial and is established by geometry, the unidirectional anisotropy will give rise to two separate reference directions for the pinned magnetization layers in the two sensor components.
[0046] The vector magnetic field sensor 900 includes a free layer 902 consisting of a soft ferromagnetic metal, for example, such as a permalloy. The vector magnetic field sensor 900 includes a separating layer 904 between the pinned ( 906 ) and free ( 902 ) magnetization layer, such as a non-magnetic metal for a spin valve or an insulator for a tunnel junction. The vector magnetic field sensor 900 includes a pinned layer 906 for different field directions consisting of a ferromagnetic metal, such as, a CoFe layer, disposed on the separating layer 904 . The vector magnetic field sensor 900 includes a pinning layer 908 for different field directions consisting of an antiferromagnet, such as, a FeMn layer, disposed on the pinned layer 906 . A pair of resistances 910 of the vector magnetic field sensor 900 are represented by R 1 and R 2 .
[0047] Referring again to FIG. 8 , the modified final structure 800 provides an exemplary demonstration sample for a vector magnetic field sensor 900 in accordance with the preferred embodiment. The modified final structure demonstration sample 800 includes the MgO substrate(100) 502 , Fe/FeF 2 bilayers 504 , and Al layer 806 . The Fe/FeF 2 bilayers 504 capped by the Al layer 806 prevents oxidation of the Fe layer.
[0048] While the present invention has been described with reference to the details of the embodiments of the invention shown in the drawing, these details are not intended to limit the scope of the invention as claimed in the appended claims. | A method is provided for producing a lithographic pattern using a mask that includes the same materials as the material to be etched, allowing the pattern to be transferred and the etch mask to be removed in one step. In accordance with features of the invention, the method includes building up of a layer or layers of material of specific thickness on top of a substrate so that temporal control of an etching process allows formation of the desired pattern. Different exchange bias directions can be established by the use of shape anisotropy for the exchange biased component of a spin valve device. This enables several different magnetic reference directions to be present on a single chip, which allows a more compact magnetic field sensor to be developed. In accordance with features of the invention, different field directions are established on one single chip by using shape anisotropy | 6 |
This application is a §371 National Stage Application of International Application No. PCT/EP02/10391, filed on 13 Sep. 2002, claiming the priority of European Patent Application No. 01203500.2 filed 14 Sep. 2001, European Patent Application No. 02076020.3 filed 15 Mar. 2002 and European Patent Application No. 02078051.6 filed 24 Jul. 2002.
FIELD OF THE INVENTION
The invention relates to a method of de-coating metallic coated scrap pieces, the metallic coated scrap pieces comprising a metallic core layer and a metallic coating layer whereby the liquidus temperature of the metallic coating layer is lower than the solidus temperature of the metallic core layer, such as brazing sheet scrap pieces, or from metallic coated scrap pieces of which the upper part of the melting range of the metallic coating layer has an overlap with the lower part of the melting range of the metallic core layer, wherein the metallic coating layer is at least partially removed from the metallic core layer of said scrap pieces by agitating the scrap pieces at an elevated temperature T above the solidus temperature of the metallic coating layer and below the liquidus temperature of the metallic core layer, together with abrading particles.
BACKGROUND OF THE INVENTION
The invention will be elucidated below for brazing sheet scrap, but the method can be used as well for other types of metallic coating layers on a metallic core.
During the production of brazing sheet a plate of an aluminium alloy having a relatively low Si content for the metallic core of the brazing sheet is on one or both sides clad by means of roll bonding with a plate of an aluminium alloy having a high Si content for the clad layer on the metallic core. This sandwich of metallic core plate and clad plate(s) is subsequently rolled so as to bind the clad layer(s) to the metallic core layer and to produce the brazing sheet product having a thickness of typically between 0.1 and 3 mm, for use in the production of for instance heat exchangers for automobiles.
During the production of the brazing sheet significant amounts of scrap are produced, for instance the heads and tails of the sandwich plates after each hot or cold rolling operation. Because the scrap contains both aluminium alloys with a high Si content and aluminium alloys with a low Si content, simple melting of the scrap would result in an aluminium alloy having a raised Si content as compared to the Si content of the metallic core, which is too high to be used for producing similar type metallic core plates, unless diluted with substantial amounts of alloys having a very low Si content.
Another source of brazing sheet scrap is formed by used products that are made out of brazing sheet, such as used heat exchangers.
Various methods are available to de-coat the clad alloy from the metallic core alloy in the scrap. One of these methods is described in international application no. WO 99/32260. According to this method, the metallic coating layer is separated from the metallic core, by rotationally tumbling or shaking the scrap metal pieces in a container together with abrading particles such as to agitate the scrap metal pieces together with the abrading particles and thereby causing multiple collisions, whereby the metallic coating layer is at least partially removed from the metallic core. During the agitating, the container is held at a temperature whereby the temperature of the scrap metal pieces is higher than the solidus temperature of the metallic coating layer and lower than the liquidus temperature of the metallic core.
It is a disadvantage of the known method that thin gauge material, in particular sheet material with a thickness gauge of less than 2 mm, is difficult to process due to excessive wear on the thin gauge by the abrasive particles, resulting in a complete loss of material.
It is another drawback of the known method, that one or more alloy elements diffuse during processing at elevated temperature from the metallic coating layer to the metallic core, thereby further contaminating the metallic core material.
It is another disadvantage of the known method, that there is a risk that removed metallic coating material adheres to the abrading particles. This results in a reduction of abrasive properties.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an efficient method of de-coating metallic coated scrap pieces, such as brazing sheet scrap, by removing a metallic coating layer from a metallic core layer of the metallic scrap pieces.
It is another object of the invention to provide such a method that is suitable to de-coat such metallic coated scrap pieces in a wide range of sheet thicknesses, including in particular, metallic scrap sheet with a thickness of less than 2 mm thickness.
It is still another object of the invention to provide such a method that is suitable for de-coating metallic coated scrap pieces with irregular morphology, such as scrapped and shredded heat exchangers.
It is still another object of the invention to provide a method of de-coating metallic coated scrap pieces such as brazing sheet scrap, with which large amounts of scrap can be processed.
It is yet another object of the invention to provide a method of de-coating such scrap that is economical on an industrial scale.
It is a further object of the invention to provide recycled metallic core and/or metallic coating alloys, which can easily be used for the production of new sheet material.
According to a first aspect of the invention, one or more of these objects are reached with a method of de-coating metallic coated scrap pieces, the metallic coated scrap pieces comprising a metallic core layer and a metallic coating layer whereby the liquidus temperature of the metallic coating layer is lower than the solidus temperature of the metallic core layer, such as brazing sheet scrap pieces, or from metallic coated scrap pieces of which the upper part of the melting range of the metallic coating layer has an overlap with the lower part of the melting range of the metallic core layer, wherein the metallic coating layer is at least partially removed from the metallic core layer of said scrap pieces by agitating the scrap pieces at an elevated temperature T above the solidus temperature of the metallic coating layer and below the liquidus temperature of the metallic core layer, together with abrading particles, wherein the abrading particles are brought into fluidisation during the agitating of the metallic coated scrap pieces, thereby forming a fluidised bed.
Fluidising converts a bed of solid particles into an expanded, suspended mass that has many properties of a fluid The abrading particles can be brought into fluidisation by feeding a homogeneous flow of a gas vertically through a quantity of particles. It has surprisingly been found that the abrading action of the particles brought in fluidisation is sufficiently high for removing the metallic coating layer, and at the same time it is sufficiently low to limit the wear on the metallic core. Because of the limited wear on the metallic core, thin scrap pieces can be de-coated.
Moreover, the fluid-like properties of the fluidised bed may result in a fairly uniform removal of the metallic coating layer, even in cases that the metallic scrap pieces have complicated shapes, such as folds or bends. Adhesion of abraded metal to the abrading particles may be reduced as a result of the continuous gas flow through the fluidised bed.
When the scrap pieces are at the temperature T within the specified temperature range, the metallic coating layer appears to be very weak and possibly partly molten and can be removed by the abrasive action of the fluidised particles. Wear on the metallic core layer is better avoided if the temperature T of the scrap pieces is kept lower than the solidus temperature of the metallic core layer.
In an embodiment of the invention, the fluidised bed is preheated to a fluidised bed temperature being at least the temperature T before introducing the metallic coated scrap pieces into the fluidised bed. The heat transfer from the fluidised bed to the metallic coated scrap pieces is very efficient. The de-coating process may therefore be relatively short, because of which the amount of diffusion of alloy elements from the metallic coating layer to the metallic core layer is limited.
Diffusion of alloying elements is even better avoided when the metallic scrap pieces are introduced into fluidised bed with the metallic scrap pieces at a temperature that is significantly below the temperature T, such as ambient room temperature.
The elevated temperature in the fluidised bed can be reached and/or maintained in various ways, one of which is using a heated gas flow to bring the particles into fluidisation.
Details of the method of the invention, such as process time, temperature, size and type of abrading particles, size of the scrap pieces, gas flow velocity, depend on the type of scrap pieces that are to be de-coated. These details can be optimised so that the desired result of removal of metallic coating layer on the core of the metallic scrap pieces is achieved.
In an embodiment, the scrap pieces are agitated by bringing them into fluidisation together with the abrading particles. Herewith a high efficiency of metallic coating layer removal, is achieved. A high degree of uniformity of the de-coating action is also achieved. In order to bring the scrap pieces into fluidisation along with the abrading particles, the shape and size of the scrap pieces should be tailored relative to the shape and density of the abrading particles, prior to inserting the scrap pieces in the fluidisation bed, for instance by using a mechanical treatment comprising shearing, cutting or chopping, preferably using a shredder.
In some cases it is particularly advantageous to keep the temperature T of the scrap pieces below the liquidus temperature of the metallic coating layer and below the solidus temperature of the metallic core layer. Herewith, adhesion of abraded and removed metallic coating layer material to the abrading particles may be reduced as a result of a lower amount of material will be in the liquid state.
Suitably the abrading particles are lumps or particles of metal, mineral, ceramic or similar hard material. Preferably, the abrading elements have irregular shapes such as lumps. But also some regular shapes can be used, such as pyramids or prisms. The abrading particles are, for example, selected from Al 2 O 3 , SiC, spinel, bauxite, ardenner split, steel slag, and ceramic rotofinish particles with a hardness such that erosion of the abrading particles is limited.
Although abrading particles of other materials may well be suitable, it is preferred to use one of those given above which are inert, in order to minimise adherence of removed metallic coating or cladding material to the abrading particles. Preferably the abrading particles used do not comprise to a significant extent any material that can react with the molten alloy ingredients of the metallic scrap pieces possibly present during the agitation, such as aluminium in case of aluminium brazing sheet scrap pieces.
The invention is particularly suitable for de-coating aluminium brazing sheet pieces, or products comprising aluminium brazing sheet. One of the properties of aluminium brazing sheet that is advantageously used in the method according to the invention is that the melting range of the metallic coating layer is purposely kept low compared to the melting range of the metallic core layer.
Typical suitable aluminium brazing sheet can have a core layer of the Aluminium Association AA 6xxx or the AA 3xxx aluminium alloys, in particular AA 6063, AA 6060, AA 3003, AA 3103, or AA 3005, and a clad layer of the AA 4xxx type aluminium alloy, such as AA 4343, AA 4047, AA 4004, or AA 4104. For these types, the Si content of the core is less than 0.6 wt. %, and the Si content of the clad layer is 6.8 to 13 wt. %.
In an embodiment of the method of the invention wherein the scrap pieces essentially consist of aluminium brazing sheet, the temperature T of the aluminium brazing sheet pieces is set at a value in the range of between 500° C. and 620° C. In this temperature range, the method is particularly suited for the removal of at least part of the metallic coating of aluminium brazing sheet, in which the metallic coating is an aluminium brazing alloy comprising Si as main alloying element in a range of 5 to 15 wt. %. The solidus temperature of the metallic core layer is of aluminium brazing sheet is typically higher than 620° C. Also, layers of aluminium alloys comprising Zn as main alloying element can be removed very effectively in this temperature range.
Preferably temperature T is set in the range between 500° C. and 580° C., in order to not exceed the liquidus temperature of the metallic coating layer of aluminium brazing sheet material. Herewith it is better ensured that abrasive action on the metallic core material is kept to a minimum, which is especially advantageous in the case of thin scrap pieces.
In an embodiment, the abrading particles have a density in the range of 3 to 7 g/cm 3 and a sieve fraction size in the range of 3 to 10 mm. Herewith a good balance is achieved between the abrasive impact of the particles and the ease of separating the removed metallic coating layer material and the remaining metallic core material from the abrading particles. The lower limit of the density range is just above the density of aluminium. In particular particles of essentially Al 2 O 3 , having a density of 4 g/cm 3 , have proven useful abrading particles.
The scrap pieces may have a thickness in the range of 0.1 to 2 mm and an area of about 4 to 40 cm 2 , depending on the density of the scrap pieces and the thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further explained with reference to the drawing, wherein
FIG. 1 shows a schematic cross sectional view of a device for performing an embodiment of the method according to the invention;
FIG. 2 shows a photographic image of de-coated metallic scrap pieces and a coated metallic scrap piece for reference;
FIG. 3 shows a graph setting out experimental results of Si-removal against process time; and
FIG. 4 shows a graph setting out experimental results of Mg-removal against process time
FIG. 5 shows a photographic image of de-coated radiator pieces of the fin type, and a coated radiator piece for reference.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Details of typical fluid bed devices are well known and can be found in for instance Perry's, Chemical Engineering Handbook, six edition.
FIG. 1 schematically shows a chamber 1 which is provided with means for bringing abrading particles into fluidisation to form fluidisation bed 15 . These means comprise a gas distribution chamber 2 and a fluidisation bed chamber 3 , which are separated from each other by a distributor 4 , which may be a finely perforated screen. The distribution chamber 2 is provided with a gas inlet 5 .
The fluidisation bed chamber 3 is provided with a perforated drum 6 that is rotatable about axis 16 . An inlet 17 for scrap material is present in the fluidisation chamber, from which inlet 17 scrap material 7 can be introduced into drum 6 . The perforation of drum 6 is such that the abrading particles and the gas can go through the drum, while keeping the scrap pieces inside the drum. The drum 6 may also be provided with a screw profile 8 on its inside.
The drum leads to the side of the fluidisation chamber 3 facing opposite the inlet 17 , where an outlet 9 is provided. This outlet is connected with sieving means 14 via a conduit, which conduit is schematically represented by arrow 18 . The sieving means is connected also to inlet 17 , as is schematically indicated by arrow 10 .
The fluidisation chamber 3 is provided in its top with a gas flow outlet 11 . FIG. 1 further shows separating means 12 which is connected via a conduit represented by arrow 19 to the gas flow outlet 11 . The separating means 12 can be for instance filtering means, or cyclone means, or any other known industrial separating means. A return conduit, as represented by arrow 13 , is provided for returning the gas to the distribution chamber 2 via the inlet 5 . Heating means are present to reheat this return gas.
The invention works as follows. Gas is pumped into the distribution chamber 2 . As a result of the gas flowing through the distributor 4 , a homogeneous substantially vertical gas flow is achieved in the fluidised bed chamber 3 . The abrading particles which are present in the fluidisation chamber 3 are brought into fluidisation as a result of the homogeneous vertical gas flow, forming the fluidisation bed 15 .
Suitably the abrading particles are lumps or particles of metal, mineral, ceramic or similar hard material, preferably having irregular shapes such as-lumps. But also some regular shapes can be used, such as pyramids or prisms. The abrading particles are, for example, selected from Al 2 O 3 , SiC, spinel, bauxite, ardenner split, steel slag, and ceramic rotofinish particles with a hardness such that erosion of the abrading particles is limited.
Scrap pieces are introduced into the fluidised bed 15 via inlet 17 . The drum 6 is rotated about its axis 16 . This rotational motion can agitate the scrap pieces. Also, the scrap pieces may be of such a density and shape that they will be brought into fluidisation together with the abrading particles. A combination of both may also be employed. De-coating occurs in the fluidised bed 15 .
When the drum is in rotation, the screw profile 8 causes a net mass distribution along the rotational axis 16 of the drum. The de-coated scrap pieces will thus eventually reach the outlet 9 , from where it may be led to sieving means 14 for separating the scrap pieces from any abrading particles that have also been led out of the fluidisation chamber 3 via the outlet 9 . The abrading particles may be recovered and returned to the fluidisation chamber via lead 10 . The de-coated scrap pieces may be collected and reused elsewhere, for instance for the production of similar types of metallic coated products as before.
In cases where the metallic coating material does not disengage from the fluidised bed via the gas flow, it may be necessary to separate the removed metallic coating material from the abrading particles by sieving as well.
In some process types, however, metallic coating material that has been removed from the scrap pieces will disengage from the fluidised bed in the form of finely distributed particles such as dust, and will flow together with the gas and leave the fluidisation chamber 3 via the outlet 11 . This metallic coating material can be filtered out of the gas in separating means 12 , and collected as a separate recycled product 20 . The gas may be recovered, re-heated, and led to the distribution chamber 2 via conduct 13 .
The temperature of the fluidised bed 15 can be used to bring the metallic scrap pieces to their desired temperature in a temperature range according to the invention. For an aluminium cladding layer alloy containing 10 wt. % Si, the desired temperature is 575° C., as an example.
Due to the homogeneous removal of the metallic coating layer, the invention is particularly suitable for treating scrapped and shredded heat exchangers that were built using aluminium brazing sheet material.
The drawing serves as a schematic example of one possible way to perform the invention, and the invention is not limited hereto.
EXAMPLE 1
In one laboratory experiment, a mixture of approximately 10 kg of Al 2 O 3 abrading particles having a particle size of between 3 and 5 mm and 160 g of platelets of 0.5 mm gauge brazing sheets measuring 25×25 mm 2 was brought into fluidisation at room temperature. The platelets and Al 2 O 3 particles remained mixed in a homogeneous fluidisation bed and the no separation was observed to occur.
EXAMPLE 2
Another laboratory experiment was performed using a closed-loop experimental set up using cyclone means to separate particulates from the fluidising gas circulation. The experimental set up was not provided with the rotating drum nor with the scrap inlets an outlets as shown in FIG. 1 .
In this laboratory experiment, three hundred platelets measuring 25×25 mm 2 and a scrapped radiator piece of the fin type and a scrapped radiator piece of the tube type, all made of 0.4 mm gauge brazing sheet having a core of an AA 3003 alloy (comprising 0.20 wt. % Si, substantially no Mg) and a 40-μm thin coating layer on each side of an AA 4004 alloy (comprising between 9.5 and 10 wt. % Si, and 1.5 wt. % Mg), were de-coated by bringing them into fluidisation together with 10 kg of bauxite particles having a particle size of between 3 and 5 mm. Various fluidised bed temperatures and process times were applied, in the range of 500° C. to 620° C. and in the range 10 min. to 60 min., respectively. For the purpose of this experiment, the fluidised bed temperature was taken to be the temperature of the fluidising gas.
FIG. 2 shows a photographic image of a platelet prior to subjecting it to the de-coating process (labeled “Vor Rec”, and a platelet that has been subjected to the de-coating process each of the conditions of 10 min., 30 min. and 60 min. at 500° C., 10 min., 30 min. and 60 min. at 550° C., 10 min., 30 min. and 60 min. at 600° C., and 10 min. and 30 min. at 620° C.
As can be seen, the pieces which have the thickness gauge of 0.4 mm are able to withstand the method. It can be derived from the amount of rounding in the comers that. higher temperatures and/or longer process times result in some more abrasion of the platelets than is the case at lower temperatures and/or process times. Up to fluidised bed temperature of 600° C. the preservation of the retrieved platelets was acceptable. The platelet that was de-coated for 10 min. at a fluidised bed temperature of 620° C. shows relatively high abrasion. After running the process for 30 min., some platelets were found clustered together, presumably due to sticking effects related to melting of the coating layer, and the majority of the platelets was completely abraded and/or broken into pieces. Hence, it is preferred to run the process at a temperature of not higher than 620° C.
After subjecting the platelets to the processes indicated above, they were remelted and chemically analysed by spark emission spectroscopy. The analysis results were compared with the results of spark emission spectroscopy analysis of remelted reference platelet that was not subjected to any of the de-coating processes.
The Si removal, as expressed in a percentage, is determined by the following formula:
Si removal=(1−(Si after −Si core )/(Si before −Si core ))×100%;
wherein Si after denotes the chemically analysed amount of Si from the remelt after the de-coating process, and Si before denotes the chemically analysed amount of Si from the remelt before the de-coating process, and Si core denotes the chemically analysed amount of Si from the core layer only.
FIG. 3 shows a graph of the percentage of Si that is found to be removed as compared to the reference platelet, as a function of process time for each of the fluidised bed temperatures 500, 550, and 600° C. As can be seen, over 50% of the Si has been removed using a temperature of 600° C. The Si removal is found to be effectuated in the first 10 minutes of the process. It is believed that Si diffuses from the metallic coating layer into the metallic core at the temperature of 600° C., and that for this reason the percentage of removable Si at 600° decreases with time.
On the other hand, it can be seen that for the alloys used in the present experiment, a fluidised bed temperature of more than 550° C. is preferred in order to obtain sufficiently high abrading action that enables de-coating in a reasonable time.
FIG. 4 shows a graph of the percentage of Mg that is found to be removed as compared to the reference platelet, as a function of process time for each of the fluidised bed temperatures 500, 550, and 600° C. As can be seen, for each temperature the Mg is removed quite significantly. The amount of Mg removed increases with both time and temperature. Within 10 minutes of de-coating at a fluidised bed temperature of 600° C., more than 60% of the Mg is found to be removed. It is believed that the efficient Mg removal is a consequence of a dynamic equilibrium involving Mg-rich surface oxides that are removed during the process on one hand and at the same time are supplemented with Mg diffusing out of the bulk on the other hand.
The cyclone content was analysed after having run the process at 600° C. Particles exceeding 0.5 mm were not analysed, since they were assumed to relate essentially to bauxite particles. The following Table I shows the percentage of Al in the particles smaller than 0.5 mm, as determined using wet chemical analysis.
TABLE 1
Process time at 600° C.
% metallic Al
10 min.
37
30 min.
24
60 min
16
The results provide an indication that the removed coating layer is at least in part carried over to the cyclone. However, when the process time is increased, a lower fraction of Al is found. It seems possible that a relatively higher fraction of the removed aluminium sticks to the bauxite abrading particles. This is confirmed by the fact that the bauxite abrading particles turned grey.
FIG. 5 shows a photographic image of a scrapped radiator piece (left) prior to de-coating and of the de-coated pieces after de-coating at the fluidised bed temperature of 600° C. during 10 min. and 30 min, respectively. It is evident that during the de-coating process, the radiator parts lost their attached fins completely. The fins were removed from the fluidised bed by the hot air stream and were collected in the cyclone together with the abraded silicon-containing layer from the above described experiments.
EXAMPLE 3
The effect of the sieve fraction size of the abrading particles on the silicon removal (see Example 2 for the method of determination) was investigated by de-coating one batch of three hundred platelets similar to the platelets from Example 2 by bringing them into fluidisation together with 10 kg of bauxite particles having a sieve fraction size of between 3 and 5 mm, and one batch using the same amount of bauxite particles having a sieve fraction size of between 1 and 3 mm The temperature of the fluidised bed was 600° C. The following Table II shows the results:
TABLE II
Si removal after 5 or 12 minutes of de-
coating of 0.4 mm platelets
Si removal
after 5 min.
after 12 min.
3-5 mm bauxite
40%
47%
1-3 mm bauxite
60%
65%
The following Table III shows results of a similar test, wherein 200 platelets of 1.5 mm thickness having a core layer and 0.15 mm thick clad layers of similar aluminium alloys as above, were de-coated.
TABLE III
Si removal after 10, 20, and 30 minutes
of de-coating of 1.5 mm platelets
Si removal
after 10 min.
after 20 min.
after 30 min.
3-5 mm bauxite
60%
64%
67%
1-3 mm bauxite
67%
77%
77%
Referring to Tables II and III, clearly a better performance can be seen when using the smaller sized bauxite as abrading particles for platelets. The number of abrading particles present in the fluidised bed increases approximately with a third power of the sieve fraction size ratio for the same total mass of abrading particles. Where a higher number density of abrading particles is present in the fluidised bed, the number of collision events on a surface of a platelet increases, leading to a higher de-coating efficiency. Since the mass of each abrading particle reduces with the same ratio, the de-coating efficiency of each collision event reduces. These two counter acting effects result in an optimum sieve fraction size that results in the highest de-coating efficiency.
EXAMPLE 4
The effect of the sieve fraction size of the abrading particles on the silicon removal was investigated by de-coating 100 g of scrapped radiator pieces of the fin type, using 10 kg of bauxite particles having a sieve fraction size of 1-3 mm, and 10 kg of bauxite particles having a sieve fraction size of 3-5 mm.
The radiator was made of 0.4 mm gauge brazing sheet having a core of an AA 3003 alloy (comprising 0.20 wt. % Si, substantially no Mg) and a 40-μm thin coating layer on each side of an AA 4004 alloy (comprising between 9.5 and 10 wt. % Si, and 1.5 wt. % Mg).
The following Table IV shows the result after de-coating at 600° C. for 10 min.:
TABLE IV
Si removal after 10 minutes of de-coating
of 0.4 mm scrapped radiator pieces
Si removal after 5 min.
3-5 mm bauxite
57%
1-3 mm bauxite
39%
In the case of scrapped radiator pieces, the sieve fraction size of between 3 and 5 mm shows a better result. Due to the higher mass of the individual particles with the higher sieve fraction size, the impact of individual collision events between an abrading particle and a scrapped radiator piece is higher resulting in a better removal of the attached fins.
EXAMPLE 5
The effect of the amount of abrading particles on the silicon removal was investigated by comparing de-coating one batch of three hundred platelets to another batch of six hundred platelets. The platelets were similar to the 0.4 mm thick platelets from Example 2. Table V shows the silicon removal (see Example 2 for the method of determination) after de-coating by bringing the platelets into fluidisation together with 10 kg of bauxite particles having a sieve fraction size of between 1 and 3 mm.
TABLE V
Si removal after 5, 12, and 20 minutes of
de-coating of 0.4 mm platelets
Si removal
after 5 min.
after 12 min.
after 20 min.
300 platelets
60%
65%
—
600 platelets
53%
55%
50%
As can be seen, the de-coating efficiency is higher when a batch of 300 platelets is de-coated than when a batch of 600 platelets is de-coated.
This is presently thought to be related to the total surface area that is to be de-coated in one batch relative to the amount of abrading particles present in the fluidised bed. In the situation of Table V, the total surface area present in the batch of platelets amounts to approximately 0.375 m 2 for 300 platelets and 0.750 m 2 for 600 platelets.
Thus, at least for abrading particles having a material density in the range of 3 to 3.5 g/cm 3 , such as bauxite, the amount of abrading particles in the fluidised bed per square meter of surface area to be de-coated is preferably chosen to be at least 10 kg/m 2 , preferably at least 13 kg/m 2 , more preferably at least 20 kg/m 2 . These numbers may be generally valid when proper account is taken of the density of and sieve fraction size of the abrading particles. | Method of de-coating metallic coated scrap pieces, the metallic coated scrap pieces comprising a metallic core layer and a metallic coating layer of which the liquidus temperature of the metallic coating layer is lower than the solidus temperature of the metallic core layer, such as brazing sheet scrap pieces, or from metallic coated scrap pieces of which the upper part of the melting range of the metallic core layer has an overlap with the lower part of the melting range of the metallic core layer. The metallic coating layer is at least partially removed from the metallic core layer of said scrap pieces by agitating the scrap pieces at an elevated temperature T above the solidus temperature of the metallic coating layer and below the liquidus temperature of the metallic core layer, together with abrading particles. The abrading particles are brought into fluidisation during the agitating of the metallic coated scrap pieces, thereby forming a fluidised bed. | 1 |
TECHNICAL FIELD
The present invention relates generally to a pulping process for nonwood materials. More particularly, this invention relates to a simple and environmentally benign process for pulping of corn stover and other nonwood fiber source materials to produce a high-quality papermaking pulp.
BACKGROUND ART
It will appreciated by one having ordinary skill in the art that trees and other woody plants are not the only source of fibers for papermaking. There are a variety of nonwood annual and perennial plants which produce fibers having sufficient strength and length to produce paper with acceptable qualities. These nonwood plants are often referred to in the art as “agricultural residues” or “fiber crops”. Examples of plants for each of these categories include:
Agricultural Residues
Fiber Crops
Wheat straw
Kenaf
Rice straw
Industrial hemp
Corn stalks
Sisal
Bagasse (sugar cane)
Textile flax straw
Rye grass straw
Hesperaloe
Seed flax straw
Flax straw
One of the main advantages of these fiber sources is that they are perceived in the art as environmentally-benign alternatives to the use of trees. Indeed, nonwoods are currently the major source of papermaking fiber for some developing countries and countries lacking significant wood resources.
For the most part, however, the development of a nonwood fiber industry in North America has been retarded due to the fact that nonwood pulps are usually more expensive on a per-ton basis than wood pulps. Recently, several factors have dramatically increased the level of industry interest in these nonwood fiber sources. Some of these factors include environmental pressure to stop using trees; projections of world fiber shortage by 2010 and the need to find alternative fiber sources; abundance of agricultural residues (such as corn stover and wheat straw) that are otherwise burned off fields; and opportunities to produce multiple products (oils, textile fibers, papermaking fibers, board fibers, plastics, food) from a simple fiber source, which provides unique opportunities for sustainable agriculture.
However, effective use of nonwood fiber sources presents some significant challenges that must be overcome. These challenges include the following:
(1) nonwoods must be harvested annually and stored, and thus, are sensitive to growing season, harvest conditions, etc.;
(2) nonwoods have a low bulk density compared to trees, and thus, can be hard to store and transport;
(3) nonwoods may require larger amounts of herbicides and pesticides as compared to trees;
(4) nonwoods generally require smaller pulp and paper mills due to transport constraints, and it is often difficult to establish efficient chemical recovery systems for small mills; and
(5) many, but not all, nonwoods comprise fibers that may be shorter, more slender, or weaker than wood fibers.
Agricultural residues represent an economically-promising source of nonwood fibers. The low bulk density and high transport costs of agricultural residues suggests a nonwood mill capable of producing 50-350 tons of pulp per day. This “mini-mill” must produce pulp which can compete with wood pulp produced in very efficient “mega-mills” producing 1000-3000 tons per day. To make the situation even more challenging, it is generally not possible to simply scale down the wood pulp processes, which rely on large production volumes to justify the high capital costs of equipment.
In order to be successful, nonwood mini-mills must therefore make use of processes which are cost effective and environmentally sound at small scale. Such processes should ideally meet the following criteria:
(1) The process should have a minimal number of processing steps, or stages;
(2) The process should utilize a minimal amount of equipment;
(3) The equipment should be as simple and low-cost as possible;
(4) The process should minimize water usage by:
(a) recycling as many filtrate streams internally as possible,
(b) minimizing the number of dilution and thickening stages required,
(c) minimizing the number of washing stages required, and
(d) minimizing the number of pH changes required;
(5) The process should use readily-available chemicals at reasonable dosage levels;
(6) The process should be odor-free and optionally, chlorine-free; and
(7) The process should use chemicals which permit recovery of all internal filtrate streams.
Given the fragile nature of agricultural residues and the quality requirements of the printing and writing grade paper markets, the successful mini-mill process should also meet the following criteria:
(1) The final pulp should have a brightness in the 70-90% ISO range for paper grades made in an integrated pulp and paper mill, and 85-90% ISO for high-end and market pulp grades;
(2) The pulp should have adequate strength properties, i.e. the fibers should be subjected to minimum damage;
(3) The drainage rate (freeness) of the pulp should be sufficiently high so that the pulp can be formed and dewatered on a typical paper machine; and
(4) The process should be able to remove the high content of pith, parenchymal cells, fines, and other non-fibrous materials often found in nonwoods; these materials make the pulp “dirty” and also cause slow drainage.
Thus, a substantial challenge in reducing nonwood raw materials into fibers for papermaking is to find a pulping method for application in a mini-mill setting which addresses the criteria set forth above. The term “pulping” is generally defined as the reduction of the bulk fiber source material into its component fibers. The key is to perform this reduction without damaging the fiber (thereby reducing strength) or without losing too much fiber that will be suitable for papermaking (termed a “yield loss”).
Several classes of pulping processes are generally known in the art. These processes include the following:
(1) Chemical Pulping—In this type of pulping, a large chemical dose is used to dissolve away most of the lignin (glue) which holds the fibers together in the raw material. This dissolution is carried out in a digester, where chemicals are mixed with the raw material and then heated to medium to high temperature (100-170° C.) and high pressure (2-15 atm). Standard digestion processes are carried out for about 1-8 hours. At the end of the digestion, the fibers are washed to separate them from the liquor, which contains dissolved lignin and spent chemicals. Elaborate systems have been developed to thicken and burn the liquor in order to recover heat energy from the lignin and regenerate the chemicals for use in subsequent digestion procedures.
Pulps from full chemical processes are characterized by high purity (high cellulose content, low hemicellulose and lignin content), suitable cleanliness levels, and suitable strength. With subsequent bleaching, high-brightness pulps for demanding printing and writing grade paper products may be produced. However, the processes often have a low yield (30-50%) due to chemical dissolution. In addition, full chemical processes require high capital investment and high operating costs. Thus, standard full chemical pulping processes are generally not suitable for nonwoods pulping applications in mini-mills.
(2) Mechanical Pulping—In this type of pulping, raw materials are separated into fibers using brute mechanical force. Usually, the raw material is placed between rotating refiner plates, which shear it apart. Heat can be applied to soften the fibers prior to refining. Yield from these types of processes is typically high (65-95%), but the quality of pulps is usually inferior to chemical pulps. Because there is still a large amount of lignin on the fiber surfaces, bonding sites are blocked, resulting in lower strength properties. Sheet flexibility is also reduced because lignin is left in the fiber walls. Overall, mechanical pulps are useful only for low-end paper grades like newsprint or catalog. However, since large quantities of chemicals are not required, chemical recovery is no problem. In addition, capital and operating costs are manageable. However, because of the limitation on pulp, and subsequently paper, quality described above, a purely mechanical process is also believed to have limited application to the pulping of nonwoods due to the fragile nature of many nonwoods.
(3) Chemi-Mechanical Pulping—This type of pulping uses aspects of both of the previously described process types. Raw material is impregnated with small amounts of chemicals to soften the lignin, and then it is mechanically treated to complete the separation. Heat is typically applied to improve pulping. With this hybrid process, good fiber properties may be developed without extensive chemical application. In addition, capital and operating costs are almost as low as for pure mechanical pulping. Pulps from chemi-mechanical processes can be used for low- to medium-quality papers, and with additional processing they may be used for some high-end purposes. However, a chemi-mechanical pulping process suitable for the pulping of nonwoods has not been described in the art.
Background art patents include U.S. Pat. Nos. 4,756,799 and 4,900,399, both to Bengtsson et al., describing methods for manufacturing bleached chemi-mechanical and semi-mechanical fiber pulp by means of a one or two stage impregnation process. However, these patents particularly describe production of a pulp from wood materials. The described methods particularly require that the wood material be preheated before it is subjected to mechanical manipulation in a standard twin disk refiner. Thus, the method steps described in these U.S. patents are not believed to have particular application to a pulping process for nonwood m materials.
U.S. Pat. Nos. 4,997,488 to Gould et al.; 4,806,475 to Gould; U.S. Pat. No. 4,774,098 to Gould et al.; and, 4,649,113 to Gould describe alkaline peroxide treatment of nonwoody lignocellulosics and products made by such treatments. However, the primary focus of these patents is the production of nutritional supplements, culture media or other compounds from cellulose in the nonwoody materials for use in feeding domestic animals, humans, or in the growth of microbial cultures. Stated differently, the focus of the methods described in these patents is to produce materials from cellulose that can be metabolized by animals.
Despite the disclosure of the foregoing U.S. patents, there has been no suggestion in the art of a pulping process for nonwood fiber source materials that meets the criteria set forth above. Indeed, for nonwoods the most sensible approach is to install a small mill at the center of a defined growing area. As noted above, this mill should use a simple process, with low operating and capital costs, to maintain economies of scale equal to those of the mega-mill. The process should render the mill almost invisible to the environment, and should require only small amounts of environmentally-benign chemical agents. Such a process is not currently available in the art.
SUMMARY OF THE INVENTION
A process for producing a pulp suitable for use in papermaking from a nonwood fiber source material has been developed by the applicants and is disclosed herein. The process comprises providing a nonwood fiber source material; digesting the nonwood fiber source material with an alkaline pulping solution at at least about atmospheric pressure; reducing the pH of the nonwood fiber source material to an acidic pH with an acid solution; treating the nonwood fiber source material having an acidic pH with ozone; and treating the nonwood fiber source material with a bleaching solution to form a papermaking pulp.
Accordingly, it is an object of this invention to provide a nonwoods pulping process that is cost effective and environmentally sound at small scale.
It is an object of the present invention to provide a nonwoods pulping process which keeps the number of processing steps, or stages, to a minimum.
It is another object of this invention to provide a nonwoods pulping process that uses readily available, inexpensive and minimal amounts of equipment.
It is still another object of this invention to provide a nonwoods pulping process that minimizes water usage by recycling as many filtrate streams internally as possible; by minimizing the number of dilution and thickening stages required; by minimizing the number of washing stages required; and by minimizing the number of pH changes required.
It is yet another object of this invention to provide a nonwoods pulping process that uses readily available and inexpensive chemicals at moderate dosage levels and that uses chemicals which permit recovery of all internal filtrate streams.
It is a further object of this invention to provide an odor-free and optionally chlorine-free nonwoods pulping process.
It is still a further object of this invention to provide a nonwoods pulp with high freeness, desirable brightness characteristics and adequate strength properties.
It is yet a further object of this invention to provide a nonwoods pulping process that removes the high content of pith, parenchymal cells, fines, and other non-fibrous materials often found in nonwoods.
Some of the objects of the invention having been stated hereinabove, other objects will become evident as the description proceeds, when taken in connection with the accompanying Examples and Drawings as best described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of an optional fiber preparation stage FP of the process of the present invention;
FIG. 2 is a schematic representation of an alkaline digestion stage E of the process of the present invention;
FIG. 3 is a schematic representation of an acid treatment stage A and ozone treatment stage Z of the process of the present invention;
FIG. 4 is a schematic representation of a screening and cleaning stage SC of the process of the present invention;
FIG. 5 is a schematic representation of a bleaching stage B of the process of the present invention; and
FIG. 6 is a schematic representation of an alternative embodiment of an acid treatment stage A′ and an ozone treatment stage Z′ of the process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The novel process of the instant invention addresses the paper industry's need for a mini-mill process for use with nonwood fibers. This process is a primarily a chemical process, using a sequence of chemical treatment steps to produce high-quality pulps.
The term “woody” is used herein both in the botanical sense to mean “comprising wood”; that is, composed of extensive xylem tissue as found in trees and shrubs, and also in the sense of being “wood-like”. Accordingly, the terms “nonwood”, “nonwoods”, and “nonwoody” refer to materials lacking these characteristics.
An excellent candidate for a source of nonwood fiber material is corn stover (stalks, leaves and husks). Other candidate agricultural residues and fiber crops include, but are not limited to, kenaf, industrial hemp, wheat straw, rice straw, bagasse (sugar cane), seed flax straw, textile flax straw, sisal, hesperaloe and rye grass.
The term “consistency”, as used herein in referring to “reaction consistency” and to “pulp consistency”, denotes percent (%) solids of the pulp slurry.
The term “freeness”, as used herein refer to “pulp freeness”, refers to the drainage rate of pulp, or how “freely” the pulp will give up its water. Freeness is important in papermaking in that, if the freeness is too low, it is not possible to remove enough water on the paper machine to achieve good sheet structure and strength. Often, mechanical pulps have low freeness due to harsh action imparted to the raw material, which produces fines and particles which plug up the draining paper mat. Many chemical pulping processes using whole-stalk (both bast and core) nonwood fiber sources materials have problems with poor freeness, due to over-pulping of the core fraction.
The process of the instant invention does not suffer from the freeness problems of prior art processes. Indeed, the process of the instant invention produces a pulp with high freeness. Particularly, for the instant process, pulp freeness is at least about 400 mL CSF. Preferably, pulp freeness is at least about 550 mL CSF, and more preferably, ranges from approximately 550-650 mL CSF. Accordingly, as used herein, the term “high freeness” is meant to refer to a freeness of at least about 400 mL CSF and above.
Many methods of measuring the degree of delignification have been developed in the art, but most are variations of the permanganate test. The normal permanganate test provides a permanganate or “K number” or “Kappa number”, which is the number of cubic centimeters of tenth normal (0.1N) potassium permanganate solution consumed by one gram of oven dried pulp under specified conditions. It is determined by TAPPI Standard Test T-214. The acceptable Kappa number range will vary depending upon the intended use of the pulp (e.g., the Kappa number requirements for brown paperboard may vary from about 50 to about 90 while the requirements for white paper stock may be less than 5).
There are also a number of methods of measuring pulp brightness. This parameter is usually a measure of reflectivity and its value is typically expressed as a percent of some scale. A standard method is GE brightness which is expressed as a percentage of a maximum GE brightness as determined by TAPPI Standard Method TPD-103. The International Standards Organization (ISO) brightness test is also used. Final pulps produced by the process of the present invention should have a brightness in the 70 to 90% ISO range, preferably in the 80-88% ISO range, and more preferably in the 85-88% ISO range (suitable for use in the manufacture of any printing and writing grade paper).
Therefore, the cost-effective and environmentally benign process of the present invention, via one initial stage of pulping and three subsequent stages of bleaching, converts corn stover and other agricultural residues into high-brightness papermaking pulps of good cleanliness, strength, and drainage rate. The process utilizes whole corn stover (stalks, leaves, husks) without any type of mechanical or chemical depithing and produces pulps having strength properties similar to those from selected hardwood pulps. A total process yield of about 35-40% on corn stalk is equal to or better than total yield values for harsher and more costly pulping and bleaching processes. Finally, the process of the present invention accomplishes this yield using moderate chemical charges, temperatures, and pressures.
Process Stages
To date, there has been no prior art process which makes use of the process steps in the order presented in accordance with the present invention. There are at least two notable differences between the process of the present invention and prior art processes currently attempted on nonwoods.
Firstly, the process of the present invention uses mild or moderate conditions for the pulping of the raw material. Most prior art processes use much higher chemical charges, temperatures, and pressures for pulping stage. While the present co-inventors do not wish to be bound by a particular theory of operation, it is contemplated that the harsh conditions of prior art processes actually make it more difficult to remove lignin from the raw material and may result in the re-depositing of lignin on the fibers.
Secondly, the harshness of ozone as a bleaching agent is well-documented. See e.g., U.S. Pat. No. 5,770,010 issued to Jelks on Jun. 23, 1998, herein incorporated by reference. Indeed, ozone often causes some damage to pulp fibers as it attacks lignin and color-causing molecules. For this reason, ozone has been avoided as a bleaching agent for nonwoods (especially cereal straw), since nonwood fibers are often slender and fragile. However, ozone offers both powerful delignifying and bleaching action in the same stage. Its use in the present inventive process thus facilitates the production of strong, white, and bright pulps from corn stover and other nonwood materials.
Therefore, in a preferred embodiment, the process of the present invention comprises the following steps or stages in the following order:
Mild Alkaline Extraction Stage
This stage uses mild conditions, including a moderate application of alkali, to degrade and/or solubilize a significant portion of the non-cellulosic material (e.g. lignin) in the nonwood fiber source material. Alkali is added to provide a Kappa number of the material after the stage of about 15-20 as this range permits full bleaching to 85-88% ISO brightness with a moderate charge of bleaching chemicals. If lower brightness levels are acceptable, the alkali charge may be reduced, resulting in a higher Kappa number after the alkaline extraction stage.
Thus, typically, a dosage of alkali ranging from about 10% weight to about 30% weight on oven dried fiber (ODF), and preferably from about 12% weight to about 15% weight ODF is applied in this stage. As noted above, the actual dosage will depend on the raw material lignin content and structure, on the desired final brightness level and on the desired bleaching chemical consumption levels.
The source of alkali for the first stage may vary widely, and any suitable source of alkali (sodium hydroxide, potassium hydroxide, calcium hydroxide, ammonium hydroxide, etc.) is contemplated for use in this stage. Sodium hydroxide, a widely-available and inexpensive source of alkali, may be used to produce high pulp brightness and quality. A preferred dosage range for sodium hydroxide is 12-15% weight on ODF, depending on the raw material being treated. Corn stover typically utilizes a dosage of approximately 12%, while denser, more pectinous structures such as wheat straw may require dosages of up to about 20% to about 30% weight on ODF.
Potassium hydroxide may also be used. Its use is contemplated to be an advantage in processing nonwood materials, since nonwood materials have a considerable content of potassium, and could thus serve as a source of makeup chemical for a mill practicing the process of the present invention. If the same dosage is used as is normally used for sodium hydroxide, the lignin content (as measured by the Kappa number) for the treated material will be higher, and the final pulp brightness will be lower at the same bleaching chemical dosages as is normally used after sodium hydroxide digestion. If higher final brightness is desired, the dosage of potassium hydroxide may be increased by about 30% weight on ODF or more than the dosages as are normally used for sodium hydroxide digestion, so that the Kappa number of the pulp after alkaline treatment is lowered to the same level as would be obtained from the use of sodium hydroxide. Alternatively, the amount of bleaching chemical in the ozone treatment or bleaching stages may be increased.
Mild temperature and mild pressure are employed in this stage. Stage temperatures may range from ambienttemperature to about 150° C., preferably from about 50° C. to about 140° C. and more preferably from about 80° C. to about 120° C. Stage pressures may range from about atmospheric to about 30 pounds per square inch gage (psig), from about 5 to about 25 psig, or from about 10 to about 20 psig. Typically, this stage lasts from about 1 to about 120 minutes, including the time associated with heating the nonwood fiber source material to the stage temperature. The material may be held at the stage temperature for about 1 to about 90 minutes, with about 30 to about 60 minutes being preferred.
Approximately 40-50% of the weight of the nonwood fiber source material is lost in this stage. After alkaline extraction/digestion, the nonwood fiber source material is lightly refined or otherwise mechanically worked to separate fiber bundles. After refining, the material is washed to remove chemical residue, which is typically referred to in the art as “black liquor”.
Acid Treatment Stage—with or without Chelation
This stage is employed to both chemically react with residual lignin and to remove metal ions from the pulp, ions which retard subsequent bleaching. The pulp is acidified to an acidic pH to cause the metal ions to be released from the pulp. A chelating agent is optionally applied to tie up the metal ions and render them unable to affect subsequent bleaching stages. The chelating agent may be omitted if higher brightness levels are not required.
The acid or acid chelation treatment stage may be carried out at low pulp consistency in a simple standpipe or flow-through tank or at higher pulp consistency in rotating batch digesters or horizontal tube continuous digesters. The washed and defibered nonwood fiber source material from the alkaline extraction stage is treated with an acid solution to an acidic pH. Stage pH may range from about 0 to about 6, preferably from about 1 to about 5, and more preferably from about 1. 5 to about 3.
Stage temperatures may range from ambient temperature to about 90° C., preferably from about 40° C. to about 80° C. and more preferably from about 50° C. to about 70° C. Typically, this stage lasts from about 1 to about 120 minutes, including the time associated with adjusting the nonwood fiber source material to the stage temperature. The nonwood fiber source material may be held at the stage temperature for about 1 to about 90 minutes, with about 30 to about 60 minutes being preferred and about 20 to about 30 minutes being more preferred.
The source of acid for the second stage may vary widely, and any suitable acid solution is contemplated in accordance with the present invention. For example, mineral acids, such as sulfuric acid, nitric acid, or phosphoric acid, may be used to achieve final high brightness. An organic acid, such as acetic acid, may also be used to achieve final high brightness.
The use of a chelating agent (such as diethylene triamine pentaacetic acid—DTPA) at a moderate dosage in the second stage acid solution is optional. When a chelating agent is utilized, high final brightness may be achieved with a moderate consumption of bleaching agent in the last stage. When it is omitted, the final brightness will be lower, and bleaching agent consumption will be higher. The necessity of the chelating agent is a function of the level of metal ions in the process filtrate, which in turn is a function of the mill water supply, water treatment, and the amount of metals found in the raw nonwood fiber source material. If metal ion content is high, the use of a chelating agent in the acid solution is recommended so that suitable brightness levels may be achieved.
After reaction, the pulp slurry is thoroughly dewatered to a consistency greater than about 35%, but no washing is required. Indeed, the preferred method is for the pulp from the acid treatment to be pressed to about 35% consistency then diluted and sent to the ozone stage. However, washing the pulp at this point also could be employed.
Ozone Treatment Stage
In accordance with the process of the present invention, the acidified nonwood fiber source material proceeds to ozone treatment without a washing step. The omission of the washing step between the acid or acid/chelation stage and the ozone stage eliminates an expensive piece of equipment (a washer), reduces water consumption, and reduces the amount of acid required to achieve the proper pH for the ozone stage.
The ozone treatment stage applies a moderate dosage of ozone, which degrades additional non-cellulosic material and causes a brightness increase in the nonwood fiber source material. Typically, a dosage of ozone of about 0.1 to about 2% weight on ODF ozone, and preferably about 0.4 to about 1% weight on ODF ozone is applied such as by bubbling ozone gas into the acidified nonwood fiber source material slurry. But, the actual dosage of ozone may be altered according to the Kappa number of the incoming pulp and the desired brightness level for the final pulp. As discussed above, the term “Kappa number” denotes a standard test used in the pulp and paper industry to measure residual lignin content of pulp. It is based on the consumption of an oxidant under controlled conditions. A higher Kappa number means that more lignin remains in the pulp, implying that it was pulped or chemically treated more mildly and/or less effectively than a pulp with a lower Kappa number.
In a preferred embodiment, ozonation is done at a low pulp consistency (about 3%). Ozonation at medium and high pulp consistency is also contemplated, given the proper equipment. However, it should be noted that medium-consistency ozonation usually involves the use of high-shear mixing, which may cause fiber damage and drainage rate loss. Similarly, high-consistency ozonation may be non-uniform, causing over-ozonation of certain areas of the fiber and subsequent strength loss. Hence, care should be exercised in the use of medium to high pulp consistency ozonation.
Typically, this stage lasts from about 1 to about 30 minutes, and preferably lasts about 5 to about 15 minutes. Stage temperature is typically maintained at about ambient temperature, e.g., about 25° C. to about 30° C. Indeed, because ozone is more rapidly decomposed at higher temperatures, a preferred embodiment of the present invention involves the lowest possible reaction temperature. Thus, preferably, no heating is applied to the pulp in this stage. Depending on the process steady state temperature, cooling may optionally be provided to the pulp entering the stage or to the filtrate used to provide dilution of the thickened pulp from the acid treatment stage.
Thus, the present invention process utilizes ozone in the third stage to further delignify and brighten the pulp, without serious damage to the pulp fibers and to subsequent sheet strength. Ozone dosage may be readily varied, and the preferred dosage ranges between about 0.4 to about 1.0% weight on ODF. The amount of ozone required is that which produces a pulp with a Kappa number such that the final bleaching stage can increase pulp brightness to the desired final value with a moderate amount of chemical.
In accordance with a preferred embodiment of the present invention, following the ozone stage, the pulp is thoroughly washed then screened and cleaned prior to subsequent bleaching stages.
Bleaching Treatment
This stage uses a moderate application of a bleaching solution, such as an alkaline hydrogen peroxide bleaching solution or a chlorine-based bleaching solution, to complete the removal of substantially all of the non-cellulosic material remaining in the pulp and to increase the pulp brightness to the desired final level. Stage conditions (e.g. temperature and pressure) typically depend on the optimum conditions for a particular bleaching agents. For example, stage conditions may be moderate (e.g. atmospheric conditions—temperatures ranging from about 70° C. to about 90° C.) if bleaching agents such as chlorine-based bleaching agents (e.g. chlorine dioxide, hypochlorite) are used. Additionally, as disclosed below, stage temperatures may be maintained at at least about 100° C., and more preferably, may range from about 105° C. to about 110° C., if an alkaline peroxide bleaching agent is employed.
Typically, the bleaching treatment stage lasts from about 1 to about 120 minutes, including the time associated with adjusting the nonwood fiber source material to stage temperature. The stage temperature is maintained for about 1 to 90 minutes, with about 30 to 90 minutes being preferred.
In accordance with a preferred embodiment of the present invention, hydrogen peroxide is used under pressurized conditions; that is, pressures above atmospheric which permit the bleaching to be done at temperatures of at least about 100° C. (e.g. about 105° C. to about 110° C.). By employing the alkaline peroxide bleaching solution at a temperature of 105-110° C., rather than at an atmospheric pressure temperature of 70-90° C. which nevertheless also may be used, hydrogen peroxide within the solution is able in a single stage and in a moderate amount of time to both remove the bulk of lignin remaining in the pulp and to increase the brightness of the pulp by approximately 30-40 points of ISO brightness. Peroxide stabilizers, e.g. chelants (such as DTPA or DTMPA), sodium silicate, and magnesium sulfate, are also incorporated within the alkaline peroxide bleaching solution. Preferably, after reaction, the pulp is washed thoroughly.
As disclosed in Example 7, the bleaching agent utilized in this stage does not have to be peroxide-based. Rather, any delignifying/brightening chemical agent may be used, although the resulting pulp quality will depend on the specific action of that chemical and process conditions used. In Example 7, chlorine dioxide, a commonly used chlorine-based bleaching agent, was applied. Lignin was effectively removed, as observed with the peroxide bleaching agent, although the final brightness was somewhat lower.
Optional Step—Screening and Cleaning Stage
The use of a screening and cleaning stage between the ozone and bleaching stages, rather than earlier in the process, is also contemplated in accordance with a preferred embodiment of the present inventive process. Placement of the screening stage at this point, rather than after the alkaline extraction stage, reduces loss of material. The intensive dilution employed with the screening also serves as a source of a good wash, thus decreasing the amount of washing in the washing device employed prior to or after the bleaching treatment stage. The intensive dilution/washing may be carried out prior to or after screening, depending on process requirements.
However, the invention is not limited to the use of screening at this point. Rather, the screening stage can be placed after the alkaline extraction stage, and an acceptable pulp would also be produced. Placement of the screening stage can thus depend on the raw material and on the quality and economic requirements for a given mill.
Pulping Schematic
The Figures presented herein have been included to schematically illustrate preferred modes of the invention. Certain aspects of the Figures are described in terms of techniques and procedures found or contemplated by the present inventors to work well in practice of the invention. The schematics presented in the Figures are based upon the use of existing commercially available equipment and machinery. In light of the present disclosure and the general level of skill in the art, those of ordinary skill in the art will appreciate that the schematics presented in the Figures are intended to be exemplary only and that numerous changes, modifications and alterations can be employed without departing from the spirit and scope of the invention. For example, a dry system could be used for fiber preparation instead of the wet system schematically illustrated in FIG. 1, and batch digesters could be employed instead of the continuous digesters schematically illustrated in FIGS. 2 and 3.
Referring now to FIGS. 1-6 of the drawings, where like reference numerals refer to like parts throughout, the process of the present invention is described schematically. In accordance with an object of the present invention, all individual pieces of equipment referred to hereinbelow are readily available commercially from a variety of manufactures, including for example, Sunds Defibrator Co. of Norcross, Ga., and Beloit Corporation of Nashua, N.H.
Referring particularly to FIG. 1, a schematic of an optional fiber preparation stage FP as performed in a preferred embodiment of the process of the present invention is depicted schematically. Stalks of material (e.g. corn stalks) are harvested whole and chopped into pieces 2-4 inches in length (this dimension typically depends on the types of conveyors and feed screws selected). Both core and bast materials are used, without separation. Separated material may be used, if desired, to get more specified properties. The raw nonwood fiber source material is introduced initially into tub grinder 10 for preliminary grinding and is then transferred via conveyor 12 to hydrapulper 14 for washing. The now damp raw nonwood fiber source material is transferred via pump 16 to magnetic separator 18 to facilitate separation of magnetically charged particulates from the raw nonwood fiber source material. The nonwood fiber source material is then introduced into a second hydrapulper 20 for an additional washing step, and then into liquid cyclone centrifuge 24 via pump 22 . The raw nonwood fiber source material is then de-watered via de-watering screen 26 . The cleaned raw nonwood fiber source material is ready for transport to the alkaline extraction stage E of the process of the present invention.
Continuing with FIG. 1, rejects from de-watering screen 26 are filtered through sidehill screen 28 , and the sidehill screen 28 rejects are transported to compactor 30 . Rejects from liquid cyclone centrifuge 24 are transported directly to compactor 30 . Water from sidehill screen 28 is conserved via transport to water tank 32 . Indeed, the environmentally benign aspects of the process of the present invention are illustrated by the recovery of water from sidehill screen 28 and from compactor 30 in water tank 32 . Dilution water may be then pumped from water tank 32 for use as a wash in hydrapulper 14 , or may be treated prior to disposal via effluent treatment device 34 .
Referring now to FIG. 2, the alkaline extraction stage E of a preferred embodiment of the process of the present invention is depicted schematically. Cleaned nonwood fiber pulp from fiber preparation stage FP is introduced via conveyor 36 to digester de-watering screw 38 wherein excess water is removed from the cleaned nonwood fiber pulp. The pulp is then introduced into horizontal tube digester 40 for alkaline extraction of lignin as described in detail herein.
Continuing with FIG. 2, the alkaline-digested nonwood fiber pulp is then introduced into discharge tank 42 and is subsequently pumped via pump 44 into mechanical refiner 46 for gentile mechanical defibering/refining. The alkaline digested nonwood fiber source material is then washed with water in brownstock washer 48 . Brownstock washer 48 is so named because at this point the pulp comprises dark colored cellulosic fibers, or “brownstock”. The nonwood fiber pulp is then ready for introduction into the acid and ozone treatment stages A and Z of the process of the present invention.
Continuing with FIG. 2, filtrate from brownstock washer 48 (called “weak black liquor”) is collected in into weak black liquor tank 50 and filtered using weak black liquor filter 52 . The weak black liquor may then be disposed of via chemical recovery procedures; may be re-introduced into digester 40 ; may be re-introduced into discharge tank 42 for use in dilution of the pulp; or may be re-introduced into refiner 46 via pump 44 as a contingency control. Any fiber reclaimed from weak black liquor filter 52 is re-introduced into discharge tank 42 for reincorporation into an alkaline-extracted nonwood fiber pulp and subsequent acid treatment.
Referring now to FIG. 3, an acid treatment stage A and an ozone treatment stage Z of a preferred embodiment of the process of the present invention are depicted schematically. The alkaline-digested nonwood fiber source material is transported via conveyor 54 to digester de-watering screw 56 forde-watering and subsequent introduction into horizontal tube digester 58 for acid treatment as described herein.
The acidified nonwood fiber source material is then introduced into screw press 60 to be pressed to about 35% pulp consistency. The pulp is then introduced to discharge/dilution tank 64 for dilution and transport to ozone treatment stage Z. A pressate solution from screw press 60 is collected within pressate tank 62 for reuse in horizontal tube digester 58 .
Continuing with FIG. 3, the acidified nonwood fiber pulp is pumped via pump 66 into static mixer 68 and upflow bleach tower 70 where ozone gas is introduced as described herein. The ozone-bleached nonwood fiber pulp is then washed in washer 72 and transported for screening and cleaning as described below. Filtrate from washer 72 is collected in weak black liquor tank 74 for reuse in washer 72 , pump 66 , discharge tank 64 , or horizontal tube digester 58 . Optionally, filtrate from weak black liquor tank 74 can be discharged for effluent treatment and disposal.
Referring now to FIG. 4, a screening and cleaning stage SC of a preferred embodiment of the process of the present invention is depicted schematically. The bleached nonwood fiber source material from ozone treatment stage Z is introduced into feed chest 76 and subsequently pumped via pump 78 to sand cleaner 80 . Rejects from sand cleaner 80 are recovered for disposal. The nonwood fiber source material then passes through multi-stage screens 82 and through multi-stage cleaners 86 . Reject materials are recovered from multi-stage screens 82 and multi-stage cleaners 86 and collected in screening reject tank 84 and cleaner reject tank 88 for reuse in alkaline stage digester 40 (FIG. 2) or for disposal via effluent treatment device 34 (FIG. 1 ), respectively. The nonwood fiber pulp is then thickened in thickener 90 for subsequent introduction into the bleaching stage B of the process of the present invention as described below.
Continuing with reference to FIG. 4, a white water filtrate is obtained from thickener 90 and is collected in thickener filtrate tank 92 . Fresh water and excess paper machine white water are also collected in thickener filtrate tank 92 and pumped via pump 94 to multi-stage cleaners 86 for reuse as dilution water or to water tank 32 (FIG. 1) for storage and reuse as dilution water in hydrapulper 14 (FIG. 1 ).
Referring now to FIG. 5, a bleaching stage B of a preferred embodiment of the process of the present invention is depicted schematically. The nonwood fiber pulp from screening and cleaning stage SC is introduced along with steam to steam mixer 96 . The nonwood fiber pulp is then pumped via pump 98 into downflow bleach tower 100 . A bleaching solution as described herein is also introduced via pump 98 into downflow bleach tower 100 , and the nonwood fiber pulp is treated at above atmospheric pressure with the bleaching solution as described herein.
Continuing with FIG. 5, after bleaching, the nonwood fiber pulp is pumped via pump 102 into a washer 104 wherein the nonwood fiber pulp is washed with water. The nonwood fiber pulp, now a suitable paper-making pulp having the brightness and freeness characteristics described herein, is pumped via MC pump 108 to a high density storage tank 110 . Filtrate from washer 104 is collected in filtrate tank 106 . The collected filtrate is then reused as a dilution liquid in pump 102 , or is discarded via chemical recovery or effluent treatment procedures.
Referring now to FIG. 6, an alternative embodiment of the present invention is depicted schematically. Particularly, an alternative acid treatment stage A′ and ozone treatment stage Z′ of the process of the present invention are depicted schematically. Alkaline-extracted nonwood fiber pulp is introduced into dilution tank 200 for dilution to a pulp consistency of about 5 to 10%. The diluted nonwood fiber pulp slurry is introduced into chemical mixer 202 along with an acid solution comprising a chelant in accordance with the present invention, and then into stand pipe 204 for acid treatment as described herein. The acid treated nonwood fiber pulp is then introduced into discharge/dilution tank 210 via screw press 206 . A pressate solution is recovered from screw press 206 and stored in pressate tank 208 for reuse in chemical mixer 202 if desired.
Continuing with FIG. 6, the acid treated nonwood fiber pulp is again diluted to a pulp consistency of about 3 to about 10% and then introduced into upflow bleach tower 216 via pump 212 and static mixer 214 . Ozone gas is introduced into static mixer 214 along with the acid-treated nonwood fiber pulp for ozone treatment in upflow bleach tower 216 as described herein. Following ozone treatment, the nonwood fiber source material is washed in washer 218 with distilled water. The acid- and ozone-treated nonwood fiber pulp then proceeds to the screening and cleaning stage SC of the present invention as described above and as depicted schematically in FIG. 4 .
Continuing with FIG. 6, a filtrate from washer 218 is collected in weak black liquor tank 220 for subsequent reuse in washer 218 , for use in controlling the consistency of the nonwood fiber pulp as it is pumped from discharge tank 210 into static mixer 214 via pump 212 , or for disposal via effluent treatment.
EXAMPLES
The Examples presented below have been included to illustrate preferred modes of the invention. Certain aspects of the Examples are described in terms of techniques and procedures found or contemplated by the present inventors to work well in the practice of the invention. The Examples are exemplified through the use of standard laboratory practices of the inventors. In light of the present disclosure and the general level of skill in the art, those of ordinary skill in the art will appreciate that the Examples are intended to be exemplary only and that numerous changes, modifications and alterations can be employed without departing from the spirit and scope of the invention.
EXAMPLE 1
Corn Stover—Acid Stage Using Nitric Acid
Air-dried whole corn stover (not depithed) was chopped into about 1- to about 3-inch lengths and soaked in tap water for 30 minutes to provide a washing action. This material was placed into a rotating pressure reactor and treated under the following conditions:
Alkaline Extraction Stage:
12% sodium hydroxide (NaOH) on
ODF
8:1 liquor-to-fiber ratio
Maximum temperature: 115-118° C.
Time to temperature: 30 minutes
Time at temperature: 60 minutes
After this stage, the free liquor was drained from the material. The drained material was passed through a twin-disk refiner with a plate clearance of 0.035 inches to promote defibration. After refining, the resulting pulp was washed thoroughly. The washed pulp was then treated under the following conditions:
Acid Chelation
5% nitric acid on ODF
Stage:
Starting pH 1.4
DTPA 0.5% on ODF (chelant)
5:1 liquor-to-fiber ratio
Temperature: 80° C.
Time at temperature: 60 minutes
After this stage, the free liquor was drained from the material by centrifuging to a consistency of approximately 35%. The material was immediately placed into a sealed reactor with a vigorous mixing rotor, diluted with distilled water to 3% consistency, and the pH was adjusted with sulfuric acid to 1.5.
Ozone gas was then bubbled into the mixing slurry. The following conditions were used for the ozone stage:
Ozone Stage:
3% consistency
Initial pH: 1.5
Temperature: 30° C.
Ozone dosage: 0.7-0.9% on ODF
Reaction time: 10 minutes
At the end of the reaction, the pulp was screened in a vibrating flat screen equipped with 0.010-inch slots. The accepts from the screen were furtherwashed with distilled water. The pulp was centrifuged to remove excess water and was then treated under the following conditions:
Bleaching Stage:
12% consistency
Sodium hydroxide dosage: 5% on ODF
Hydrogen peroxide dosage: 4% on ODF
DTMPA (high-temperature chelant)
dosage: 0.2% on ODF
Magnesium sulfate dosage: 0.5% on ODF
Sodium silicate dosage: 0.5% on ODF
Temperature: 105° C.
Reaction time: 90 minutes
The following results were obtained:
Kappa after first alkali stage: 20.1
Final pulp:
Brightness: 87.4% ISO
Freeness: 619 ml CSF
Kappa number: 1.3
Total yield: 39.1%
Peroxide dosage consumption: 89.3%
Strength properties, after refining in a PFI mill, were obtained as shown in Table 1.
TABLE 1
Strength and Optical Data
Bleached Corn Pip (87-88 ISO)
Averages are shown, with standard deviation values in parentheses.
PFI Revolutions
0
750
1500
3000
Freeness, ml CSF
619
350
208
92
Basis Weight, g/m 2
62.6
64.4
64.1
63.2
Caliper, mils
3.69
3.42
3.11
3.15
Apparent Density, g/cm 3
0.668
0.741
0.811
0.790
Bulk, cm 3/g
1.50
1.35
1.23
1.27
Brightness, % ISO
87.4
87.4
87.4
87.4
TAPPI Opacity, %
65.8
59.4
52.4
44.3
(0.90)
(2.2)
(1.0)
(1.3)
Printing Opacity, %
67.0
60.7
55.4
49.4
(1.3)
(1.7)
(1.2)
(2.6)
Tear Factor, dm 2
75.9
48.0
47.7
54.4
(9.9)
(5.9)
(8.0)
(13.9)
Burst Factor, g f /cm 2 /
31.1
48.6
52.4
61.7
g f /m 2
(1.5)
(3.4)
(4.4)
(3.4)
Tensile Breaking Length,
5.02
7.15
6.70
6.10
km
(0.16)
(0.28)
(0.39)*
(0.91)*
% Stretch
3.06
2.78
2.52
2.12
(0.28)
(0.37)
(0.45)
(0.74)
Tensile Energy
71.0
89.0
76.0
58.4
Absorption, J/m 2
(8.4)
(15.6)
(20.5)
(30.1)
*The tensile test samples for 1500 and 3000 revolutions broke at the clamp.
Kajaani FS-200 Fiber Length Distribution Data
Bleached Mixed
Bleached
Southern
Corn Pulp
Hardwood Market Pulp
Arithmetic avg. length, mm
0.44
0.40
Weight-weighted avg. length,
2.06
1.36
mm
Length-weighted avg. length,
1.09
1.00
mm
Coarseness, mg/m
0.106
—
P (fines) fraction, number %
41.32
58.64
EXAMPLE 2
Corn Stover—Acid Stage Using Nitric Acid Without Chelating Agent
The conditions for this Example were identical to those for Example 1, except that the DTPA chelating agent in the acid treatment stage was omitted. The following results were obtained:
Kappa after first alkali stage: 20.1
Final pulp:
Brightness: 82.9% ISO
Freeness: 575 ml CSF
Kappa number: 1.2
Total yield: 39.6%
Peroxide dosage consumption: 99.1%
EXAMPLE 3
Corn Stover—Acid Stage Using Acetic Acid
The purpose of this Example was to demonstrate the use of a milder, organic acid (e.g. acetic acid) in the present inventive process, to obtain results similar to those obtained by using a strong mineral acid. The conditions for this Example were identical to those for Example 1, except that acetic acid was used instead of nitric acid in the acid treatment stage, and 25% acid on ODF was added to achieve an initial pH of 3.4. The following results were obtained:
Kappa after first alkali stage: 20.1
Final pulp:
Brightness: 86.2% ISO
Freeness: 572 ml CSF
Kappa number: 1.5
Total yield: 38.2%
Peroxide consumption: 97.3%
EXAMPLE 4
Corn Stover—Acid Stage Using Sulfuric Acid
The purpose of this Example was to demonstrate the use of sulfuric acid, the cheapest and most predominant industrial acid, in the acid treatment stage of the present inventive process, using milder process conditions as compared to those used for wood-based acid chelation. The conditions for this Example were identical to those for Example 1, except that the following conditions were used in the acid treatment stage:
Acid Treatment stage:
Sulfuric acid to initial pH 1.5
Consistency 6%
Temperature: 60° C.
Time: 30 minutes
The following results were obtained:
Kappa after first alkali stage: 20.5
Final pulp:
Brightness: 88.0% ISO
Freeness: 594 ml CSF
Kappa number: 1.7
Total yield: 35.7%
Peroxide dosage consumption: 99.1%
EXAMPLE 5
Corn Stover—Alkaline Stage Using Potassium Hydroxide
The purpose of this Example was to demonstrate the use of potassium hydroxide, an alkali source with contemplated environmental benefits, in the present inventive process. The conditions for this Example were identical to those for Example 4, except that 15.6% potassium hydroxide was charged on ODF in the alkaline extraction stage. The following results were obtained:
Kappa after first alkali stage: 24.2
Final pulp:
Brightness: 84.6% ISO
Freeness: 570 ml CSF
Kappa number: 2.6
Total yield: 41.8%
Peroxide consumption: 94.8%
EXAMPLE 6
Wheat Straw
The purpose of this Example was to demonstrate the effectiveness of the present inventive process on other promising agricultural residues, in this case, wheat straw. Air-dried wheat straw was chopped into 2-3-inch lengths. Other process conditions were identical to those used for Example 4. The following results were obtained:
Kappa after first alkali stage: 32.0
Final pulp:
Brightness: 70.0% ISO
Freeness: 476 ml CSF
Kappa number: 10.2
Total yield: 37.8%
Peroxide dosage consumption: 98.6%
As anticipated, the more dense and more pectinous nature of the wheat stalk makes it more difficult for the alkali to penetrate and react under the conditions used in the alkaline digestion stage, resulting in a higher Kappa number than that observed for the corn stover. The higher Kappa number typically does not permit the higher final brightness values to be achieved, and the final Kappa number is significantly higher than for corn stover. It is contemplated that increasing the application of ozone and/or peroxide permits a higherfinal brightness to be achieved. Similarly, the amount of alkali charged in the alkaline extraction stage may be increased to reduce the Kappa number to the value of approximately 20 that was obtained for corn stover. It is also contemplated that the use of a shredding device or other device able to mechanically open up the straw stem structure permits better reaction of alkali with the raw material, thereby decreasing the Kappa number after the alkaline extraction stage and improving final brightness.
EXAMPLE 7
Wheat Straw—Chlorine Dioxide Bleaching Agent in the Bleaching Stage
The purpose of this Example was to demonstrate that other bleaching agents may be used in the bleaching stage of the present inventive process. Instead of hydrogen peroxide, chlorine dioxide was used under the following conditions:
Chlorine Dioxide
3.5% consistency
Stage:
Initial pH: 3
Temperature: 50° C.
Chlorine dioxide dosage: 3.1% on OD fiber
Reaction time: 60 minutes
Other process conditions were identical to those used for Example 4. The following results were obtained:
Final pulp:
Brightness: 52.6% ISO
Freeness: 426 ml CSF
Kappa number: 11.0
Total yield: 36.3%
Chlorine dioxide dosage consumption: 99.5%
The application of chlorine dioxide resulted in a reduction in Kappa number and an increase in brightness, although the effect at this dosage was lower than that observed with peroxide bleaching. Clearly, more chlorine dioxide may be applied, and it is contemplated that the amount may optionally be doubled, thereby decreasing the Kappa number and increasing the final brightness to a value of at least about 80 ISO.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims. | A process for producing a pulp suitable for papermaking from a nonwood fiber source material. Representative nonwood fiber source materials include corn stover and wheat straw. The process includes the steps of providing a nonwood fiber source material; digesting the nonwood fiber source material with an alkaline pulping solution at at least about atmospheric pressure; reducing the pH of the nonwood fiber source material to an acidic pH with an acid solution; treating the nonwood fiber source material having an acidic pH with ozone; and treating the nonwood fiber source material with a bleaching solution to form a papermaking pulp. | 3 |
This is a division of application Ser. No. 07/207,484, filed Jun. 16, 1988.
BACKGROUND OF THE INVENTION
The present invention relates to an automatic exchanging apparatus for exchanging cops in a shuttle-type loom. More particularly, the invention relates to an automatic cop exchanging apparatus for exchanging an old cop received in a shuttle with warp threads for a new cop.
In general, in a conventional loom employing shuttles, opening operations for repeatedly separating the wefts into upper and lower groups are repeatedly performed, while simultaneously the shuttle incorporating therein the warps is passed between the upper and lower wefts in synchronism with the opening operation. For example, as shown in FIGS. 2A and 2B, the conventional shuttle 1, which has generally a boat-like shape, has a recess 1a which receives an elongated cop 2 around which the threads of the weft 4 are wound. A tong is provided in a rear portion of the recess 1a mounted so as to be rotatable through about 90° so as to be movable from a horizontal position to a vertical position. The cop 2 is received in a horizontal position within the recess 1a under the condition that the tong 3 is inserted into a hole 2a formed in the bottom of the cop 2. Then, the wefts 4 are extracted to the outside through a hole 1b formed in the front portion of the shuttle 1.
With this construction, the amount of weft 4 held within the shuttle 1 decreases as the shuttle performs its reciprocating motion. When the weft has been completely consumed, it is necessary to stop the operation of the machine. Therefore, in the conventional machine, when it is observed that the remaining amount of the weft 4 is small, the operator, who, for this purpose, must stand by the machine, must manually perform the exchange of cops. That is, the weft of the old cop, which has nearly been expended, is cut and the old cop manually removed from the shuttle 1. Then, a new cop is loaded into the shuttle 1, and the new and old threads are tied together.
Generally, therefore, it is necessary that an individual operator be assigned to each loom during its operation since the cops 2 must be replaced frequently. This of course is a major factor in the total labor costs for operating the loom. Also, since looms employing high speed shuttles are inherently very noisy, the operator may fatigue easily.
Thus, it is desirable to reduce the cost of operating a loom while simultaneously improving the quality of the working environment around the loom. In the prior art, however, due to the complexities of the operations involved in handling the threads, automation of the cop-replacing operation had not been attained.
SUMMARY OF THE INVENTION
Overcoming the above-discussed drawbacks of the prior art, the invention provides an automatic cop exchanging apparatus for exchanging a cop on which weft yarn is wound in a loom in which a shuttle is passed between upper and lower warps. The automatic cop exchanging apparatus includes a hand for gripping a cop, a rotary arm plate on which the hand is mounted, drive means for rotating the rotary arm plate and for straightly moving the rotary arm plate in an axial direction of rotation, and a drive shaft for moving the rotary arm plate to an exchange position for the cop.
Further, the invention provides an automatic cop exchanging apparatus for exchanging a cop on which weft yarn is wound in a loom for producing woven material in which a shuttle is passed between upper and lower warps, the apparatus including cop pick up means for picking up a new cop and delivering the new cop to a predetermined position, cop setting means for picking up an old cop within the shuttle, receiving the new cop delivered by the pickup means, and setting the new cop in the shuttle, thread processing means for processing the threads of the new and old cops by making the threads of the new and old cops coincide in position, tying means for tying the ends of the threads together, and reel means for diffusing positions of the knot portions of the tied threads through woven material.
In accordance with another aspect, the invention provides an adjusting device for a loom in which weaving is effected by passing a shuttle containing a cop around which a weft yarn is wound between upper and lower warp yarns, the adjusting device including a disc-shaped reel provided with circumferential channel parts for accommodating a wound thread thereon, thread holding means projecting outward of the circumferential channel parts of the reel for holding threads, and hooking means for hooking the threads held by the holding means and rotating the threads so as to twist the threads, thereby winding the twisted threads onto the circumferential channel parts of the reel.
In accordance with still another aspect, the invention provides a thread tying apparatus including a pair of gripper claw means for gripping old and new threads at two respective locations, and then performing a rotating and retracting movement to form crossing points in the threads, pressing lever means for locating the crossing points to one side, and gripping claw means for gripping a part of the threads located on the one side and tensioning the threads to tie a single-bundle knot with the old and new threads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagonal view of a loom and automatic cop-replacing apparatus constructed in accordance with the present invention.
FIGS. 2A and 2B are sectional views of a shuttle with a cop placed therein, of which FIG. 2A shows the vertical posture of the cop at the time of its replacement while FIG. 2B shows the state of a cop accommodated inside the shuttle.
FIG. 3 is a front view of a cop-unloading apparatus; FIG. 4 is a sectional view of the cop-unloading apparatus of FIG. 3.
FIG. 5 shows a front view showing relations in the arrangement of the various apparatuses, including the cop unloading apparatus and the setting apparatus, as installed on a frame pedestal, shuttle box, and thread-tying apparatus.
FIGS. 6 through 8 illustrate a grasping device for the cop-unloading apparatus.
FIG. 9 is a right side view of the cop unloading apparatus.
FIG. 10 is a right side view of a delivery apparatus located in a position for receiving a cop.
FIG. 11 is a right side view showing the delivery apparatus in the course of operation.
FIG. 12 is a front view of the delivery apparatus illustrated in FIG. 11.
FIG. 13 is a right side view of the setting apparatus with one part thereof cut away.
FIG. 14 is a sectional view of the apparatus of FIG. 13 taken along a line XIV--XIV.
FIG. 15 is a plane view of the secondary shaft and the rotating arm plate for the setting apparatus.
FIG. 16 shows a sectional view of a top portion of the setting apparatus in the proximity of a third shaft and a fourth shaft.
FIG. 17 is a front view showing a thread-tying apparatus and a new and existing thread drawing apparatus at points above the shuttle race.
FIG. 18 is a sectional view. as viewed from the right side, showing the thread-tying apparatus and the shuttle draw-out apparatus installed on the shuttle race.
FIG. 19 is a schematic plane figure showing the relationship between the reel apparatus and the position of knots in the thread.
FIG. 20 is a sectional view of a reel apparatus used as a thread-adjusting apparatus for the automatic cop-replacing apparatus.
FIG. 21 is a drawing of the reel for the same reel apparatus of FIG. 20 viewed from the shuttle race side.
FIG. 22 is a front view of an existing thread drawing apparatus used as a thread-processing apparatus.
FIG. 23 is a right side view of the thread-drawing apparatus.
FIG. 24 is a front view of a thread drawing apparatus employed as a thread-processing apparatus.
FIG. 25 is a right, side view of the thread drawing apparatus of FIG. 24.
FIG. 26 is a sectional view of the base body for the thread drawing apparatus of FIG. 24.
FIG. 27 is a sectional view of FIG. 26 taken along a line XXVII--XXVII.
FIG. 28 is a sectional view of the thread-tying apparatus as viewed from the front side.
FIG. 29 is a front view of the thread-tying apparatus: FIG. 30 is a right side view of the thread-tying apparatus.
FIG. 31 is a sectional view showing a driving mechanism for a gripping claw.
FIG. 32A is a plane view of the knot of a new thread and existing thread as tied in a "single bundle knot".
FIG. 32B is a rear view of the same knot as illustrated in FIG. 32A: and
FIGS. 33 through 41 are diagonal views showing the forward end part of the thread-tying apparatus, which drawings are "action-illustrative" drawings showing in sequence steps performed by the apparatus in making a "single bundle knot" of the threads.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description will now be given with reference to FIG. 1 and subsequent figures of an automatic cop-replacing apparatus 10 constructed in accordance with the teachings of the present invention.
The loom L in this example is capable of performing hollow weaving of thick felt for use in paper making, with two types of weft accommodated inside of the two shuttles 1, the latter being reciprocated over a shuttle race 12 while a shuttle box 11 is moved upward and downward in synchronization with the shedding motion of the warp. A detailed description of the elements is, however, omitted here since they are essentially the same as in the conventional loom.
In this embodiment, the loom is provided with an automatic cop-replacing apparatus, which is operated for automatically replacing the cop in the shuttle 1 with the aim of achieving a higher working efficiency. A detailed description of the construction and operation of each of the component parts of the inventive automatic cop replacing apparatus will now be given with reference to the general diagonal view drawing in FIG. 1 and other drawings showing individual parts.
As illustrated in FIG. 1, the frame pedestal 13 is provided on one side of the shuttle race 12. In this figure, the position of the frame pedestal 13 is shown shifted in order to clearly illustrate the construction and positional relations of the various elements. In the actual arrangement, the front side of the frame pedestal 13 in the longitudinal direction is parallel to the shuttle race 12, as shown by an arrow (a) in the figure, and the central part of the front side of the frame pedestal 13 is in a position approximately opposite to the end part of the outer side of the shuttle box 11, as illustrated also in FIG. 5.
(A) Cop-Unloading Apparatus
On the frame pedestal 13 is installed a cop-unloading apparatus (A), which takes out the cop 2 accommodated in the prescribed position and transports the same by grasping and moving its hand in directions crossing each other at right angles.
As illustrated in FIGS. 3 to 5, the frame structure 14 is installed solidly on the upper surface of the frame pedestal 13 along the longer side of the frame pedestal, this side being positioned apart from the shuttle race 12. Between the pillar members 14a of the frame structure, two guide shafts 15 are set and fixed parallel with each other. At a point midway between the two guide shafts 15, a driving screw shaft 16 is installed in parallel with the guide shafts 15 in such a manner as to permit its free rotation. One end of the screw shaft 16 is connected for interlocking motion with the motor M1 installed securely on the outer side of one pillar member 14a. On the above-mentioned guide shaft 15 is provided an X slider 17 mounted in such a manner as to permit its free sliding motion, with the screw shaft 16 meshing with the nut part 17a fixed in the center of the X slider 17. Therefore, the apparatus is constructed so that the X slider 17 moves freely in the X direction along the guide shaft 15 when the motor M1 is rotating,
Between the pillar members 14a of the frame structure 14 mentioned above, a beam member 18 is arranged fixed in the horizontal direction at a position lower than the above mentioned guide shaft 15. This beam member 18 is made of a channel bar with the channel facing upward. As illustrated in FIG. 3, is provided a cable holder 17b for protecting the cable led out of the X slider 17. In the same channel, a plural number of positioning members 19 are provided at predetermined intervals, as illustrated in FIG. 3 and FIG. 4. Also, on the lower end surface of the X slider 17, a proximity switch 20 is provided facing each positioning member 19. Thus, when the X slider 17 is to be moved, it is possible to move the X slider 17 through the prescribed length in the X direction by the use of a detection signal which the proximity switch 20 generates for each positioning member 19. Furthermore, limit switches LS1, LS2 are respectively provided on both ends of the beam member 18, these switches establishing the range of movement of the X slider 17 in the X direction.
On the above-mentioned X slider 17, two guide shafts 21 have their respective one ends set solidly in parallel to each other in the direction where they cross the above mentioned two guide shafts 15 and the screw shaft 16 at right angles. On the other ends of the two guide shafts 21 is fixed a supporting plate 22 having a longer vertical side, and a roller 22a is set in such a way as to permit its free rolling motion on the rail member 23 provided on the frame pedestal 13 so that the roller is parallel to the frame structure 14.
At a point midway between the two guide shafts 21 mentioned above, a drive shaft 24 is provided in parallel with the guide shafts 21. The two ends of the drive shaft 24 are supported with bearings provided on the above-mentioned X slider 17 and supporting plate 22. One end of the drive shaft on the X slider 17 side projects into the area outside the X slider 17. This protruding end of the drive shaft has a pulley 25 fixed thereon, the pulley being connected with a belt 27 for interlocking motion with the output pulley 26 of the motor M2. On the above-mentioned guide shaft 21 is provided a Y-slider 28 mounted in such a way as to permit its free sliding motion. The drive shaft 24 is meshed with a nut part 28a set securely in the center of the Y slider 28. Therefore, when the drive shaft 24 is rotated by the motor M2, the Y slider 28 can move along the two guide shafts 21 in the Y direction, which crosses at right angles with the X direction, i.e., the moving direction of the X slider 17 mentioned above. As shown in FIG. 4, a connecting plate 29 is provided across and fixed between the lower end part of the supporting plate 22 and the lower end of the X slider 17 mentioned above. On the connecting plate 29 are provided a plural number of positioning members 30 at prescribed intervals, Furthermore, a proximity switch 31 is provided on the lower end surface of the Y slider 28 mounted at a point opposite the positioning members 30. It is possible to move the Y slider 28 by a prescribed length in the Y direction, using the detection signals which the proximity switch 31 generates in response to the individual positioning members 30. Also, limit switches 3LS and 4LS are provided on the ends of the connecting plate 29, these limit switches establishing the range of movement of the Y slider 28 in the Y direction.
The Y slider 28 is provided with a grasping device or the like for taking up the cop 2 and moving it upward or downward in the perpendicular direction. As shown in an enlarged view in FIGS. 6 to 8, the Y slider 28 is fitted with the barrel of the cylinder CY1 set in the vertical upsidedown position by way of a mounting jig. At the top end (i.e., the lower end) of the rod of the cylinder CY1 is fixed a mounting plate 32 bent in an "L" shape in the downward direction. On the lower portion of the mounting plate 32 is provided a driving source 33, the lower end of which is fitted with a hand, or jaw HA1 for gripping and holding the head part of the cop 2. This hand HA1 is provided with another hand HA2 by way of a pair of bars 34 so that the hand HA2 can grip and hold the rubber cap fixed at the top part of the cop 2 while holding the end part of the thread.
As illustrated in FIGS. 3 to 5, an area on the upper area of the frame pedestal 13 between the frame structure 14 and the rail member 23 is designed so as to accept the installation of containers 35 which accommodate many pieces of the cop 2. The positions for the installation of the individual containers 35 in relation to the apparatus for taking out the cop 2 are determined by the positioning plate 13a, etc. provided on the frame pedestal 13. Many short bars are hung in a matrix state on the inside bottom area of each container 35 in such a way that the intervals thereof are equal to the intervals of the arrangement of the abovementioned positioning members 19, 30, with respect to each of the X direction and the Y direction, each of said short bars 35a being inserted in a respective hole 2a in the bottom part of the cop 2, thereby holding each cop 2 in its prescribed position. In this embodiment, the hand HA1 provided on the Y slider 28 will be set directly above the cop 2, located in a position corresponding to the desired position mentioned above, when the X slider 17 and the Y slider 28 are set in their desired positions by means of the two positioning members 19, 30 and the proximity switches 20, 31. In this embodiment, moreover, different kinds of weft may be put respectively in the two shuttles, and the two containers 35 are designed so as to be capable of accommodating differentiated cops 2 with respectively different types of thread wound therearound.
With the cop-taking apparatus (A) arranged as described above, it is possible to move the hands HA1 and HA2 to the desired positions by moving the X and Y sliders 17, 28 by the driving of the two motors M1, M2 utilizing the signals from the two proximity switches 20, 31. Furthermore, it is possible to grasp and take up the head part of the desired cop 2 and to transport it for the subsequent process.
(B) Delivery Apparatus
This apparatus, provided in a position on the frame pedestal 13 between the cop-taking apparatus (A) described above and the cop-setting position to be described in (C), receives the cop 2 by grasping its bottom part as the cop 2 is brought to it, being transported with its head part grasped by the cop-taking apparatus (A), and then delivers the cop to the cop-setting apparatus (C) in the subsequent process.
As shown in FIG. 9, the barrel of the cylinder CY2 is fixed on the frame pedestal 13, with the top of the rod being directed towards a diagonally upper point. As illustrated in FIGS. 10 to 12, the base part member 36 is fixed at the top of the rod for the cylinder CY2. A plate piece part 36a of this base part member 36 is provided with an oscillating member 38 by way of the shaft member 37, and a hand HA3 is provided at the forward end of the oscillating member 38. A plate member 38a approximately triangular in shape is provided on the side of the oscillating member 38, and the other end of the spring 39, one end of which is attached to the protrusion on the inner side of the plate member 38a, is attached to the mounting piece 36b provided on the side of the plate member 38a of the base part member 36. On the upper part of the forward end of the plate piece part 36a for the base part member 36 is provided a stopper 36c having a protrusion extending towards the side of the oscillating member 38. Consequently, in a state such as that in FIG. 11 where the rod of the cylinder CY2 remains extended, the oscillating member 38 is constructed so as to be moved upward by the force of the spring 39, coming into contact with the stopper 36c, and the hand HA3 is turned in the same direction as the rod for the cylinder CY2. Also, the upper-side mounting jig 40, securing the cylinder CY2 on the frame pedestal 13, has an arm-shaped plate body 40a fixed thereon. The forward end of the plate body is provided with a cam follower 40b, which contacts the periphery of the abovementioned plate member 38a and which is installed in such a manner as to permit its free rotating motion. Accordingly, the plate member 38a comes into contact with the cam follower 40b as the rod of the cylinder CY2 is drawn into the cylinder, and performs a rotating movement in the direction in which it stretches the spring 39. It is constructed so that the oscillating member 38 and the hand HA3 move downward together with the plate member 38a in their rotational movement centering around the shaft member 37, the hand HA3 assuming a horizontal position as shown in FIG. 10 when the rod is completely drawn into the cylinder. Moreover, FIG. 41 shows an apparatus for holding down the end of the weft lest it should come apart when the hand grasps the cop.
With the delivery apparatus (B) having the construction as described hereinabove, it is possible to receive the cop 2 from the above-discussed cop-taking apparatus (A) in the position where the hand HA3 assumes its horizontal posture with the rod being drawn into the cylinder, as shown in FIG. 9, and to deliver the cop 2 to the setting position (C) (to be described later in detail) in the upper position to which the rod is extended (as shown by a dotted line).
(C) Cop-Setting Apparatus
As illustrated in FIG. 5, a setting apparatus for the cop 2 (C) is installed on the frame pedestal 13 adjacent the cop-taking apparatus (A) As FIGS. 13 and 14 indicate, the primary driving shaft 43 (hereinafter referred to as the primary shaft 43) is held by a pair of bearings 42a in such a way as to permit its free rotational motion on the mounting frame 42 installed rigidly on the frame pedestal 13. One end of the primary shaft 43 protrudes into the outer area, penetrating through one of the bearings, i.e., bearing 42a. The motor M3 is installed on the frame pedestal 13 via another mounting frame 44 in a position adjacent that of the mounting frame 42. One end of the primary shaft 43 is connected for interlocking operation with the output shaft of the motor M3 by way of a joint. A base plate 46 rectangular in shape is solidly fixed via a bracket 45 to the primary shaft 43. The lower forward part and lower rear part of the base plate 46 are respectively provided with a stopper member 46a. Moreover, the mounting frame 42 mentioned above is provided with shock absorbers 47 arranged in such a way that they severally come into contact with the respective two stopper members 46a. Therefore, the base plate 46 and the members installed on the base plate 46 are constructed so that they can perform their oscillating motion within the prescribed angle range, moving around the primary shaft 43.
On the above-mentioned base plate 46 are fixed a pair of supporting blocks 48 each having a bearing. On the bearings of the supporting blocks 48, a second driving shaft 49 (hereinafter referred to as the second shaft 49) is installed in such a way as to permit its free rotational motion, the second shaft 49 being set so as to cross the above-mentioned primary shaft 43 at a right angle. The rear end of the second shaft 49 is connected for interlocking operation via a joint with the output shaft of the rotary actuator 50 installed solidly on the base plate 46 by way of the bracket 50a. The rear end of the rotary actuator 50 is provided with a proximity switch for detecting the rotational angle of the second shaft 49 and a stopper, etc, for setting the range of the rotational movement of the secondary shaft 49.
As shown in FIG. 9, the second shaft 49 is designed so that it has a length sufficient for it to reach the position where the cop 2 is to be replaced on the shuttle race 12 of the loom. A housing approximately in a box shape is fixed at the forward end of the secondary shaft 49. As illustrated in FIG. 16, a shaft case 52 in a cylindrical shape is fixed on the outer wall of the housing 51 in such a manner that the secondary shaft 49 and the shaft line cross each other at a right angle. In the inside of the shaft case 52 is provided a third driving shaft 53 (hereinafter referred to as the third shaft 53) mounted by way of a pair of bearings in such a way as to permit its free rotational motion and also to prevent movement of the shaft in the axial direction. The third shaft 53 is cylindrical in shape. A boss 53a with spline thread provided on its inner circumference is inserted and fixed in the opening in the upper end of the shaft. This boss has a spline shaft 54, which serves as a fourth driving shaft (hereinafter referred to as the fourth shaft 54), inserted in it in the axial direction in such a manner as to permit its free sliding motion.
As shown in FIG. 15 and FIG. 16, a revolving arm plate 55 in the shape of a windmill with three arms 55a is mounted via a bush 56, etc., at the top of the fourth shaft 54. The revolving arm plate 55 is arranged within a plane perpendicular to the axial line of the third shaft 53 and the fourth shaft 54. On the forward end of each of the arms 55a is provided a hand HA4 constructed in such a way that it is capable of grasping the cop 2 in a posture parallel to the third shaft 53 and the fourth shaft 54. The housing 51 has a servomotor M4 mounted on its lower surface on the side opposite to the shaft case 52. The output shaft of the motor M4 is connected with the third shaft 53 by way of a joint. Therefore, by rotating the third shaft 53 and the fourth shaft, which is inserted into and connected with the third shaft 53 via a spline, it is possible to rotate the rotating arm plate 55 and each hand HA4 through a desired rotating angle. A cylinder CY3 is installed solidly on the circumferential wall of the shaft case 52 in parallel with the third shaft 53 and the fourth shaft 54. On the forward end of the rod in the cylinder CY3 is mounted a working plate 57. The forward end of the working plate 57 is fitted, in such a way as to permit its free sliding motion, into the outer circumferential channel 56a of the mounting bush 56 provided at the top of the fourth shaft 54. Accordingly, by extending or retracting the rod by the action of the cylinder CY3, it is possible to slide the fourth shaft 54 and the rotating plate arm 55 having the hand HA4 along the axial line of the shaft.
The setting apparatus (C) of this embodiment is capable of handling the cop 2 with a high degree of smoothness owing to the fact that the apparatus is equipped with proximity switches, limit switches, etc., at all important points of the various driving parts thereof with the operating range, stopping positions etc., for the entire apparatus being thereby determined accurately.
With the cop-setting apparatus (C) having a construction as described hereinabove, it is possible to perform such tasks as receiving the cop 2 from the above-described delivery apparatus (B) in the upper position (indicated by the imaginary line in FIG. 9) and setting a new cop 2 in the shuttle 1 in the lower position (indicated by the solid line in the same figure), or grasping and taking out the old cop.
Moreover, as shown in FIG. 1, a funnel-shaped cop chute 58 is provided at a point adjacent the setting position mentioned above, constructed so that it is possible to discard the old cop 2 taken out from the inside of the shuttle 1 by means of the setting apparatus (C).
(D) Shuttle Draw-Out Apparatus
As shown in FIGS. 1, 17 and 18 a beam member 59 is provided at a point above the shuttle race for the loom. The beam member 59 is fitted with a wall body 60 for mounting the various component devices of which the automatic cop replacing apparatus 10 is composed. As shown in FIG. 17, a box-shaped mounting frame 61 is provided via the bracket member 61a on the left part of the wall body 60. This mounting frame 61 is employed for installing a thread-tying apparatus (J) (to be described in detail under (J) below). A shuttle draw-out apparatus (D) is provided on the lower side of the mounting frame 61. This apparatus (D) is employed for drawing out onto the shuttle race 12 the shuttle 1 which has reached the shuttle box 11 after it has passed over the shuttle race 12 so that the cop may be replaced. On the lower surface of the mounting frame 61 is fixed a cylinder CY4 by way of a pair of brackets 62 in such a way that the forward end of the rod is directed towards the shuttle box 11 and the cylinder is set in parallel with the shuttle race 12. A guide bar 63 is supported, so as to permit free sliding motion, with linear bearings provided respectively at the lower ends of the brackets 62. The top of the guide bar is connected for interlocking operation with the rod of the cylinder 4CY by way of the connecting plate 64. At the lower end of the connecting plate 64, a rotary actuator 65 is installed solidly in the area opposite to the shuttle box 11, and an oscillating arm 66 is fixed on the output shaft of the rotary actuator 65, the output shaft protruding into the shuttle box 11 side after its penetration through the connecting plate 64. At the forward end of the oscillating arm 66, a suction pipe 67 is provided in parallel with the shuttle race 12. At the forward end of the suction pipe 12 is mounted a vacuum pad 67a for applying suction to and thereby holding the shuttle. At the rear end of the suction pipe 67 is provided a suction tube 67b, which is connected to and communicates with the pipe 67 and the vacuum pad 67a, making it possible to apply suction to the shuttle 1 via the vacuum pad 67a. Also, the rotary actuator 65 is provided with proximity switches for setting and detecting the rotational motion range.
The rod of the cylinder CY4 is retracted while the rotary actuator 65 swings the oscillating arm 66 upward, thereby keeping the vacuum pad 67a, etc., in a standby state in the upward position while the loom is in its normal operating condition. When the cop 2 is to be replaced, the rotary actuator swings the vacuum pad 67a, thereby bringing it down to a position directly above the shuttle race 12, extends the rod of the cylinder CY4, thereby holding the shuttle 1 in the shuttle box 11 by means of the vacuum pad 67a, and then retracts the rod of the cylinder CY4, thereby drawing out the shuttle in the box onto the shuttle race 12.
(E) Yarn Draw-Out Apparatus, etc.
As shown in FIGS. 1 and 5, a thread draw-out apparatus (E) is provided on the frame pedestal 13 adjacent the copsetting apparatus (C) described above. The thread draw-out apparatus (E) is composed of a cylinder CY5, which moves its rod in the direction perpendicular to the longitudinal direction of the shuttle race 12, and a hand HA5, which is provided at the top of the rod of the cylinder CY5. As illustrated in FIG. 19, moreover, a thread hold-down apparatus (E1) and a thread guide (E2) are provided in positions to the left and right on the peripheral part of the front end of the shuttle race 12, with the working axial line for the thread draw-out apparatus (E) forming the center. The thread hold-down apparatus (E1) has a cylinder CY6, which moves its rod in the perpendicular direction, and a hold-down plate connected to the rod of the cylinder CY6. One end of the weft at the woven fabric 69 side, which is led out of the shuttle 1 and woven into the warps on the shuttle race 12 at the time of replacement of the cop, is fixed under a holddown pressure in the space between the shuttle race 12 by means of the hold-down plate of the thread hold-down apparatus (E1). The thread draw-out apparatus (E) is constructed so that it grasps the weft 70 with its hand HA5 and draws the weft towards this side by means of the cylinder CY5. Accordingly, the thread draw-out apparatus is designed so that, as illustrated in FIG. 19, the weft 70 is held securely with the hold-down plate 68 and is at the same time supported so as to permit its free sliding motion by means of the thread guide (E2), being thereby led out in an approximately triangular shape towards this side.
The components described hereinabove are provided for the purpose of making adjustments of the knot N connecting the new weft and the existing weft, with the weft 70 wound and taken up by the reel apparatus (F) described in the following Section F.
(F) Reel Apparatus (Thread-Adjusting Apparatus)
As illustrated in FIGS. 1 and 19, a reel apparatus (F), which acts as a thread-adjusting apparatus capable of winding and taking up by a desired number of turns the weft 70 drawn out in a triangular shape towards this side by means of the thread draw-out apparatus (E), etc., is provided between the thread draw-out apparatus (E) and the thread guide (E2). As shown in FIG. 20 and FIG. 21, a hollow block body 71 is fixed, by way of a mounting jig, on a fixed loom part at a point towards this side of the shuttle race 12. On the rear end area of the block body 71 (on the side of the frame pedestal 13) is mounted a motor M5 by way of a speed reduction gear 72. Also, on the forward end area of the block body 71 (on the side of the shuttle race 12) is fixed a disc-shaped reel 73 on which a circumferential channel part 73a is formed for taking up the thread on the outer circumferential part of the reel. The output shaft 72a of the speed reduction gear 72 driven by the motor M5 is connected to one end of the revolving shaft 74 inside the block body 71, while the other end of the revolving shaft 74 protrudes from the front end side of the reel 73, being supported by a bearing 73b provided in the shaft core part of the reel 73. In the circumferential area of the protruding part of the revolving shaft 74 is formed a penetrating hole 74a extending perpendicular to the axial direction. A guide bar 75 is inserted in the penetrating hole 74a, On one end of the guide bar 75 is fixed a hooking device for snagging the weft 70 to wind it around the reel 73. The hooking device 76 is in contact with the forward area of the reel 73. On the forward end of the reel 73, a guide channel 77 in an approximately spiral shape is formed for approximately two rounds. The guide channel 77 is composed of an outer circumferential channel 77a in a circular shape and innerside spiral channel 77b, the spiral channel 77b being continuous with the outer circumferential channel 77a. At the point of confluence of the two, a point plate 78 is mounted in such a manner as to permit its free oscillating motion. Within the guide channel 77, a member 76a, which is attached to the above-mentioned hooking device 76 so as to permit its free rotating motion, is connected for interrelated operation.
On the rear end area in the lower part of the reel 73 is fixed a suspending device for suspending the abovementioned weft 70, which is pulled around by the rotating hooking device 76. The revolving shaft 74 inside the block body 71 is provided with a detecting boss 74b, and it is constructed so that the forward end of the proximity switch 80 provided through the circumferential wall of the block body 71 is positioned counter to the detecting boss 74b, thus making it is possible to detect the rotational speed of the revolving shaft 74, i.e., of the hooking device.
A thread guide 81 is provided along a line from the left and right side walls of the block body 71 to the upper-half part of the forward end of the reel 73. The thread guide is constructed so that it can lead the weft pulled around by the hooking device 76 into the circumferential channel part 73a on the reel 73. A tactile sensing switch 82 is provided in the vicinity of the thread guide 81, so that it is possible to directly detect the number of times the thread-winding operation is performed.
The guide bar 75 and the hooking device 76 are rotated motion when the motor is driven, with the result that the guide bar 75 can slide in relation to the penetrating hole 74a, the hooking device 76 thereafter moving in the circumferential direction with the roller member 76a guiding it into the guide channel 77. When the hooking device 76 has completed one round from the position where it started its rotational movement the hooking device 76 can make the hook part at its forward end protrude into the outside region from the outer circumference of the reel 73, getting hold of the weft 70 as pulled out and held on the suspending device 79 and winding the same around the circumferential channel part 73a on the reel 73.
As the length of the existing weft from the end of the already woven fabric 69 to the shuttle 1 is approximately constant, the knot N formed by tying the newly supplied thread 70a and the existing thread 70b will appear repeatedly in a fixed position in the woven fabric, as illustrated under (b) in FIG. 19, with the result that such knots may occur in positions which are in succession in the warp direction as the weaving continues. This means that the fabric suffers a change in its properties in a specific place, which is a disadvantage. Therefore, if the existing thread 70 is wound with a change in the number of times of the winding operation by the use of the reel device (F) described herein, before the old cop is removed with the existing thread cut off, at the time when the cop 2 is replaced, then the positions in which the knots N formed of the wefts after the tying of the thread can be dispersed in an appropriate way to appear at different points in the woven fabric 69, as shown at (c) in FIG. 19. Also, the winding of thread after it is tied eliminates the free play which would otherwise occur on the weft in the junction between the new thread and the existing thread, making it possible to prevent such accidents as the clogging of the weft. As described below, moreover the knots N of the thread can be led into the outside area out of a hole provided in the forward part of the shuttle 1.
(G) Shuttle Hold-Down Apparatus, etc.
As shown in FIGS. 1 and 17, the wall body 60 provided on the beam member 59 is provided with a cylinder CY7, as a shuttle hold-down apparatus (G), and a cylinder CY8, as a cop hold-down apparatus (G1), arranged side by side on the wall body by way of a bracket plate 83. These two cylinders CY7 and CY8 are positioned directly above the shuttle race 12 with their rods directed downward. When the shuttle draw-out apparatus (D) has pulled out the shuttle 1 from the shuttle box 11 onto the shuttle race 12, the setting apparatus (C) makes the existing cop in the shuttle 1 rise up to assume an upright position as illustrated in FIG. 2A, at which time the cylinder CY7 starts operating and holds down the top part of the shuttle 1 so as to prevent the shuttle 1 from being lifted up out of its place on the shuttle race 12. Moreover when the replacement of the cop 2 is completed, the setting apparatus (C) places a new cop 2 in its horizontal position in the shuttle 1, at which time the cylinder CY8 goes into action, pushing the new cop 2 securely into the inside of the shuttle 1 by holding down the head part of the new cop 2, and then ascertaining that the new cop 2 has been placed properly in the shuttle 1, while at the same time checking the presence or absence of the cop 2.
As shown in FIG. 17, the bracket plate 83 mentioned above is provided with a thread-handling apparatus (G2). This apparatus (G2) is composed of a cylinder CY7, with the top of its rod being positioned horizontally towards the side of the thread-tying apparatus (J) (described below), and a thread-handling rod 84 provided at the top of the rod.
(H) Existing Thread Drawing Apparatus, etc., (Thread-Processing Apparatus)
As illustrated in FIGS. 1 and 17, an existing thread drawing apparatus (H), acting as a thread-processing apparatus, is provided between the thread-handling apparatus (G2) and the thread-tying apparatus (J) described above. When the existing cop 2 is to be replaced with a new one, it is necessary to tie the two wefts held on the new cop and the existing cop. For this purpose, it is necessary to cut the existing weft and, for the above-discussed setting apparatus (C), to remove the existing cop from the shuttle 1. During the time for such a handling process, and also during the period until the process for tying the new weft to the existing one is completed, the end part of the existing weft lying outside the shuttle 1 on the shuttle race 12 is held by the apparatus (H).
As shown in an enlarged view in FIG. 22 and FIG. 23. the wall body 60 is provided with a mounting bracket 85 fixed thereon, and, on the front side of this mounting bracket 85, a cylinder CY10 is installed in a perpendicular downwardlooking position. On the top of the rod of the cylinder CY10 is fixed a rotary actuator 86. The rotary actuator 86 is provided with a stationary arm 87 fixed on its case, and its output shaft is fitted with an oscillating arm 88. The stationary arm 87 is directed vertically towards the wall body 60 in the horizontal plane. The oscillating arm 88 is a rod body having its central part bent slightly downward for easy hooking of the weft. The oscillating arm 88 is constructed in such a manner as to permit its free oscillating motion by 90° from a position parallel to the shuttle race 12 to a position parallel to the stationary arm 87 on the horizontal plane. A suction pipe 89 is installed, in parallel with the cylinder CY10, on the back side of the bracket 85. The open lower end part of the suction pipe 89 has a pair of vertical notched channels 89a formed on its front side and back side, and it is constructed so that the central part of the oscillating arm 88 set in the vertical direction in relation to the wall body 60 can enter the suction pipe 80, being inserted through the notched channels 89a, when the rod is lifted upward by driving the cylinder CY10. A duct hose 90 is connected to the upper end of the suction pipe 89. Thus, the apparatus is constructed so that it is capable of applying suction in an upward direction and holding there the end part of the existing weft drawn into the inside of the suction pipe 89 by means of the oscillating arm 88 of the cylinder CY10.
As shown in FIG. 1, a cop guide (H1) is provided on the lower part of the existing thread drawing apparatus (H). The existing cop 2 is drawn out, together with the shuttle 1, onto the shuttle race 12 and held in an approximately vertical state by means of the setting apparatus (C). The cop guide (H1) is constructed so that the existing cop can be held in such a state by means of a pair of holding plates 91, capable of performing free oscillating motion. One of the holding plates 91 is provided with a rod-form thread guide 92 approximately in the shape of the letter S. As shown in FIG. 2A, it is constructed so that the horizontally positioned existing thread 70b is cut off, by a cutter 93 installed near the cop guide (H1), when the existing thread 70b is pulled in the horizontal direction by means of the thread guide 92, with the holding plate 91 put into its operation, after the existing thread 70b is pulled upward to form a rectangular shape by the oscillating arm 88 of the existing thread drawing apparatus (H).
(I) New Thread Drawing Apparatus (Thread-Processing Apparatus)
As shown in FIGS. 1 and 17, a new thread drawing apparatus (I), operating as a thread-processing apparatus, is installed at a point adjacent to the existing thread drawing apparatus (H) described above and between the existing thread drawing apparatus (H) and the thread-tying apparatus (J), (described hereinafter).
As illustrated in FIGS. 24 and 25, a slide rail 94 is provided on the wall body 60, and, a slide block 95 is coupled to the slide rail 94 in such a way as to permit its free movement. On the side of the slide block 95, two bracket plates 96a, 96b are mounted solidly. The top of one bracket plate 96a is connected to the rod of a cylinder CY11 rigidly mounted on the wall body 60, forming a construction capable of freely moving the slide block 95 upward and downward along the slide rail 94. On the forward end of the other bracket plate 96b, a hollow box-shaped base body 97 is mounted with a shaft bolt 97a in such a way as to enable its free oscillating movement. With the lower surface of the base body 72, a suction barrel 98 for external application to a new cop 2 to cover it in an upright position on the shuttle race 12 is connected in such a way as to define a through passage. Nozzles for high-pressure air are provided (though not illustrated in detail) in a plural number of locations on the lower end of the opening of the suction barrel 98, making it possible to pull apart by wind pressure the end part of the new thread wound around the new cop 2. With the upper surface of the base body 97, a suction duct 99 joined to a suction device (not illustrated) is connected to define a through passage, forming a construction that makes it possible to suck up a new cop 2 contained inside the suction barrel 98 and to suck the end part of the new thread into the inside region of the duct.
Furthermore, as shown in FIG, 26 and FIG. 27, an oscillating plate 100 for cutting of the passage is provided in the inside area of the base unit 97. The oscillating shaft 101 on which the oscillating plate 100 is mounted projects beyond the base body 97. The rod of the cylinder CY12, with the barrel installed on the rod in such a way as to permit its free oscillating motion in relation to the suction duct 99 is connected to the end part of the oscillating shaft 101. Also, on the side opposite to the slide rail 94, with the suction duct 99 positioned in between, another slide plate 102 is provided. A roller 104 installed at the forward end of the arm 103 provided on the suction duct 99 is joined together with the slide plate 102 in such a way as to permit free rotational motion thereof.
This apparatus 1, constructed as described hereinabove, is designed so as to operate when a new cop 2 is set in a perpendicular state as shown in FIG. 2A in relation to the shuttle 1 pulled out on the shuttle race 12. Specifically, as illustrated in FIG. 25, the apparatus lifts the end part of the new thread upward by sucking up the new cop 2 with the suction barrel 98 externally applied over the cop and retains the new thread in the same state in preparation for the next thread-tying action, side by side with the end part of the existing thread held lifted perpendicularly upward in the neighboring section.
(J) Thread-Tying Apparatus
This apparatus is used to make a "single bundle knot" of the end part of the new thread 70a and the end part of the existing thread 70b, which are placed side by side with each other in a state in which they are lifted perpendicularly upward. A "single bundle knot" is a knot tied by tying method in which the two threads 70a, 70b, are placed together, making a ring of the threads by crossing them, and putting the part of the threads other than their ends through the ring, as illustrated in FIGS. 32A and 32B. This knotmaking method permits one easily to untie a knot by pulling the end parts of the two threads.
The present embodiment is intended for the manufacture of hollow-weave fabric for use for filter material for papermaking. In the case of hollow weave, the weft is in a state of continuum, and thus it is inconvenient for such uses to have many knots lined up in the fabric. As mentioned above, the positions of the knots N are thus intentionally dispersed in the woven fabric 69 by means of the reel apparatus described above. Furthermore, if the knots of the wefts 70 are formed by the "single bundle knot" method, it is possible to untie by hand the knots N of the wefts 70 woven into the fabric after the completion of weaving, which means that unevenness, etc., of the textile due to the knots N can be corrected.
As shown in FIGS. 1, 5, and 17, a mounting frame 61 is provided in the vicinity of the existing thread drawing apparatus (H) and the new thread drawing apparatus (I) in the area above the shuttle race 12. In the inside of this mounting frame 61, a thread-tying apparatus (J) is arranged in such a manner that the apparatus is free to perform a sliding movement in the horizontal sideways direction. A cylinder CY13 is installed rigidly, in parallel with the shuttle race 12, inside the mounting frame 61. The rod of the cylinder CY13 is connected with the thread-tying apparatus (J) and is designed to be able to advance the entirety of the thread-tying apparatus (J) to the thread-tying position at the right-hand side in the figure (i.e., a position almost immediately over the new thread drawing apparatus (I) as located in its most elevated position).
As shown in FIGS. 28 to 31, an introducing part 110a for the thread is formed on the forward end edge of the horizontal lower surface plate 110 of the thread-tying apparatus (J), and a guide channel 110b for positioning the introduced thread 70 is formed in the rearward center of the introducing part 110a. The lower surface plate 110 has a mounting plate 111 fixed vertically approximately in its center, and supporting pillars 112 are erected in the two side areas in the forward section. The mounting plate 111 and the supporting pillar 112 are provided with an upper surface plate 113, with an introducing part 113a and a guide channel 113b of the same shape, fixed horizontally in the same position as that of the above mentioned lower surface plate 110. A shaft hole is formed in the proximity of the center of the mounting plate 111, and a cylinder-shaped guide 114 interconnected with and leading into the shaft hole is installed rigidly in a vertical position on the back surface of the mounting plate 111. The guide 114 has a slide pipe 115 inserted into it. The front end of the slide pipe 115 projects forward through the shaft hole, while its rear end projects backward from the rear end of the opening of the guide 114. A helical guide channel 116 is formed on the outer circumferential area of the slide pipe 115. and a guide pin 114a in the form of a protrusion on the inner circumferential area of the guide 114 is joined with the guide channel 116. The cylinder CY14 is, fixed on the outer circumferential area of the guide 114, and the top part of the rod of the cylinder CY14 is connected with a bush 228 provided on the rear end of the slide pipe 115 projecting rearward.
A working shaft 118 is inserted into the inside region of the slide pipe 115 in such a way as to permit its free sliding motion in the forward and backward directions. The forward and rear ends of the working shaft 118 protrude respectively from the forward and rear ends of the slide pipe 115. On the bush 117 is fixed a cylinder CY15 by way of a mounting plate 117a. The row of the cylinder CY15 is connected with the rear end of the working shaft 118. Also, a base frame having a rectangular shape with the left side open is fixed on the front end of the slide pipe 115. Two shafts 120 are provided in parallel with each other between the upper and lower flanges 119a for the base frame. In the upper and lower positions of the two shafts 120 a total of four claw plates 121, with the tips turned inward, are installed in such a way as to permit their respective free rotational motion. The pair of claw plates 121 at the upper level and the pair of claw plates at the lower level are respectively connected with each other by means of link mechanisms for their interlocking operation, forming two pairs of grasping claws, 122, namely, upper and lower pairs. The forward end of the working shaft 118 is connected in such a way as to permit their free rotational motion, with the link mechanisms 123 connecting the two shafts 120.
As explained above, the various apparatuses are constructed in such a way that, when the cylinder CY14 is placed into its operation, the slide pipe 115 performs its sliding movement forward and backward along the guide 114 while they also are rotated and haft 118 slides in relation to the slide pipe 115, actuating the two pairs of grasping claws 122 simultaneously by way of the shafts 120 and the link mechanism 123 so as to perform their opening and closing operations. That is, these apparatuses are constructed in such a manner that they are capable of getting hold of the two threads (only one of which in the figure) which pass through the upper and lower guide channels 110b, 113b and twisting them by 180°, as illustrated in FIGS. 33 to 35.
A pressing lever 124 is provided at a point below the grasping claws 122. The pressing lever 124 is connected for interlocking operation with the actuator fixed on the mounting plate 111. The lever is constructed so as to be capable of turning by 90° upward. That is, the pressing lever is constructed so as to be capable of hooking the crossing point of the thread 70 as pulled about by the grasping claws 133, 122 and pulling the thread to one side, as shown in FIG. 36.
On one side of the grasping claw 122, a hook-shaped small claw 126 and a large claw with a pressing bar 127a fixed on its top are connected coaxially, for interlocking operation, with the actuator 128 provided on the mounting plate 111. That is, the apparatus is constructed in such a way as to be capable of holding by its small claw 126 the crossing point of the thread 70 pulled to one side by the pressing lever 124, and at the same time pushing down one part of the thread 70 by the pressing bar 127a on the large claw 127.
Then, as illustrated in FIGS. 29 to 31, a gripping claw 129 is provided between the large claw 127 and small claw 126 on one side and the grasping claw 122 on the other. The sliding pipe 131 is inserted, in such a way as to permit its free movement into the guide cylinder 130 connected from the back surface side, permitting through passage, with the shaft hole in the mounting plate 111. Inside the sliding pipe 131, a working rod 132 is installed in such a way as to permit free sliding thereof, by way of a bearing, and the rear end of the working rod is connected with the rod of a cylinder CY16 fixed on the rear end of the sliding pipe 131. A gripping claw 129, composed of a pair of claw members 129a, is installed with the shaft, in such a way as to permit its free oscillating movement, on the frame member 133 fixed on the forward end of the sliding pipe 131. The rear end part of each claw member 129a and the forward end part of the working rod 132 are connected with each other by means of a link mechanism. A cylinder CY17 is provided on the outer circumference of the guide cylinder 130. The rod of the cylinder CY17 is connected with the rear end of the sliding pipe 131. When the cylinder CY17 is placed in operation, the gripping claw 129 can as a whole move forward and backward, and, when the cylinder CY16 is operated, the gripping claw 129 can perform its opening and closing operations. As shown in FIGS. 28, 30 and 33 to 41, a thread-tightening cylinder 125 is installed on the mounting plate 111 in such a way as to permit its free forward and backward movement. On the thread-tightening cylinder 125 is provided a thread-tightening arm 125a, which is to be used for hooking and pulling the thread. That is, the apparatus, as illustrated in FIGS. 38 to 41, is constructed so that it is capable of making a "single bundle knot" of the thread 70 by a thread-tightening operation with the thread-tightening cylinder 125 operated and advanced after moving forward the gripping claw 129, grasping with the gripping claw 129 the thread 70 as pushed downward by the large claw 127, and thereafter releasing the gripping claw 122 and the small claw 126. Further, as shown in FIGS. 29 and 30, a heat cutter 134, which is to be used of cutting off any unnecessary portion of the thread 70, is provided at a point above the gripping claw 122. As illustrated in FIGS. 28 and 30, an apparatus which is to be used to hold the thread 70 inserted and passing through the upper and lower guide channels 110b, 113b and to apply the prescribed tension to these threads is provided on the inner sides of the guide channels.
In the construction described hereinabove pressurized air is used for the source of driving power for the individual cylinders, the actuators, etc.
Next, a description will be given with regard to the working of the replacing apparatus 10, which is composed of the individual apparatuses described in the individual sections (A) to (J) hereinabove.
First, the cop 2 is taken out of the container 35 by means of the cop-taking apparatus (A), For this purpose, the X and Y sliders 17, 28 are moved along the guide shafts 15, 21, respectively by the driving of the two motors M1, M2, and the X slider 17 and the Y slider 28 are brought to a stop in the desired positions on the basis of the detection signals which the two proximity switches 20, 31 generate for the two positioning members 19, 30. Next, the cylinder CY1 is put into operation, and the hand HA1 is moved downward and operated so as to get hold of the head part of the cop 2 located in the desired position. Then, with the cylinder CY1 and the motors M1, M2 actuated for operation,. the cop 2 is transported to the delivery apparatus (B).
The delivery apparatus (B) receives the cop 2 from the cop-taking apparatus (A) (in the position represented by a solid line in FIG. 9). When the hand HA3 of the delivery apparatus (B) in the horizontal state as represented in FIG. 10 has grasped the bottom of the cop 2, the above-mentioned cop-taking apparatus (A) first removes the rubber cap from the cop 2 using the hand HA2. Thereafter, the cylinder CY2 of the delivery apparatus (B) goes into action, extending its rod. The oscillating member 38 and the hand HA3, which are placed on the top of the rod, move upward in rotational motion centered around the shaft member 37, the hand HA3 moving upward (in a diagonally upward direction) in a rectangular posture with the cop 2 held in grip. The delivery apparatus (B) hands over the cop 2 to the hand HA4 installed on the rotating arm plate 55 of the setting apparatus (C) placed in an upper position In this embodiment two kinds of cops 2 can be replaced with different kinds of wefts thereon. Two out of the three hands HA4 for the setting apparatus (C) should respectively grasp different kinds of cops 2 while the remaining hand HA4 should be employed of handling the existing cop 2.
When the weft 4 remaining in the shuttle 1 has been reduced to a small amount, the loom is automatically brought to a stop at the moment when the shuttle 1 has entered the inside of the shuttle box 11 after passing the shuttle race 12. First, as illustrated in FIG. 17, the shuttle draw-out apparatus goes into operation and draws out the shuttle 1 from the shuttle box 11 onto the shuttle race 12. Then, as shown in FIG. 19 the cylinder CY6 operates, and thereupon the hold-down plate 68 moves downward, fixing the weft 70 located on the side of the woven fabric 69. Also, approximately at the same time as this operation, the thread draw-out apparatus (E) goes into action, drawing out the weft towards the side in a triangular shape by means of the thread guide (E2) and the hold-down plate 68. In order to disperse the knots as discussed above, the apparatus hands over the weft to the reel apparatus (F), making an adjustment of the weft 70 by winding the existing weft by an appropriate number of times.
Then, the cop-setting apparatus (C) goes into operation. First, the motor M3 operates and moves the primary shaft 43 downward, into the state shown in FIG. 9. Then, the rotary actuator 50 operates. rotating the secondary shaft 49. That is, the secondary shaft is rotated in such a way that the rotating arm plate 55, as seen in FIG. 9, oscillates by 90° towards the side shown in the drawing, and after this operation, the rotating arm plate 55 will be in a state where it is rectangular with respect to the horizontal plane. In this state, the hand HA4 on which the rotating arm plate 55 is located has come to a position where it grips the head part of the existing cop 2 laid down inside the shuttle 1 (not specifically shown in the drawings). It is possible to place the existing cop 2 inside the shuttle 1 in its upright position as shown in FIG. 2A by putting the hand HA4 into operation so that it grasp the existing cop 2, and operating the rotary actuator 50 to turn by 90° in the direction reverse to that in the earlier operation while the hand holds the existing cop 2 in grip. In this case, an attempt at raising the existing cop 2 to its upright position by oscillating the hand HA4 in the upward direction would also cause the shuttle 1 to rise from the shuttle race 12 because the existing cop 2 is placed on the tong 3 located in the rear part of the shuttle 1. Therefore, as shown in FIG. 17, the shuttle hold-down apparatus (G) is put into operation approximately at the same time as this action and the part of the shuttle 1 in the proximity of its top is pressed down between the rod of the cylinder CY7 and the shuttle race 12 to keep the part secured there. In this regard, when the existing cop 2 is placed in an upright posture inside the shuttle 1, the existing thread 70b, as shown in FIG. 22, extends in a diagonal direction under tension between the existing cop 2 and the shuttle 1 (not illustrated in the figure).
Then, the existing thread drawing apparatus, which is a thread-processing apparatus, goes into action. First, the cylinder CY10 operates, and the two arms 87, 88 move downward. Then, the oscillating arm 88 rotates, and the two arms 87, 88 hold the existing thread 70b in grip. With the drawing action by the cylinder CY10, the two arms 87, 88 move upward with the existing thread 70b held thereon, entering, together with the existing thread 70b, into the interior of the suction pipe 89 via the notched channel 89a. The cop guide (Hl) (shown in FIG. 1) effects an opening action of the hold-down plates 91. which have been holding down the existing cop 2, and pulls the existing thread 70b in the horizontal direction by means of the thread guide 92, as illustrated in FIG. 2A. The existing thread 70b so pulled comes into contact with a heat cutter 93 and is fused and cut off thereon by heat. The end portion of the existing thread 70b, which has been cut off from the existing cop 2, is sucked into the inside of the suction pipe 89 and held in a perpendicular state by suction.
Then, the setting apparatus (C) is again operated. As mentioned above, the setting apparatus (C) at this time assumes a posture approximately as shown by the solid line in FIG. 9, and it is also in a state where it holds in grip the head part of the existing cop 2 in a perpendicular state as mounted on the shuttle 1. The cylinder CY3 is put into operation, and the fourth shaft 54 is thereby driven in the upward direction by which the rotating arm plate 55 and the hand HA4 are moved upward in the direction indicated by the arrow (d) in FIG. 13. Since the existing cop 2, which is held in grip by the hand HA4, has been brought upward, the existing cop 2 is pulled out from the tong 3 in the shuttle 1. Next, the servomotor M4 is put into motion, by which the third shaft 53 is rotated, which shaft thus causes the rotating arm plate 55 to rotate. The direction of rotation at this stage is selected depending on the point which of the new cops 2 held in grip by the hand HA4 is to be set inside the shuttle 1. The angle of rotation is approximately 120°. Specifically, the existing cop 2 is taken away from the tong 3 on the shuttle 1 and a new cop 2 is set on top of the tong 3. Then, the cylinder CY3 retracts its rod and puts a new cop 2 onto the top 3 of the shuttle 1. The hand HA4, which has held the new cop 2 in grip, opens, and, with a small amount of rotation of the servomotor M4, the hand HA4 retreats from the vicinity of the head part of the new cop 2.
The new thread drawing apparatus (I). operating as a thread-processing apparatus, goes into operation. First, the cylinder CY11 operates, whereby the suction duct 99 and the suction barrel 98, etc., are moved downward. As illustrated in FIGS. 17 and 25, the suction barrel 98 sucks the air inside it upward while enveloping the new cop 2 in an approximately perpendicular suspended state on the shuttle race 12. At that time, a plural number of nozzles provided in the proximity of the lower end of the opening in the suction barrel 98 blow out high-pressure air, thereby forming a current of air around the new cop 2 in the direction reverse to that for the winding of the thread. Consequently, the end part of the new thread 70a wound tightly around the new cop 2 is taken apart forcibly, thereafter being sucked into the duct 99 by way of the base body 97 in an upper position. When the suction barrel 98 reaches the end of its descending stroke, the cylinder CY12 goes into action, thereby setting into motion the oscillating plate 100 located inside the base body 97 and holding the end part of the new thread 70a sucking into it in a grip between the plate and the opening of the base body 97.
Then, the cylinder CY11 performs a retracting operation, whereupon the suction barrel 98, etc., grasping the new thread 70a by its end, move upward. At this time, the new thread on the new cop 2 set in the shuttle 1 is in a state of tension in the upward direction, and the end part of the existing thread drawn out of the front part of the shuttle 1 is led upward side by side with the new thread 70a. When the suction barrel 98 has reached the end of its ascending stroke, the cylinder CY12 is operated, releasing the grip by moving the oscillating plate 100 located inside the base body 97 and thereby letting the end part of the new thread 70a be subject to a suction effect.
When it is detected by a sensor (not shown) that the end part of the new thread 70a has been sucked into the barrel by an appropriate length, the servomotor M4 for the setting apparatus (C) is driven to rotate the rotating arm plate 55, the hand HA4 thereby holding down the new cop 2 by the head, preventing any excessive sucking of the thread. At the same time, the cylinder CY9 for the thread handling apparatus (G2) is operated, and the thread handling rod 84 thrusts the end parts of the new and existing threads 70a, 70b in the direction of the thread-tying apparatus (J). At the same time, the cylinder 13 operates, and the entirety of the threadtying apparatus (J) is slid downward to a point below the new thread drawing apparatus (I). The end parts of both new and existing threads 70a, 70b are led from the upper and lower inlet sections 110a, 113a for the thread-tying apparatus (J) into the upper and lower guide channels 110b, 113b.
Then, an operation is carried out making a "single bundle knot" of both threads, i.e., the new thread and the existing thread, with the thread-tying apparatus as explained with reference to FIGS. 28 to 41. (The two threads, i.e., the new one and the existing one, are represented together as if they were one thread for the sake of simplicity in FIGS. 28 to 41).
(1) First, with reference to FIG. 33, the cylinder CY15 is operated, and, by pulling the working shaft 118, the thread 70 is held by means of the two pairs of gripping claws 122 and the upper and lower thread hold-down and gripping claws (not illustrated).
(2) When, with reference now to FIGS. 34 and 35, the slide pipe 115 is pulled after the cylinder CY14 is put into operation, the slide pipe 115 performs a rotating motion in the guide channel 116, being guided by the guide pin 114a. That is, the gripping claw 122 twists the thread by 180° while pulling it.
(3) Referring to FIG. 36, with the actuator operational, the pressing lever 124 is rotated upward by 90° and the crossing point of the thread 70 pulled about by the gripping claw 122 is thrusted towards the side of the large claw 127 and the small claw 126.
(4) Upon operating the actuator 128, with reference now to FIG. 37, the small claw 126 suspends the crossing point of the thread 70, and also the pressing bar 127a of the large claw 127 pushes one of the collected threads 70 in the downward direction.
After this, the pressing lever 134 returns to the lower point.
(5) With the cylinder CY17 put into operation, the gripping claw 129 is moved forward, and the thread 70, pushed downward by the large claw 127, is held in grip by means of the gripping claw 129 by the action of the cylinder CY16. (See FIGS. 38 and 39). The suspension of the thread 70 by means of the gripping claws 122, the large claw 127, and, the small claw 126 is then released.
(6) When the cylinder 125, which is in a stand-by state in the rear part of the lower guise channel 110b, is operated the thread held by the gripping claw 129 and the gripping claw provided in the upper part of the lower guide channel 110b (not illustrated) is pushed out and the knot thereof is tightened. The two threads, i.e., the new one and the existing one, are tied together in a "single bundle knot" as illustrated in FIG. 32. and also the unnecessary portion of the threads is cut off at a point above the knot by means of the heat cutter 134. (See FIG. 40 and FIG. 41). The fragments of the upper-part thread thus cut off are sucked into the suction duct 99 and the suction pipe 89.
After the two threads, i,e., the new one and the existing one, are connected with each other in the manner described above, the setting apparatus (C) goes into operation again. The rotating arm plate 55 is rotated by approximately 90° by driving the rotary actuator 50, so that the plate becomes perpendicular to the plane. In specific terms, the new cop 2 is laid down together with the tong 3, and the new cop 2 is thereby set inside the, shuttle 1.
The tied portions of both the new thread and the existing thread 70a, 70b from the top of the new cop 2 to the hole 1b in the forward part of the shuttle 1 are unnecessarily long after the thread-tying operation, and these free-play portions are liable to be caught on various structures. Therefore, approximately at the same time as the operation for laying down the new cop 2, the reel apparatus (F) is operated again, by which the weft is wound up. When the new cop 2 is set inside the shuttle 1 and the free play of the weft 70 is eliminated by the thread-winding operation with the reel apparatus (F), the cylinder CY8, operating as the cop hold-down apparatus (G1), is put into operation. Specifically, the new cop 2 is charged positively into the inside of the shuttle 1 by thrusting the head part of the new cop 2 downward by means of the top part of the rod, as illustrated in FIG. 17, and also the presence itself of the new cop 2 is checked by means of a reed sensor (not shown).
Next, the reel apparatus (F) is again operated. When the weft 70 is wound by the reel apparatus (F) around the circumferential channel part on the reel 73, the knots N of the threads come into the back side of the shuttle 1 passing through the hole 1b in the shuttle 1 because the woven fabric 69 side of the weft is fixed with the pressing plate 68. Tension in excess of what is needed may be exerted on the knot N of the thread when the knot passes through the hole 1b while the loom is being operated, and it is conceivable that the thread may be broken, depending on circumstances. Therefore, it is extremely effective, for preventing the work in progress from being interrupted, to pull the knot N out behind the shuttle 1 in advance by means of the reel apparatus (F), as in the above-described case. As mentioned also under (F), moreover, it is possible to disperse the positions of the knots N to different points on the woven fabric 69, as shown at (c) in FIG. 19, by having the reel apparatus (F) take up the existing weft 70 by an adequate amount prior to the replacement of the cop 2, making it possible to eliminate inconsistencies in the properties of the woven fabric 69 (for example, water permeability) from one point to another. Then, the motor M5 for the reel apparatus (F) is rotated in reverse by one revolution, by which the hook part at the forward end of the hooking apparatus 76, set so as to permit its free rotational motion, is moved away from the outer circumference of the reel 73 to the inner area thereof, and also the shuttle 1 is thrusted into the inside of the shuttle box 11 by means of the shuttle drawing apparatus (D). The shuttle drawing apparatus (D) is swung and moved away in the upward direction to prevent the apparatus from interfering with the shuttle 1 in its flight. Additionally, the hand HA5 for the above-mentioned thread-drawing apparatus (E) is released.
After the replacement of the existing cop with a new cop is completed in the manner described hereinabove, the loom can be put into operation again.
As described above, the system in this embodiment is capable of selectively taking out a desired kind of cop stored in a prescribed position by handling it with the copunloading apparatus, and charging the new cop into the inside of the shuttle by means of the setting apparatus (C), which works independently in four directions, or taking out an existing cop from the shuttle. The system is also designed in such a way that the new and existing thread drawing apparatuses (H), (I) process the two threads, i.e., the new thread and the existing one, which are thin and hard to keep in shape, and in such a way that the thread-tying apparatus (J) equipped with various claw devices operated by means of cylinders can tie together the new and existing threads. Since it is possible to disperse the knots of the weft to different points by means of the reel apparatus (F), this system offers extremely great advantages in the weaving of special-purpose textiles by the hollow weave process.
As mentioned earlier, the replacing apparatus 10 is equipped with a large number of limit switches and sensors, etc., for the purpose of setting the working ranges of various members and apparatuses and detecting the amounts of work done or the positions of the various members, apparatuses, etc. Furthermore, the replacing apparatus and the loom may be provided with many detecting devices, such as limit switches, proximity sWitches, and sensors, other than those explicitly mentioned in the above description, in order that operating conditions may be monitored to detect problems and failures. The replacing apparatus and the loom are designed to utilize signals generated by these detecting devices and to carry out the above-described operations under control and supervision performed by the controlling and supervising system, which is an essential part of this embodiment. Thus, the system, which is a complex arrangement of a large number of equipment groups, is capable of smoothly operating the replacing apparatus and the loom, which handle various operations as an integrated system. With the replacing apparatus 10 attached to the loom in the described manner, it is possible to accomplish automation of the cop-replacing work, which could only be done manually in the past, above all, the cop-replacing work in a hollow weaving process in which continuous wefts formed by the tying of threads are woven into fabric. | An automatic cop replacing apparatus for a shuttle-type loom with which a cop contained in the shuttle is automatically replaced, including tying the threads together of the old and new cops, and requiring no operator intervention. The apparatus includes a hand for gripping the cop. A rotary arm plate on which the hand is mounted, a drive device for rotating the rotary arm plate and for straightly moving the rotary arm plate in the axial direction, and a drive shaft for moving the rotary arm plate to an exchange position for the cop. A thread tying device holds and ties together the treads of the old and new cops. | 3 |
BACKGROUND OF THE INVENTION
It is known to use a vacuum bag molding process to pressurize while heat curing a composite structure. To obtain a quality part it is necessary to remove all the trapped air from a layup being formed into the part, however, the path for removal of air also provides a path for excessive amounts of resin to flow during the cure cycle. In U.S. Pat. No. 3,703,422 a vacuum bag molding process is shown with layers of glass cloth communicating between a vacuum source and bleeder layers covering a panel being formed. The layers of glass cloth not only provide a path for removal of air, but also a path for resin to bleed or flow into when the resin viscosity is lowered during the cure cycle. In another known method a porous parting layer covers the layup and the parting layer in turn is covered by a glass cloth layer. The glass cloth layer acts as a bleeder to remove air, however, during the heating cycle excess resin bleeds into the glass cloth layer. The cure cycle is accomplished in two steps. After the vacuum is applied the unit is first heated up to a temperature where the resin begins to gel and is held at that temperature for a time to partially cure the resin and prevent excessive run off. Next pressure is applied to the outside of the vacuum bag and the temperature raised to and held at the cure temperature for a time sufficient to cure the resins. Even with this controlled rate of resin run off the resin lost into bleeder layers often amounts to 25% or more and varies with different resins and different suppliers' resins. To obtain the desired resin to fiber percentage in the finished product one provides an excess of resin for run off and tries to control the amount of the run off.
It was found that non-bleed vacuum bag molding can be accomplished wherein the air is completely removed from a layup, but the breather means closes off when resin starts to flow into it, and the cure is accomplished in one step instead of two steps.
SUMMARY OF THE INVENTION
Vacuum bag molding of composite structures with a breather strip or tape to which a vacuum is applied is spaced away from a layup of the composite and uses a strand of fibers to communicate between the layup and breather strip. The pressurized layup is raised to temperature and cured. The resin trying to pass through the strand quickly sets up in the strand to close off the flow of resin and prevent bleeding.
It is an object of this invention to prevent bleeding of resin during bag mold curing of the resin in a layup.
It is another object to closely control resin to fiber percentages in a composite structure by preventing bleeding of the resin.
It is yet another object of this invention to provide a method of curing a composite structure without requiring variations in method due to different flow characteristics of different vendors' resins.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of apparatus used in this invention.
FIG. 2 shows a fragmented perspective view of one embodiment of this invention.
FIG. 3 shows a fragmented perspective view of another embodiment of this invention.
FIG. 4 shows a fragmented perspective view of yet another embodiment.
DETAILED DESCRIPTION
The vacuum bag set up 10 of this invention uses a mold or platen 12 upon which a part is formed. In FIGS. 1 and 2 the part or layup 14 is a laminate made up of several layers of a fiber reinforced resin. In a preferred embodiment the layup will be prepared of graphite fibers as the reinforcement and an epoxy resin as the bonding agent. It is not desired to limit the layup to those materials, however, as other reinforcing fibers such as glass, boron, or kevlar may be used and other resins such as a polyester may be used to name a few of the materials. An edge strip or tape 16 of a breather material is located on the mold and is spaced away from the layup with a minimum distance of at least 1/2" preferred. The breather material is preferably layers of glass cloth or fibers, however, other materials may be used such as polyester cloth or fibers. A tube 18 having perforations 20 is placed over the breather strip and covered with porous tape 22. The tube is connected to a vacuum source not shown to provide a means of introducing suction from the vacuum into the edge breather strip. A sealing strip 24 of a putty like material having an adhesive is placed adjacent the outer periphery of the mold to act as a seal for vacuum bag 26. An impervious film of "Teflon" 28 which may be either tetrafluoroethylene or fluorinated ethylene propylene acts as a parting agent and is located over the layup and the edge breather. A strand of fibers 30 is located to communicate between the layup and the edge breather strip. This strand is preferably of glass, however, it may also be of other fibers that can withstand the heat and pressure of the process without closing off the multitude of air passages provided by the strand. This strand serves a dual purpose. It acts as a channel for the passage of gasses passing from the layup into the breather strip, but acts as a stop off when resin tries to flow over the same strand pathways.
When preparing a laminated composite the surface 32 of mold or platen 12 is covered with a release agent and the strand of glass fibers 30 placed on the platen. The layers of graphite reinforcing fibers in an epoxy resin making up the layup 14 is placed on the platen and in contact with the strand. Next the breather strip 16 of glass fibers is placed on the platen in contact with the strand of fibers 30 but spaced away from the layup. The tape 20 and tubing 18 is placed on the breather layer. A Teflon parting film 28 is located to cover the layup and extend over the breather strip, the sealing strip put in position and the vacuum bag 26 put in position. As the vacuum is introduced into the edge breather strip and the air evacuated, the bag follows the contour of the various parts which introduces pressure against the layup and seals off contact between the layup and the breather strip except for the strand of fiber. Air is pulled from the layup through said strand. The platen with assembly is placed in an autoclave not shown and pressure introduced to the outside of the bag, the pressure raised up to about 85 p.s.i., and at the same time the temperature is raised to the cure temperature for the resin which in this case is about 355° F. and kept at that temperature until the resin completely cures, which in this case is about two hours. It is preferred that the vacuum to the edge breather strip be vented to atmosphere when the outside pressure reaches about 20 p.s.i. As the epoxy heats up it first becomes quite liquid and flows to give uniform distribution to the layup. At the same time the liquid resin is pulled through the strand of fiber, but before the resin reaches the end of the strand the resin gels to close off the strand and prevent bleeding of resin from the layup.
If the layup is contoured such as is the case in the embodiment shown in FIG. 4, additional breather paths are supplied to allow the bag to closely follow the contour of the layup. In that Figure as well as in FIG. 3 the same parts will be identified with the same numbers as previously used. In FIG. 4 the layup 14a is made up of honeycomb core 34, is covered on the top face with a layer 36 and the bottom face with a layer 38, and each layer has an epoxy adhesive adjacent to the face and is then covered with graphite reinforced epoxy resin layers. The honeycomb core is reduced in thickness and tapers downward toward the edges and the facing layers are joined together around the edge. A breather layer of glass fibers 40 extends over the layup and is located between the vacuum bag 26 and the impervious parting layer 28a which in this embodiment covers the layout and extends about halfway over the edge breather layer 16. A strand of glass fibers 30a extends from the joined face layers 36 and 38 to the edge breather strip 16. A second strand 30b of glass fibers extends from the cover breather layer 40, between parting film 28 and vacuum bag 26 to control edge breather strip 16. This strand supplied a path for air to be evacuated from the bag to permit the bag to closely follow the layup regardless of the contour.
FIG. 3 shows yet another embodiment where a layup 14b has a honeycomb core 34a with face layers 36a and 38a. In this embodiment the edge 42 of the layup is square and is formed by placing a frame 44 on the platen 12 and abutting the layup against the frame. A strand 30c of fiberglass is located to contact face layer 38a, pass over the frame and contact the edge breather strip 16, and a second strand 30d of fiberglass is located to contact face layer 36a, pass over the frame and extend to contact edge breather strip 16. These strands each provide a channel for evacuation of air from the layup and a stop off means to prevent resin bleeding when the layup is being cured under heat and pressure.
In the embodiments where the layup includes a honeycomb core the procedure for curing the resin to form the composite is also a one step process. When the assembly is completed a vacuum is introduced into the edge breather strip, pressure introduced on the outside of the vacuum bag, and the temperature raised to curing temperature and held at that temperature until the resin is cured. The pressure on the outside of the bag is preferably raised to only about 45 p.s.i. for the honeycomb containing layup, but again it is preferred to exhaust the vacuum line to atmosphere when the outside pressure reaches about 20 p.s.i. | A composite structure is prepared in a mold using a vacuum bag with an edge breather separated from a layup to be formed into a composite. A means of communication between the edge breather and the layup provides a path for air being drawn from the layup and to provide a path that closes off and prevents excess resin flow from the layup as it cures. | 1 |
FIELD OF THE INVENTION
This invention relates to compositions having positive temperature coefficients of resistance and the method by which they are made. In another aspect it relates to compositions useful in self-regulating heating elements. In yet another aspect, it relates to compositions of a fluorocarbon polymer and carbon.
BACKGROUND
Polymer compositions that contain particles of a metal or cconductive carbon may be electrically conductive. Many such compositions, particularly those having a crystalline polymer base, exhibit the property that, as their temperature is raised, a substantial rise in the compositions ' electrical resistance occurs at a specific temperature or over a relatively narrow temperature range. In the case of compositions based upon crystalline polymers, this phenomenon is exhibited at or near the crystalline melting point or melting range.
Compositions that exhibit this property are said to possess a positive temperature coefficient (PTC) of resistance. The compositions themselves are frequently referred to as PTC compositions.
In recent years, PTC compositions have been usefully employed as components in self-regulating heating elements for electrical appliances having a variety of applications. In operation, at a constant applied voltage directed across a PTC heating element, the current (I=E/R) through the heater will be large at low temperature. The power (P) generated by this current (P=I 2 R) is dissipated as Joule heat thereby warming the PTC composition. If the applied voltage is high enough, the temperature will continue to rise without a significant increase in resistance until the T s temperature is reached. At this point, a further increase in temperature results in a significant rise in resistance. Since the applied voltage is constant, concomitant with the increase in resistance is a large decrease in current and, therefore, power generation. In effect then, the heater is switched off.
The heat built up in the PTC composition dissipates by heating its surroundings, which might, for example, be a heating plate for a coffee pot, until its temperature drops below T s at which point the power output of the heater again rises. In actual practice, a steady state condition is attained at about the T s temperature as heat lost to the surrounding is offset by heat being generated within the PTC composition. The net effect of all this is that the power being generated by the current in the PTC composition remains relatively constant as does its heat output without resort to thermostats or a protective device such as a fuse.
To those skilled in the art, the availability of simple self-regulating heating devices that do not require expensive and/or bulky heat control devices suggests many applications for heating elements comprising PTC compositions. A particularly useful element takes the form of a thin ribbon or strip of carbon filled polymeric material having electrodes at its opposite edges, typically bundles of copper wires embedded in the polymer strip along its edges, parallel to the long axis of the strip. The two electrodes establish a potential gradient along the plane of the strip and transverse to its long axis. Therefore, a voltage can be applied across the electrodes to heat the entire strip to about its T s temperature. Such strips can be wrapped about and used to heat tubular or irregular conduits or vessels, for example, to thaw their contents, to prevent the salting out of solids in solution, etc.
As indicated supra, in the case of PTC compositions based on crystalline polymers, T s is related to the crystalline melting point or range of the polymer. Therefore, in principle at least, to achieve a heating element having a specific self-regulating temperature, it is only necessary to select a composition having a base polymer with the desired T s . However, the development of resistance heating elements employing PTC compositions has been hampered by the fact that many otherwise suitable polymers lack thermal or hydrolytic stability at elevated temperatures. One organic polymer that has been found to be very useful in the production of PTC compositions for high temperature applications is the largely head to tail polymer of vinylidene fluoride referred to as polyvinylidene fluoride (PVF 2 ) having the repeat unit --CH 2 --CF 2 --CH 2 --CF 2 --. This crystalline polymer exhibits good thermal stability. In addition it has excellent chemical resistance and is tough, flexible and non-flamable.
The sum of these properties makes PVF 2 ideally suited for use as the base polymer in a variety of PTC applications. A PVF 2 composition, containing carbon black that has been crosslinked by being irradiated with gamma rays or high energy electrons has been shown to be an excellent PTC composition. The crosslinking by exposure to radiation has been demonstrated to be enhanced by the presence of the carbon. Crosslinking, as is well known to the art, allows the base polymer in a PTC composition to retain its mechanical properties above the crystalline melting point. Without crosslinking, temperature excursions above the crystalline melting point can cause the polymer to flow and, in this condition, its resistance may suddenly drop resulting in runaway heating.
It has been observed that the radiation crosslinked compositions of PVF 2 and carbon black exhibiting PTC characteristics described above can be reliably employed in self-regulating heating elements when powered at relatively low voltages, i.e. at about 110 volts or below. However, it has recently been found that this composition when subjected to the higher stresses that accompany the use of higher voltages, undergoes a gradual but irreversible increase in its resistance until it reaches a level at which the heating element no longer gives off sufficient heat to be useful. Therefore, notwithstanding its many advantages, the voltage instability exhibited by PVF 2 based PTC compositions have rendered them of little or no utility in many applications tht require voltages above about 110 volts.
Accordingly, in view of the shortcomings of the prior art compositions, it is an object of this invention to provide a novel PTC composition.
Another object of this invention is to provide a PTC composition having enhanced voltage stability.
Another object of this invention is to provide improved self-regulating electrical heating appliances.
The accomplishment of these and other objects will be apparent to those skilled in the art in view of the description of the invention that follows:
SUMMARY OF THE INVENTION
According to the present invention, the aforementioned objects are attained by blending a homopolymer or copolymer having the repeat unit --CH 2 --CF 2 -- with conductive carbon black, in an amount sufficient to impart PTC character to the composition, and a polymerizable polyethylenically unsaturated monomer in an amount which will improve the voltage stability of the composition of the invention followed by crosslinking the composition. The resulting compositions exhibit excellent PTC characteristics and have significantly improved voltage stability. The preferred mode of crosslinking is one initiated by ionizing radiation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 are graphs showing the effect on the electrical resistance character of PTC compositions when subjected to varying voltages.
FIG. 5 depicts a self-heating article employing the compositions of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The PTC compositions of the present invention in general can be based upon a variety of homopolymers and copolymers containing the repeat unit --CH 2 --CF 2 --. Typically, such polymers are obtained by polymerizing vinylidene fluoride, a compound of the formula CH 2 =CF 2 by conventional techniques well known to the art. A commercially available homopolymer of vinylidene fluoride, usually referred to as polyvinylidene fluoride (PVF 2 ) is commercially available under the trademark Kynar from the Pennwalt Corporation. PVF 2 typically is a polymer in which the --CH 2 --CF 2 -- repeating unit is ordered in a head to tail relationship thusly:
--CH.sub.2 --CF.sub.2 --CH.sub.2 --CF.sub.2 --.sub.x
It is within the scope of this invention to employ copolymers of vinylidene fluoride with other olefinically unsaturated comonomers such as ethylene, propylene, haloolefins such as tetrafluoroethylene and the like in amounts that do not too greatly dilute the desirable properties of thermal and hydrolytic stability imparted to the polymer by vinylidene fluoride. Therefore, preferably such copolymers are comprised predominantly of vinylidene fluoride, and more preferably greater than about 80% vinylidene fluoride on a stoichiometric basis.
Yet another polymer within the scope of this invention having the repeat unit --CH 2 --CF 2 -- in a head-head:tail-tail relationship is derived by copolymerizing tetrafluoroethylene with ethylene to achieve the following arrangement:
--CH.sub.2 --CH.sub.2 --CF.sub.2 --CF.sub.2 --CH.sub.2 --CH.sub.2 --CF.sub.2 --CF.sub.2 --.sub.x
Such a polymer is commercially available under the trademark Tefsel from the Dupont Co. Preferably, this polymer comprises at or near one mole of tetra fluoroethylene per mole of ethylene although larger or smaller amounts can be employed to obtain copolymers useful in the present invention.
Of the polymers hereinbefore described it is presently preferred to employ this homopolymer PVF 2 as it exhibits the optimum thermal and hydrolytic stability as well as chemical resistance yet is a flexible and tough resin.
The conductive carbon black useful in the present invention can be selected from a wide variety of such materials known to the prior art including, but not limited to conductive furnace, channel and acetylene blacks. The amount of carbon black required to impart PTC characters to the composition can vary according to specific black employed. However, it is well within the skill of the art to determine, by routine experimentation, effective amounts of carbon black. A presently preferred black is a furnace black sold under the trademark Vulcan XC-72 from Cabot Corporation. Using this material, useful PTC character can be imparted to the composition with amounts that vary over the range from about 4-50% by weight of the composition. It is presently preferred to use 4-12% by weight XC-72 to achieve the base resistance level most useful in self-regulating heating elements of the parallel conductor, flexible strip heater type described more fully infra.
The polymerizable, polyethylenically unsaturated monomers useful in the present invention are those of the character disclosed in Lanza, U.S. Pat. No. 3,580,829, the disclosure of which is incorporated by reference. Characteristically, such monomers are selected for their compatibility with the base polymer and for having a sufficiently low volatility such that they do not escape during processing.
Examples of suitable monomers are the polyallyl esters of carboxylic acids and other acid moieties such as cyanuric acid, e.g. triallyl cyanurate, diallyl aconitate, tetraallyl pyromellitate, triallyl isocyanurate; bis and tris maleimides, e.g. N,N 1 - ethylene - bis-maleimide and N, N 1 - m - phenylene-bis-maleimide; acrylic and methacrylic esters of polyhydric alcohols, e.g., dipentaerythritol hexamethacrylate, ethylene glycol dimethacrylate, 1,3-butylene glycol dimethacrylate and penta-erythritol tetramethacrylate; vinyl esters of polybasic acids, e.g., trivinyl cyanurate, trivinyl citrate; vinyl and allyl ethers of polyhydric alcohols, e.g. tetra-allyl ether of pentaerythritol and the tetravinyl ether of pentaerythritol; bis acrylamides, e.g., N, N 1 -methylene-bis-acrylamide and N, N 1 -p-phenylene-bis-acrylamide.
Each of the aforementioned monomers possesses a single type of ethylenically unsaturated functional group. It will be appreciated by those skilled in the art that monomers having different functional groups on the same molecule or a mixture of monomers may be used.
The amount of monomer employed necessary to optimize voltage stability can vary according to the nature of the monomer, polymer and carbon employed and the relatie proportions of polymer and carbon in the composition. A presently preferred monomer is triallylisocyanurate (TAIC) and generally compositions that comprise about 1-9% by weight of this monomer is adequate to improve voltage stability. It will be appreciated that more or less monomer may be useful in particular applications. In the case of mixtures of PVF 2 and XC-72 carbon black it is presently preferred to employ TAIC in an amount equal to about 3-6% by weight of the composition.
The PTC composition may further comprise other conventional additives normally associated with or employed in polymeric compositions including antioxidants and ultraviolet stabilizers. The polymers of the present invention are also subject to an acid catalyzed breakdown. In many cases the acid is generated by thermal excursions above the temperature at which the polymers are stable. Accordingly, a presently preferred additive is an acid aceptor which may be a basic material or the salt of a strong base and weak acid. It is presently preferred to use calcium carbonate for this purpose in an effective amount (generally up to about 3% by weight of the PTC composition).
Prior to their irradiation, the components of the composition may be blended by methods well known to those skilled in the art using conventional equipment. However, it is preferred to employ blending equipment other than the types that exert a high shearing action such as Banbury mixers and the like. More reproducible results are obtained when mixing techniques of low shearing action are used, particularly in the case of high molecular weight polymers. Such action may be obtained using ball mills, Henschel blenders or extruders, for example, a twin screw extruder. The monomer facilitates blending in that it functions as a plasticizer for the base polymer.
In a presently preferred application, prior to its irradiation, the blended ingredients are extruded about suitable electrodes and jacketed with a thermoplastic to form an article like that shown in FIG. 5. FIG. 5 is a perspective of a heating element 11 employing a PTC composition of the present invention. In FIG. 5, the PTC composition 12 has been extruded about elongate electrodes 13 of copper or other suitable material, which are coextensive with the heating element and establish a potential gradient across the element and transverse to its long axis. As shown in FIG. 5, a protective outer layer or jacket 14 is extruded over the PTC composition. This jacket is typically a thermoplastic polymer and preferably is not adversely affected by radiation. It should also possess chemical resistance and physical durability to abrasion and the like. The outer layer may be PVF 2 or other polymer such as Halar, the trademark for the copolymer of ethylene and CF 2 --CFCl. Tefzel is also a useful jacketing material.
After jacketing and before its irradiation, the article of FIG. 5 is annealed to relax the stresses in the PTC composition created by the blending and extrusion steps and to allow the carbon black to order itself in its preferred orientations. This is done at a temperature above the crystalline melting or softening point of the base polymer of the PTC composition. The function of the jacket is to prevent the PTC composition from flowing during this treatment. Accordingly, the material of the jacket should have a melting point sufficiently higher than that of the PTC polymer to allow such treatment. The preferred PVF 2 used in this invention for the PTC composition has a crystalline melting or softening point at or about 170° C. Annealing may be done at about 180° C. or above, but not higher than the decomposition point of the polymer. Accordingly, an upper temperature of about 240° C. is a practical limit. Preferably annealing is done at about 200° C.
Annealing is done for a period of time that reduces the resistance of the composition to a minimum value. The time can vary but it is preferred to employ times ranging from about 6 to about 24 hours.
When annealing is complete, the PTC composition, for example, as embodied in an article like that of FIG. 5, is cooled to room temperature and irradiated using ionizing radiation which may be gamma radiation or high energy electrons. For ease of manipulation, high energy electons are preferred. The dosage may vary and generally is effective over the range of from about 6-24 megarads. In the case of the compositions based on PVF 2 , a 12 megarad dosage is presently preferred. Although the preferred method of crosslinking the compositions of the instant invention is by the use of ionizing radiation, it will be realized by those skilled in the art that chemical methods of initiating crosslinking, for example, by using peroxides, can be employed to advantge using techniques well known to the art.
In some instances, it may be desirable to follow the irradiation with a further annealing step which is also conducted above the softening point of the polymer. The temperature ranges previously discussed are applicable in this step as well. Typically annealing at 200° C. for about 90 minutes is adequate. The effect of this annealing process is to raise somewhat and stabilize the base resistance level of the PTC composition. In the case of self-regulating heaters such as the above mentioned flexible strip heaters, the desired resistance at room temperature is from about 2,000-4,000 ohms per foot.
It is contemplated that this final annealing step can be accomplished after installation if the environment in which the article employing the PTC composition is used is caused, for example, by other heating means to exceed the crystalline softening or melting temperature of the base polymer for an appropriate period. In those cases where the inherent flexibility of an element employing the PTC compositions of this invention is exploited by causing it before or after crosslinking, to conform to the shape of the heated article, for example, about a pipe or other vessel, in-service annealing will tend to set the heater element in its new shape thereby reducing its tendency to withdraw from the heated article.
The advantages that flow from the practice of this invention will be apparent from a consideration of the following comparative examples.
EXAMPLES
In the examples that follow, the test samples were prepared in accordance with the procedure described below unless otherwise indicated. The ingredients, expressed in % by weight, were ball milled for two hours and extruded into pellets. Heater core elements like those of FIG. 5 were extruded having a cross-section of approximately 3/8"×0.05". Embedded in the core were parallel wire electrodes of 18 gauge, 7 strand, tin coated copper wire. A jacket of Tefzel resin (20 mils thick) was extruded over the core. One ft sections were annealed for 24 hours at 200° C. and irradiated with a 12 megarad dose of high energy electrons. Following irradiation, each sample was further annealed at 200° C. for 90 minutes. For each example, one foot sections were aged at 0, 120, 220, 330 and 480 volts and the effect of this aging on resistance measured and graphically recorded. These data are shown in FIGS. 1-4 in which changes in resistance (ΔP) with time at the various voltages are displayed in relative rather than absolute amounts. Initial resistance for each sample is arbitrarily assigned the value of 1.
EXAMPLE 1
Test samples were made as described above from Kynar 451 (83%), a high molecular weight PVF 2 (M.I. 0.82) XC-72 carbon black (13%), and CaCO 3 (3%) as a stabilizer. The test samples had an initial resistance before aging of 760 ohms/foot. The voltage stability of this composition is displayed graphically in FIG. 1.
EXAMPLE 2
Test samples were made as described above from Kynar 451 (87.5%), XC-72 (8.5%), CaCO 3 (3%) and triallyl isocyanurate (1%). The test samples had an initial resistance of 700 ohms/foot. Pelevant voltage stability data are shown in FIG. 2.
From a comparison of the data of FIGS. 1 and 2, the beneficial effect of including an amount of polyethylenically unsaturated monomer in a PTC composition of low resistance is readily seen. Though stable at 120 volts, the composition of Example 1 exhibited a steep rise in resistance with aging at 220° volts and above. By comparison, the composition of Example 2 was stable to 370 hours at 220 volts and exhibited a less drastic rise in resistance at 330 volts and 480 volts.
EXAMPLE 3
Test samples were made as described above using Kynar 451 (85.5%), XC-72 (11.5%) and CaCO 3 (3%). The samples had an initial resistance of 4210 ohms/foot. The voltage stability data are shown in FIG. 3.
EXAMPLE 4
Test samples were made as described above using Kynar 451 (86.5%), XC-72 (7.5%), CaCO 3 (3%) and triallyl isocyanurate (3%). The samples had an initial resistance of 4380 ohms/foot. The voltage stability data are shown in FIG. 4.
A comparison of FIGS. 3 and 4 clearly show the stabilizing effect on a PVF 2 based PTC composition of relatively high resistance of triallyl isocyanurate relative to a composition of similar resistance without it. The composition of Example 3 was relatively stable at 220 volts but suffered a catastrophic rise in resistance when aged at 330 volts. By comparison, the composition of Example 4 containing triallyl isocyanurate was stable to 330 volts for 1000 hours and underwent a much slower increase in resistance at 480 volts than did the composition of Example 3.
EXAMPLE 5
Test samples were made as described above but for the use of a Banbury mixer, rather than a ball mill, using Kynar 901 (83.5%), a lower molecular weight PVF 2 than Kynar 451 having a M.I. of 45.6, XC-72 (7.5%), CaCO 3 (3%), and triallyl isocyanurate (6%). The resistance before aging of the samples was 4300 ohms/foot. The voltage stability of these samples was comparable to those of Example 4 using Kynar 451 and demonstrates that PVF 2 of different molecular weight can be employed in the present invention.
The foregoing has stressed the presently preferred embodiments of the invention. It will be understood by those skilled in the art that modifications can be made that do not depart from the spirit or scope of the invention. For that reason the invention should be regarded as limited only by the claims that follow. | The voltage stability of crosslinked compositions of fluorocarbon polymers and conductive carbon black that exhibit a positive temperature coefficient of resistance can be improved by incorporating into the composition prior to its crosslinking an effective amount of a polymerizable polyethylenically unsaturated monomer such as, for example, triallylisocyanurate. | 2 |
FIELD OF THE INVENTION
The invention relates to the cleaning of ion sources for ion generation by desorption, in particular by matrix-assisted laser desorption.
BACKGROUND OF THE INVENTION
Desorption ion sources, especially ion sources for the ionization of samples by matrix-assisted laser desorption (MALDI), are increasingly being used for the ionization of large molecules, for example large biomolecules or artificial polymers. Ever increasing sample throughput is required.
In MALDI ion sources, bombardment with a pulse of laser light generates a plasma cloud each time, from which the ions formed are then extracted by means of an accelerating field. The plasma cloud also partially contains solid or liquid spray particles from the quasi-explosion of the matrix material. The plasma cloud expands further, depositing part of the material, matrix substance and analyte substance vaporized or sprayed in this way on the accelerating electrodes, mainly on the first acceleration electrode. As an alternative to the accelerating electrode, this type of desorption ion source can also incorporate a set of guide electrodes. After a few hundred thousand shots, there is a visible coating on these electrodes. This insulating coating can become charged and thus lead to interference of the acceleration process. The coating must therefore be removed.
The only method known until now for removing this coating is manual cleaning after venting and opening the ion source. The cleaning is usually carried out using solvents such as ethanol or acetone, and can usually be done without removing the accelerating electrode. But even without disassembling the ion source, cleaning, including the restoration of a good vacuum, takes a few hours and often requires a new adjustment and usually a completely new calibration after the mass spectrometer has been restarted.
In the following, the accelerating electrodes and the set of ion guide electrodes which are present in a desorption ion source in analytic operation (i.e. not during the cleaning operation) opposite the sample support plate are referred to collectively as “ion guide electrodes”.
A method of cleaning, in particular, of the first accelerating electrode without opening the ion source is indispensable for genuinely high throughput operation; accelerating electrodes which are usually further away remain uncontaminated for a longer time. For sustained operation, however, it is also necessary to clean the more distant accelerating electrodes.
The ion source usually also contains a video camera and a spot light to identify the samples on the carriers.
SUMMARY OF THE INVENTION
The invention involves a method and device for cleaning contaminated electrodes of a mass spectrometer. The electrodes are used for accelerating or guiding the ions in the ion source, and are cleaned using a special cleaning plate having a shape and outline like that of a typical sample support plate for that spectrometer. This cleaning plate can thus be introduced into the vacuum system of the ion source of the mass spectrometer via the sample support lock without opening the ion source. The cleaning plate can be equipped with cleaning scrubbers that may be moved out when necessary and that can carry out the cleaning by dry rubbing or with the help of high-boiling point solvents for the matrix substances. The moving out of the cleaning scrubbers can be controlled with a remote method, for example by triggering a photosensitive component on the plate using a coded sequence of pulses from an external laser. In another embodiment, the cleaning plate can also be equipped with spray nozzles connected to a reservoir of cleaning fluid that are used to spray the fluid onto the surface of the electrodes. In this embodiment, evacuation of the vented ion source chamber may be used to effect the spraying.
In the cleaning scrubber embodiment, the cleaning plate incorporates one or more cleaning scrubbers to clean a flat ion guide electrode, for example the first accelerating electrode, using the x-y movement mechanism for the support plate to move the scrubbers. If the design of the ion source so allows, the cleaning scrubbers can protrude so far that it is possible to clean without moving out the cleaning scrubbers further; but they can also be recess mounted and able to be moved out for cleaning. Since most ion sources and sample support locks cannot accommodate cleaning scrubbers which keep protruding, it may be advantageous to allow that the cleaning scrubbers can be moved out.
The cleaning scrubbers have a soft cover made of fabric, felt, leather, sponge, steel wool, emery wool or brush hairs. The covers can be soaked in a liquid with a high boiling point, such as glycerin, which can dissolve the material adhering to the accelerating electrodes.
Where necessary, the cleaning scrubbers can be moved out of the cleaning support plates by battery-driven electromechanical devices such as relays or motors. All of these devices, including the battery, are incorporated in the cleaning plate and are vacuum proof. Light-sensitive elements on the cleaning plate can be used to control the moving out of the cleaning scrubbers by means of a laser shot or a coded series of laser shots. Another option is to effect the control using coded pulses of light from the spot light of a video camera used to view the spectrometer. Electronic time switching, for example, can be used to move out the cleaning scrubber with a delay, leaving time to position the scrubber directly in front of the contaminated center of the accelerating electrode. The electronic time switching can also ensure that the cleaning scrubber is retracted again after a preset time.
In another embodiment, the cleaning plate incorporates one or more spray nozzles connected to a reservoir of cleaning fluid in the inside of the cleaning plate. Ethyl alcohol or acetone can be used as cleaning fluid, for example; for a nozzle diameter of around 50 to 300 micrometers, favorably about 100 micrometers, five to ten milliliters of fluid is sufficient for a cleaning time of around ten to twenty seconds. This cleaning plate with spray nozzles is introduced via the lock into the vented ion source chamber. It begins spraying in the form of a fine, needle sharp jet after the beginning of an evacuation of the ion source chamber with the help of the vacuum forepump. A rotating or meandering motion of the cleaning plate brought about by the movement device of the sample support plates effects cleaning in a few seconds. In the case of flat accelerating electrodes, the jet can also reach the second accelerating electrode via holes in the first accelerating electrode and clean this as well.
As is the case with the sample support plates, both types of cleaning plates can be equipped with a machine readable identification code, in a transponder or as a barcode, for example. The encoded information can be read by the mass spectrometer during introduction and used to automatically call up a control program for the cleaning procedure which suits the cleaning plate version currently being used or meets the analytical requirements of the sample preparation being used at that time. In this way, cleaning plates can be stacked together with normal sample support plates and automatically fed into the mass spectrometer by feed robots as part of a series of sample support plates. In critical cases, cleaning of the accelerating plates of the ion source can thus be carried out after the analysis of a predetermined number of sample support plates (which each contain 384 or 1536 samples, for example).
A method for cleaning a flat accelerating electrode with scrubbers can proceed as follows: First of all the cleaning plate is introduced via the vacuum lock into the vacuum chamber of the ion source of the mass spectrometer, thereby reading the identification code, and the cleaning plate is positioned in front of the accelerating electrode. A cleaning scrubber is then moved out of the cleaning plate is such a way that it softly presses against the accelerating electrode. As a result of the x-y movement mechanism for the sample support plate, the cleaning plate is moved in such a way that the accelerating electrode is cleaned of the material adhering to it. The movement of the x-y stage is controlled by a computer program for the cleaning process.
A dampened cleaning scrubber can be used for the cleaning, for example, but a dry cleaning scrubber is also effective, especially when emery is incorporated into it. After cleaning with a damp scrubber, the electrode can be polished with a dry one; brushes can be used to remove dirt from the internal edges of the ion optical apertures. Finally, the cleaning scrubber used last is retracted again and the cleaning plate is removed via the lock. In this way, all of the dirt is removed via the lock and it is then easy to clean the cleaning scrubbers and prepare them for a new cleaning process.
One of the cleaning scrubbers can be soaked in a high-boiling liquid before the cleaning plate is introduced via the lock to make it easier to remove the material adhering to the accelerating electrode. Glycerin can be used as a cleaning fluid, for example. Glycerin is a trivalent alcohol which does not begin to boil even under vacuum conditions. Other high-boiling liquids can also be used here, for example vacuum pump oil. The type of liquid depends to a great extent on the type of contamination which, in turn, consists mainly of the matrix material for the MALDI ionization, as a rule.
The cleaning method is different when a cleaning plate with spray nozzles is used, as has been briefly described above, since, in this case, the ion source chamber must be vented.
Both types of cleaning plate can also incorporate one or more mirrors which enable the cleaning success to be checked by the naked eye or by video camera. In particular, several mirrors at several different angles can be mounted in order to see different parts of the acceleration aperture. The cleanness can be checked visually or automatically by means of image processing programs.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which:
FIG. 1 shows schematically a first cleaning plate according to the invention;
FIG. 2 shows schematically a cleaning plate having a central spray nozzle via which cleaning solution may be sprayed onto the ion guide electrodes;
FIGS. 3A and 3B show two schematic cross sections through a cleaning plate like that of FIG. 2 , one oriented for vertical spraying and the other oriented for horizontal spraying; and
FIG. 4 shows a schematic view of some of the components of a typical spectrometer arranged to make use of a cleaning plate according to the present invention.
DETAILED DESCRIPTION
The invention relates to both devices and methods for cleaning ion guide electrodes in a laser desorption ion source. In one embodiment, shown in FIG. 1 , the main body ( 1 ) of a cleaning plate, shown here with the outline of a microtitre plate, has recessed cleaning scrubbers ( 2 ) and ( 3 ) with covers. In this figure, the cleaning scrubber ( 2 ) is shown having been moved out of its recess, while the scrubber ( 3 ) remains in its recess. The moving out can be started by laser bombardment onto a light sensitive element ( 4 ), which is electrically connected to a circuit that effects movement of the scrubbers. The cleaning plate here carries both a transponder ( 5 ) and a barcode ( 6 ) mounted on the front end. The mirrors ( 7 , 8 , 9 ) inset at different angles make it possible to check on the cleaning success with the video system of the mass spectrometer (not shown). This type of device may be used when the ion guide electrodes to be cleaned are the first of the flat accelerating electrodes.
For the invention, it is favorable if the sample support plate is neither too small nor too thin. The cleaning plate has an outer contour similar to that of a standard sample support plate, such as a microtitre plate, intended for the spectrometer to be cleaned. As such, it can be introduced into the vacuum system of the ion source of the mass spectrometer via a conventional sample support lock. A plate the size of a microtitre plate also has sufficient room to accommodate the cleaning scrubbers and other necessary components.
In order to be able to move the cleaning scrubbers out of their respective recesses, the cleaning plate incorporates a controller ( 20 ), which includes electrical and electromechanical devices such as a vacuum proof battery, control electronics, relays or electric motors. Light sensitive elements of the control electronics on the outside of the cleaning plate can react to laser bombardment or to the video spot light of a video camera. This can be used to control the moving out of the cleaning scrubbers to suit the prevailing situation. In each case, the cleaning scrubbers are moved out so far as to softly press on the accelerating electrode. A spring may also be used with the controller and can generate a uniform pressure of the desired strength.
Each cleaning scrubber carries a cover which can be made of an elastic or soft porous or otherwise flexible material. The covers can be made of paper, fabric, felt, leather, steel wool, rubber or sponge, or they can be in the form of a brush. Coarse or fine emery particles can also be embedded into the cover material. The surface of this cover is used with a scrubbing action to clean the accelerating electrode. The cover material of a cleaning scrubber can be soaked in a high-boiling liquid before the cleaning plate is introduced via the lock, the high-boiling liquid chosen being able to dissolve the material adhering to the accelerating electrode, which consists mainly of matrix substance. Polyvalent alcohols such as glycerin or glycol, or liquids such as diffusion pump oils (polyethylene glycol) are suitable liquids for this purpose. Ether bonds in the polyvalent alcohols create liquids which remain in the liquid state in spite of their low vapor pressure. It is advantageous if these liquids develop enough residual pressure so that a thin residual film remaining after wiping with a dry material dries within a few tens of minutes. After cleaning with a liquid, it is favorable to wipe and polish the accelerating electrode with a dry absorbent cleaning scrubber, covered, for example, with velvet.
In another embodiment, shown in FIG. 2 , the cleaning plate incorporates one or more spray nozzles. In this embodiment, the cleaning plate ( 15 ) has a central spray nozzle ( 10 ) lying in a catch basin ( 11 ) in order to catch the cleaning fluid which drips down when vertical spraying is employed. This type of cleaning plate can be used with ion guide electrodes which are not necessarily flat in shape; it can also especially be used to clean a second, flat accelerating electrode. The spray nozzles are equipped with one or more tubes or pipes dipping into a reservoir of cleaning fluid inside the cleaning plate. The reservoir is typically only partly filled in order to create an air cushion within the reservoir. Ethyl alcohol or acetone, for example, are suitable cleaning fluids, depending on the matrix substance, but other organic solvents can also be used. Nozzle diameters of 50 to 400 micrometers may be used. For a nozzle diameter of around 100 micrometers, five milliliters of fluid in ten milliliters reservoir volume is sufficient for a cleaning time of about twenty seconds.
Like the plate of FIG. 1 , it is desirable to have the cleaning plate ( 15 ) be of an outer contour similar to that of a standard sample support plate, so that it may be introduced via the lock into the vented ion source chamber. It begins the spraying in the form of a fine, defined jet after the beginning of the evacuation of the ion source chamber by the spectrometer's forepump. Very rapid cleaning is achieved by using the x-y movement device of the sample support plate to move the cleaning plate in a circulating, meandering or other movement which provides all-over cover. In the case of flat accelerating electrodes, the jet can also reach the second accelerating electrode via holes in the first accelerating electrode in order to clean this one as well. Experience has shown that the thin coating layers dissolve in seconds and drop with the cleaning fluid into lower, uncritical regions of the ion source chamber. In the case of vertical spraying, the cleaning fluids drop back onto the cleaning plate. They vaporize completely within a few minutes because of the effect of the evacuation.
When the phrase “vented ion source chamber” is used herein, it can mean that only the ion source chamber is vented if this can be closed off from the rest of the mass spectrometer by means of a valve. It can, however, also mean that the mass spectrometer in its entirety, or large parts thereof, has to be vented, if there is no such valve between the ion source chamber and the rest of the mass spectrometer. The venting must naturally include the ion source chamber.
FIGS. 3A and 3B show two schematic cross sections through the cleaning plate ( 15 ) with spray nozzle ( 10 ), one oriented for vertical spraying and the other oriented for horizontal spraying. In both figures, the spray nozzle ( 10 ) has a tube ( 12 ) or a pipe which dips into the cleaning fluid ( 13 ), which only partially fills the reservoir volume in order to create an air cushion at atmospheric pressure. This air cushion presses the fluid out of the spray nozzle during evacuation. The form of the reservoir is such that the cleaning plate can be used to spray vertically and horizontally.
Each of the cleaning plates ( 1 ) and ( 15 ), shown in FIGS. 1 and 2 respectively, can incorporate a machine readable identification code. This may be accomplished using, for example, a built-in transponder or a barcode printed on the plate, similar to techniques used for normal sample supports. It is then possible to read the information contained in the code in a reading station of the mass spectrometer. On the basis of this information, the control program of the mass spectrometer can then call up and execute a special cleaning control program. Each type of cleaning plate can also incorporate one or more movable or immovable mirrors which can be used to check on the cleaning by means of the video system of the mass spectrometer.
The method of cleaning the accelerating electrode with scrubbers involves introducing the cleaning plate in the same way that a normal sample support plate would be introduced, i.e., through the lock into the evacuated vacuum chamber of the ion source of a mass spectrometer. The cleaning plate is then positioned in front of the accelerating electrode, and one of the cleaning scrubbers from the cleaning plate is moved against the accelerating electrode. Using the x-y movement mechanism of the sample support plate to move the cleaning plate together with the cleaning scrubber, the accelerating electrode is cleaned of the material adhering to it. Finally, the cleaning scrubber used last is retracted and the cleaning plate is removed via the lock.
This method can be extended so that the cleaning is carried out first of all using a damp scrubber, then a dry one. Or it can initially be rubbed with coarse emery, then wiped with a damp material before being dried with a soft material. It is preferable if the wiping is done using the x-y movement device which is already available to position the samples on the sample support plate. It is, however, also possible to let the extended cleaning scrubber move on its own, for example by rotating a brush-shaped cleaning scrubber. A combination of movement of the cleaning scrubber with the movement of the x-y stage is also possible.
FIG. 4 is a schematic depiction of some of the components of a typical spectrometer arranged to make use of a cleaning plate. In this figure, a feeding robot ( 23 ) is shown that is used to feed the cleaning plate ( 1 ) into the ion source chamber via vacuum lock ( 22 ). In the chamber, the plate is secured to movement device ( 21 ), and may be moved adjacent to ion guide electrode ( 27 ), which the electrode may be reached with the cleaning plate scrubbers. A pulse laser ( 24 ) with focusing lens 25 allows the delivery of light pulses to the cleaning plate, and video camera 26 is also present and focused on the cleaning plate position.
The cleaning procedure is controlled by a cleaning control program located in a control computer of the mass spectrometer. This can be started manually by the user of the mass spectrometer. It can also be started automatically, for example via the information in a transponder incorporated into the cleaning plate which can be read by a reading station of the mass spectrometer. It is thus possible to stack the cleaning plates together with normal sample support plates and to have them automatically fed into the mass spectrometer by feed robots as part of a series of sample support plates. After analyzing a given number of sample support plates (which each may contain 384 or 1536 samples, for example) the first accelerating plate of the ion source can automatically be cleaned, for example in high throughput analysis runs of many ten thousands of samples which are carried out over a weekend.
When using a cleaning plate like that shown in FIG. 1 , the cleaning scrubber can be moved out using an electronic time control, for which a one off initialization is necessary and this can be done by introducing it into the vacuum chamber, for example. It can also be initiated by a mechanical contact which can be triggered by the x-y movement unit for the support plate, for example, by hitting a fixed protrusion on the wall of the vacuum chamber. It is useful, however, to have more flexible control of the cleaning procedure by means of a contact-free signal transmission to the cleaning support plate. A very simple method of signal transmission can be provided by a coded series of laser shots onto a light sensitive element of the cleaning plate, for example. In this way, certain cleaning steps can be repeated again and again as required by the samples and the situation. A coded switching on and off of the video spot light can also be used.
In this situation, a signal from one or more laser shots via the light sensitive element can cause the immediate or delayed moving out of one of the cleaning scrubbers. It is useful if the retraction is carried out automatically after a preset period of time to ensure that, whatever happens, the cleaning plate can be removed from the mass spectrometer via the lock again.
Before the cleaning plate is removed via the lock, the cleaning procedure can be checked. The checking can be done simply from the outside by using windows; it is particularly favorable to use the video equipment of the mass spectrometer, however. For this purpose, mirrors can be inserted into the cleaning plate, said mirrors being inclined at such an angle that they reflect the critical parts of the accelerating electrode. As a rule, the slightly extended object distance of the video optics still provides images which are sharp enough to assess the cleanliness. The mirrors can also improve the imaging characteristics by use of an appropriate curvature. It is also possible to move out the mirrors from the surface of the cleaning plate, in a similar way to that used for the cleaning scrubbers, in order to produce an optimum viewing distance of the video camera which normally is focused onto the samples on the sample support plate.
When using a cleaning plate like that shown in FIG. 2 , the method of operation is somewhat different: In this case, the vacuum lock is not evacuated for introducing the plate but, instead, the ion source chamber is vented (for example with dry nitrogen). The machine-readable code on the cleaning support plate must therefore be read before the vacuum lock is evacuated. The cleaning plate is then introduced via the lock into the vented ion source chamber and positioned in front of the ion guide electrodes. Only then is the forepump for evacuating the ion source chamber switched on and, after a short time, a needle sharp fine jet of cleaning fluid shoots out of the spray nozzle (or nozzles if two or more spray nozzles are present). The cleaning plate is now set into a circular or meandering motion in order to clean the ion guide electrodes. The cleaning is done within a few seconds using ethyl alcohol or acetone.
The cleaning fluid initially drops from the ion guide electrodes but quickly begins to vaporize because of the low pressure. The vapors of the cleaning fluid are also pumped away by the forepump. Experience has shown that the vapors are not harmful to the forepump, on the contrary, they seem to clean the forepump oil.
In the case of manually started cleaning, the checking can be done visually by the operator examining the image on the screen. It is also possible, however, to have automatic checking carried out by an image evaluation program. It is then particularly possible to document the cleaning using pictures. | The invention relates to the cleaning of contaminated accelerating or guiding electrodes of ion sources used for ion generation by desorption. A cleaning plate is used that has an outer contour similar to that of a standard sample support plate, and may be equipped with cleaning scrubbers that can be moved out when necessary to contact the electrodes. The scrubbers may include soft covers, and can carry out the cleaning by dry rubbing or with the help of high-boiling solvents for the matrix substances. The moving out of the cleaning scrubbers can be controlled by external light pulses from a laser or video camera spot light. Alternatively, the cleaning plate may be equipped with spray nozzles connected to a reservoir of cleaning fluid which is sprayed onto the electrodes, and the evacuation of the ventilated ion source chamber may be used to initiate the spraying. | 8 |
BACKGROUND OF THE INVENTION
Moving bin sheet collators or sorters for use with office copiers and printers have evolved in which a set of receiver trays are supported for movement relative to a sheet entry location, at which sheets enter the sorter from a copier or printer, so that the trays are close together at positions above and below the sheet entry location but are widely spaced apart at the sheet entry location to facilitate entry of the sheets into a bin.
Examples of such sorters are illustrated in the prior patents of Lawrence, U.S. Pat. No. 4,343,463 granted Aug. 10, 1982; DuBois and Hamma, U.S. Pat. No. 4,328,963 granted May 11, 1982; and DuBois, U.S. Pat. No. 4,478,406 granted Oct. 23, 1984, as well as in Hamma application Ser. No. 06,483,596, filed Apr. 11, 1983, owned commonly herewith.
Such sorters utilize cams to engage cam follower portions of the trays to move the ends of the tray adjacent to the sheet entry location between the closely spaced positions above and below the cams which define the enlarged space between the trays at the sheet entry location. The cams are driven in opposite directions by a drive motor under control of suitable means to cause operation of the motor as required to collate a desired number of sets of sheets having a desired number of sheets per set. The motor control means may be self-contained in the sorter or the control means may be incorporated, as well, in the host copier.
In any event the motor is caused to be driven in opposite directions and intermittently depending upon the sorting task to be performed, so that the sorting is bi-directional, i.e., the trays move up and down during sorting operations to receive sheets supplied from the copier or printer.
Each revolution, or partial revolution, of the cams, depending on the profile of the cam and the motor controlling means, causes the cams to move from a stationary dwell position to an active position to move the trays. Activation of the cams, in many forms, will inherently cause initial impact with the cam followers before the followers commence to move the trays. This impact causes objectionable noise which is increased when the cam follower portions of the trays are spring biased in one direction into contact with the cams to cause the cams to engage the follower portions of the trays and/or when the cam must move at a high rate of speed.
In the case where the cam follower portions of the trays directly abut when the trays are in their closely spaced positions above and below the cams, the noise problem can be alleviated, to some extent by segregating the follower portion and the tray spacing portions of the tray, particularly in the case of utilization of certain cam forms like the helical form of Lawrence U.S. Pat. No. 4,343,463 or DuBois U.S. Pat. No. 4,478,406.
However, in the case of cam wheels of the type referred to in DuBois and Hamma U.S. Pat. No. 4,328,963 and the Hamma application Ser. No. 483,596, as "Geneva" wheels having one or more radial openings formed in the periphery of a rotary mechanism, the noise problem is severe, in part due to the fact that such sorters typically employ a spring to load the trays located below the cams upwardly for engagement with the cams.
The magnitude of the noise is a function of a) the speed of travel of the cam when the follower on the tray engages in the radial notch or is disengaged from the notch by engagement with a wall defining a guide slot for the follower and b) the load on the follower caused by springs and/or the weight of the trays, including paper therein. Accordingly the problem is exacerbated in the higher speed sorters in which the cams must be rapidly moved to shift the trays during a relatively short period of time between copies.
SUMMARY OF THE INVENTION
The present invention relates to reducing the noise problems of the types described above.
A major advantage of such noise reduction relates to the fact that not only is the noise level objectionable to the user and others in an office environment, but also noise level limits on office equipment are subject to increasingly stringent regulation by various authorities in different market areas, such that, certain sorters of the class here involved may not be capable of operation at acceptable noise levels.
The present invention contemplates minimizing the noise caused by impact of the cam followers on the trays with the cam followers with cam follower guides and impact and shock loading of the cam followers with one another as the cams are rotated from a dwell position into a tray shifting position, in either direction, by rotating the cams at relatively low speed at the time of transition between dwell and raising or lowering of the trays, compared with the relatively high speed at which the cams are rotated to raise or lower the trays following engagement with the cam followers.
More particularly, the invention provides for varying the speed of the cam drive motor by changing the duty cycle of the power supplied to the electric drive motor and sensing the position of the cam followers with respect to the cams, so that from the normal or stationary dwell positions of the cam until following transition from the dwell positions to active positions at which the followers are being shifted to move the trays, the motor drives the cam at a relatively low speed and then at a higher speed until just prior to completion of the shifting movement, but thereafter again at the low speed as the cam followers return to the dwell position.
The manner in which noise is minimized will be better understood by reference to the accompanying drawings in light of the following description of a preferred form of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation illustrating one form of sorting machine to which the subject matter of the invention is applied, showing the movable sorter trays in a non-sort condition;
FIG. 2 is a view corresponding with FIG. 1, but showing the trays in one sorting position; FIG. 3 is a top plan view of the sorter;
FIG. 4 is an enlarged fragmentary detail view of the tray shifting means at one side of the apparatus, as taken on the lines 4--4 of FIG. 3;
FIG. 5a is a fragmentary detail view showing the bin shifting cam of FIG. 4 in a position with the trays in the non-sorting condition of FIG. 1;
FIG. 5b is a view corresponding with FIG. 5a showing the cam rotated to engage a cam follower portion of the top tray;
FIG. 5c is a view showing the tray shifting cam as it moves the top tray upwardly at a high speed to increase the sheet receiving space;
FIG. 5d is a view showing the tray shifting cam as it discharges the top tray at low speed;
FIG. 5e is a view showing the tray shifting cam in transition from the point of discharge of the top tray to the point of stopping prior to lifting the next sub-jacent tray;
FIG. 5f corresponds with FIG. 5a, showing the cam stopped in position to engage the next sub-jacent tray;
FIG. 6 is a diagram of the preferred drive motor control system; and
FIG. 7 is a graph showing the preferred speed curve of the drive motor compared with the variation in the duty cycle of the applied motor power.
DETAILED DESCRIPTION
As seen in the drawings, referring first to FIGS. 1-3 one form of sorting machine is generally illustrated. Such a form of sorter is illustrated and described in greater detail in the above referred to U.S. Pat. No. 4,328,963.
The sorting machine comprises, in the form shown, a frame structure 1 which supports a set of sheet receiving trays 10. At their outer ends 11, which extend from the frame structure, the set of trays is supported on a base support 12 provided by the frame structure, the individual trays 10 having their outer ends 11 supported for pivotal movement one on the other and enabling the inner ends of the trays to be shifted vertically by tray transfer or shifting means 13 in succession and intermittently between positions at which the inner ends of all of the trays are disposed below the shifting means 13, as shown in FIG. 1, to positions at which the inner ends of the trays successively are positioned above the shifting means 13, as shown in FIG. 2.
During such shifting movement of the trays, an enlarged sheet entry space 15 is provided between trays into which sheets of paper are fed, in the form shown, by sheet transport rolls 16, as the sheets are supplied from the exit rolls 17 of a copying machine or printer adapted to supply copies of a page or sheet of a document to the sorter for collation of successive copies or to receive individual documents. The apparatus thus may function as a collator in conjunction with a copier or as a receiver or mailbox in conjunction with a printer. As is well known, such sorters are operable under the control of suitable systems which, following the feeding of a sheet into one tray, causes the transfer means to shift the tray vertically either to the upper tray position or the lower tray position defining the sheet receiving space 15 to facilitate entry of the sheet, while the trays are closely nested together at all other positions.
The transfer means 13, in the illustrated form, as best seen in FIGS. 3 and 4, includes a tray transfer wheel 18 at each side of the frame structure mounted on a horizontally extended shaft 19 to be rotated together in opposite directions by a drive motor 20 and belt or chain 21 at one side of the frame structure. The feed rolls 16, as seen in FIG. 3 are on a balloon counter shaft 16a driven by a sheet feed motor 16b.
At the inner ends, or the sheet receiving ends adjacent to the sheet entry location of the feed rolls 16, the trays are adapted to be engaged by the transfer wheels 18 so as to be vertically shifted. Accordingly, the inner ends of the trays have cam followers in the form of trunnions or rollers 22 extending laterally at opposite sides of the trays through vertically extended guide slots 23 in the frame structure so as to be engaged by the transfer wheels 18, whereby upon rotation of the transfer wheels in either direction the tray ends will be shifted vertically.
To engage the trays, the transfer wheels are provided with one or more radial notches or recesses. In the illustrative embodiment there are two notches 24 on opposite sides of the center of the wheel which are formed to receive the cam followers or trunnions 22 on the trays. Thus, each semi-revolution of the transfer wheels will cause the cams to engage the follower of a first tray in a notch and move the tray end upwardly or downwardly, depending upon the sense or rotation of the cams, to form between adjacent trays the enlarged space 15.
In the case of the sorter herein illustrated, gravity causes the trays above the transfer wheels to rest on the circular periphery 25 of the wheels and to engage in the slots 24. On the other hand, a suitable bias is provided to cause the trays below the cams to engage the circular periphery 25 and move into the notches 24 when the transfer wheels are rotated. As shown, coiled tension springs 26, only one of which is shown, are connected at opposite sides of the assembly to the lowermost tray, at its inner end, and to the frame structure at a location above the transfer wheels to load the trays upwardly into engagement with the transfer wheels. The spring 26, therefore, must be rated to lift the cumulative weight of the trays, plus the weight of the sheets of paper in the trays.
At this point, it will now be recognized that when the trays are being moved downwardly, the weight of the trays and paper above the transfer wheels forcing the followers 22 into the cam notches 24 will cause an impact of the followers entering the notches and shock loading of all of the super-jacent followers. Also, as the followers 22 at the low side of the transfer wheels are being displaced into the downwardly extending slot 23, and depending upon the speed of movement of the transfer wheels, there is an impact of the cam followers being discharged with the next followers below in the slot, as well as with the side wall of the slot, coupled with shock loading of the sub-jacent cam followers, downward movement of which is resisted by the upward bias of spring 26.
The same impact problem and shock loading exists when the trays are being pivoted upwardly by the transfer wheels or cams. However, the cause of the problem differs because, in this case, the spring causes impact and shock loading of the cam followers below the transfer wheel as the top followers below the wheel are forced into the cam notches, while the over-burden of the trays, and paper therein, above the transfer wheels resists upward movement of the upper trays, coupled with impact of the followers being discharged from the cam notches against the side wall of the upwardly extending guide slot.
All of this impact and shock loading of trunnions in the usual sorters of the type here involved results in a noise level which is objectionable, particularly in the case of use of the sorter with more modern and quieter copiers and printers and even more particularly where regulation places stringent limits on the noise level accompanying operation of office equipment.
In this type of sorter, while the merger of the circular periphery or dwell portion 25 of the cam with the side wall of the notches may be arched to reduce the abruptness of the change, i.e., smooth out the transition between the dwell and the tray moving action of the cam, or for that matter between the dwell and active faces of other cam forms, there is a practical limit to such efforts to reduce impact and shock loading and resultant noise.
Therefore, the present invention has as its salient feature control of the cam speed as the cam follower engages with and disengages from the active portion of the cam so as to reduce the momentum of the impact and shock loading and, thus, the resultant noise, e while also after engagement with an dis-engagement of the upper and lower tray ends, driving the cam at a sufficiently higher rate of speed to complete tray transfer during the available time before the sorter is to receive another sheet.
This concept will be better understood with reference to FIGS. 5a-5f.
As seen in FIG. 5a, tray 10a represents the uppermost tray of the set of trays below the cam and the cam follower 22 of tray 10a is on the dwell or circular periphery 25 of the cam or transfer wheel 18 at a location adjacent to one of the radial recesses or slots 24, while the cam followers of trays above the cam during continued sheet sorting operations as seen in FIG. 2 would be located in the guide slot 23 and rest on the circular dwell portion 25. At this time the cam 18 remains stationary until the drive motor is activated to rotate the cam in a counterclockwise direction. Under the conditions that the cam is stationary any output of sheets from the host copier or printer will be received in the tray 10a.
During the sorting operations of the sorting machine the trays are to be moved in sequence upwardly at the ends 10a, 10b, 10c, et seq., not shown, to ultimately provide the enlarged sheet receiving space 15 (seen in FIG. 5f). If will be understood from the description above that upward movement of the tray ends into engagement with the cam is caused by the strong bias of the spring 26 which must lift the weight of the entire tray set together with any paper previously received in the trays during sorting operations. The cam 18 is caused to rotate in a counterclockwise direction, in half revolution increments, as seen by the arrow in FIGS. 5b-5e to cause upward movement of the trays, as the upper trunnion is engaged in the notch 24 and carried upwardly until discharged from the notch, as the follower 22 is caused to move in and follow the upwardly extending guide slot 23 while displacing upwardly the subadjacent cam followers. The period of energization of the drive motor is controlled, by a one-half revolution switch 35, but if only one notch 24 is provided the motor is energized for the period of a full revolution, under the control of variable speed control means later to be described.
The motor speed control means just referred to causes the cam to rotate to the position of FIG. 5b at low speed, so that the impact of the follower 22 with the base of the notch 24 and the impact of the trailing face of the notch 24 with follower 22 is also at low speed, resulting in less noise from impact and shock loading of all the sub-jacent cam followers as they are urged forcefully upwardly by spring 26.
In FIG. 5c the cam and follower are in a state at which the cam has been moved at high speed or full speed of the motor through the arched section 23a of the guide slot to proximity with the upwardly extending guide slot 23. The motor operates at reduced speed momentarily as impact occurs between the follower 22 and the confronting vertical edge of slot 23, and with the cam follower next above which must be lifted, as the follower is displaced from the notch 24.
Thereafter from the condition of FIG. 5d, the cam is driven again at high speed through the position of FIG. 5e to return to the position of FIG. 5f, the same cam position as FIG. 5a, but with tray 10a elevated and held in position above tray 10b to provide enlarged sheet entry space 15 between trays 10a and 10b.
These operations are repeated successively with each one-half revolution of the cam, under the control of the usual sorting control selector which determines in such sorters the number of trays to be shifted depending upon the number of sets of documents being collated or collected in the case of a printer which supplies collated sets.
Motor 20 which drives the cams 18 is preferably a direct current motor the power to which is controlled so as to cause the low speed and high speed operation. As shown in FIG. 6, a motor bridge drive 30 is controlled by a microcontroller 31 programmed to provide power to a motor enable input 32 and to motor forward and motor reverse inputs 33 and 34, respectively.
Microcontroller 31 also receives motor control signals from micro switch 35 which is operated by one of the bin shifting cams 18. The switch arm, as seen in FIGS. 5a-5f rides on the outer periphery of the cam 18 in a normally off condition. The cam 18 has a pair of substantially diametrically spaced low cam regions 36 and 37 providing circumferentially spaced leading edges 36a and 37a and trailing edges 37a and 37b, respectively. Low cam 36 is operable during rotation of the cam in a counterclockwise direction, as illustrated in FIGS. 5a-5f, and low cam 37 is operative during clockwise rotation of the cam, to cause signals to the motor to stop the motor and cam at a position for engagement with the next cam follower during the next cycle of operation, as will be described below.
Microprocessor 31 is programmed so that for slow speed operation, power is supplied to the motor in a short series of pulses; while during high speed operation the motor is fully energized for a longer period of time, then de-energized to cause deceleration, and then pulses are resumed to cause low speed rotation for a brief period before the motor is energized for high speed operation to a point where the motor is briefly energized in the opposite direction to cause it to stop.
This periodic, or pulse width modulation energization of the motor is shown by a full line in FIG. 7 and the approximate resultant acceleration-deceleration curve for the motor is shown by the broken line representing one-half revolution of the cams. If the cam had only a single notch, then the high speed mode would be applied through an additional 180 degrees of rotation of the cam.
From the foregoing and with reference to FIG. 7, it will be understood that the sequence of operation as seen in FIGS. 5a-5f and described above is as follows:
The normal position of the cam when it is at rest but ready to commence a cycle of operation to shift a tray, say tray 10a in FIG. 5a, is seen in FIG. 7 in the bracketed section 5a of the power and speed versus time graph at which power is off. Then, as seen by the bracketed time period designated 5b in FIG. 7, power is applied to the motor for a short period of time in a series of pulses sufficient to initiate revolution of the cam and rotate it through an angle necessary to engage the follower 22 on tray 10a in the notch 24, as seen in FIG. 5b. At this time continuous power is supplied to the motor over a period of time sufficient to cause the motor to accelerate to the high speed level as indicated by the bracketed time period FIG. 5c in FIG. 7. As the cam follower in the cam notch approaches the upwardly extending guide slot 23, as seen in FIG. 5d, the motor is again energized only by a series of pulses illustrated by the bracketed time line designated FIG. 5d in FIG. 7, so that as the follower impacts with the upwardly extending side wall of the guide slot 23, as well as with the follower already disposed in the guide slot 23, the motor and cam decelerated to the low speed mode thus reduces the noise caused by input and shock loading. Thereafter, for a brief period represented by the bracketed time line of FIG. 7 designated FIG. 5e, uninterrupted power is again supplied to the motor causing it to again accelerate to move the cam towards a position at which it will engage and commence upward movement of the tray 10b. At this point, in order to stop the motor the low cam portion 36 of the cam is in a position relative to the switch 35 that the micro switch has signaled to the controller 31 as a result of passing over the cam section 36a that it will receive a motor stop signal. The motor stop signal is given when the micro switch is actuated by the low cam section 36b, and at this time, for a brief moment, micro processor 31 causes the energization through connector 34 of the motor 20 in a reverse direction which causes the motor to abruptly stop as indicated by the portion of the time line of FIG. 7 designated FIG. 5f, showing the negative application of power.
During upward movement of the trays successively, the above operation is repeated, pausing only so long as necessary for a new copy sheet to be fed through the sorter to the enlarged sheet receiving space 15. It will be understood that the interval between actuation of the tray shifting means is keyed to the interval between the feeding of such sheets, and, therefore, the total time period during which the successive trays must be shifted and the relationship between high and low speed operation is keyed through the micro processor 31 to the interval between the feeding of sheets. Thus the relationship between high and low speed transitional movement can be adjusted to accommodate sorters of different speeds and cams with one or more notched 24 or other profiles.
It will also be recognized that the noise problem encountered in such sorters is more acute in machines operating with a brief inter-copy interval and that the ability of the present invention to reduce noise by low speed operation of the sorter at the critical points of contact between the cam and the follower and between the follower and the side wall of the slots and other followers is particularly advantageous in the sorters operating at higher speeds.
In the preferred form herein shown and described the specific control means for the motor involves the use of pulse modulated power application for low speed operation, since heat generation is minimized. However, other ways, such as the use of variable resistors and/or capacitors are extant or controlling electric motor speeds, but such other means are more difficult to adjust or tune to the specific needs of sorters of the type here involved. | A moving bin sheet sorter has rotatable cams which engage portions of the sorter trays to move the trays at the ends adjacent to a sheet entry location between positions at which those tray ends are closely spaced above and below the sheet entry location and further spaced apart at the sheet entry location for receiving sheets supplied from a copier or printer. The cams are driven by an electric motor which is controlled to operate at a low speed as the trays are initially engaged and disengaged from the cam and a high speed during the major movement of the trays, thereby reducing noise resulting from high speed impact and shock loading of the cams and cooperative portions of the trays, as well as reducing noise resulting from high speed impact of said cooperative portions of the trays in guides for the trays. | 1 |
RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 10/688,472 entitled “Traffic Alert Police Radar” and filed on Oct. 17, 2003, in the names of Alan B. Mead, John L. Aker, Robert S. Gammenthaler, and James Kevin McCoy; which is hereby incorporated by reference for all purposes.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention pertains to technologies for alerting a vehicle operator potentially hazardous traffic conditions prior to or during certain common driving maneuvers, such as interception U-turns, and pulling into moving traffic from a roadside.
BACKGROUND OF THE INVENTION
[0003] There are many types of vehicles which, during the routine course of their operation, are exposed to hazardous traffic conditions. Police cruisers and highway patrol vehicles often must re-enter moving traffic from a roadway shoulder after detaining another vehicle, or when intercepting a vehicle for speeding or another violation. Law enforcement vehicles operating on divided highways and boulevards often make U-turns to intercept a vehicle traveling in the opposing lanes, or to respond to a dispatch call.
[0004] However, law enforcement vehicles are by no means the only type of vehicle which routinely must operate in hazardous traffic conditions. For example, another emergency vehicle such as an ambulance or fire truck may also have to return to the roadway from a stopped position on the shoulder (e.g. after completing a call to an injury, wreck, or fire), or may have to make a U-turn to respond to a fire call or medical emergency.
[0005] Non-emergency vehicles also may have to make similar maneuvers, such as a construction or street maintenance vehicle, or a utility vehicle (e.g. telephone, electrical, water, sewage or natural gas service truck or van, or school bus). When completing a job or when attempting to arrive at a place for a job near or on a roadway, these types of non-emergency vehicles may be exposed to the same traffic hazards as a police vehicle, ambulance, or fire truck.
[0006] Therefore, the following description of certain hazardous situations applies equally well to all of these types of vehicles, and not just to police and highway patrol vehicles. For the remainder of this disclosure, we utilize the term “primary vehicle” to refer to any vehicle which is subjected to a potentially hazardous traffic condition, such as a police or trooper vehicle, or alternatively another emergency or non-emergency vehicle as previously described. Additionally, we employ the term “secondary vehicle” as a vehicle which may be involved in a particular scenario, the position and condition of which the operator of the primary vehicle is aware, such as a vehicle a patrolman has detained alongside a road, or a vehicle which an ambulance or fire truck is servicing. Further, we will refer to other vehicles which pose a potential danger to the primary vehicle as a “closing vehicle”, such as a vehicle which is moving in a lane of traffic in which the primary vehicle is entering, and especially of which the operator of the primary vehicle may not be aware.
[0007] Police cruisers and highway patrol vehicles are generally supplied with several types of equipment, including an enhanced engine, suspension, and braking systems, as well as voice and data communication equipment. Such vehicles are also equipped with a variety of rotating beacons, strobe lights, and LED warning indicators, which, when used separately or in conjunction with a siren, can provide warning to other motorists of the patrol vehicle's status and position. Many law enforcement vehicles are also equipped with radar guns which can determine the speed of a target vehicle in traffic, mainly for the purposes of enforcing roadway speed limits. While these types of devices are useful in many applications of law enforcement, they provide inadequate safety to the officers operating the patrol vehicle in certain scenarios.
[0008] For example, in one common law enforcement scenario ( 10 ) as shown in FIG. 1 , a trooper vehicle T is traveling in a first direction at an initial position ( 14 ) on a lane ( 12 ) of a divided highway, wherein the divided highway also has a median ( 13 ) and an opposing traffic lane ( 11 ).
[0009] Initially, the trooper may be measuring the speeds of vehicles in the opposing traffic lane ( 11 ), using a police radar unit, such as determining the speed of vehicle A in an initial position ( 15 ) in front of the trooper vehicle T in its initial position ( 14 ). At this point, the police radar unit has a line-of-sight ( 17 ) from the trooper vehicle T to the vehicle A.
[0010] When the trooper decides to intercept vehicle A, he must make a U-turn maneuver ( 18 ) through the median ( 13 ), falling into a pursuit position ( 14 ′) traveling in the opposing lane ( 11 ) behind vehicle A, which has now moved to position A ( 15 ′).
[0011] However, if another vehicle B is also traveling ( 16 ) in the opposing lane ( 11 ) at the time of the trooper's U-turn maneuver ( 18 ), there may be a danger of a collision with the trooper's vehicle. Vehicle B may not be initially visible when the trooper turns due to poor roadway lighting, inclement weather, or another visual impediment. As the trooper must slow his speed during the U-turn, and regain highway speed following the U-turn, vehicle B may be closing on the trooper vehicle at a considerably faster speed. If the trooper is operating the emergency lights (e.g. strobes, beacons, etc.) or the siren, the operator of vehicle B may be alerted to the danger of collision with the trooper, but the trooper is provided no warning of the potential collision.
[0012] In this particular scenario, the trooper vehicle T represents a primary vehicle, the intercepted vehicle A represents a secondary vehicle, and the vehicle B with which a collision danger exists is the closing vehicle. In alternate versions of this scenario, the primary vehicle may be a fire truck, ambulance, utility van, school bus or maintenance truck. Even though there may not be an intercepted vehicle in such a variation of this scenario, there certainly can be a closing vehicle which presents a collision danger when the primary vehicle is making a U-turn.
[0013] In another common law enforcement scenario ( 20 ) as illustrated by FIG. 2 , a trooper vehicle T ( 24 ) is initially stopped ( 24 ) alongside ( 21 ) a roadway ( 22 ), sometimes with a detained vehicle A, which is also stopped ( 25 ). Alternatively, the trooper vehicle T may not be accompanied by a detained vehicle A, such as the case when a trooper is “speed trapping” or investigating a situation to the side of the road.
[0014] As the trooper's transaction with the detained vehicle is completed, or when the trooper decides to return to patrol, he executes a driving maneuver ( 23 ) to return to the roadway ( 22 ) by pulling into the closest lane of traffic, such as by driving into position ( 24 ′). However, there may be another vehicle B traveling ( 26 ) in this same lane, approaching the trooper's position ( 24 ′). As the trooper is in transition from being stopped to achieving highway speed, the speed difference between the other-vehicle B and the trooper's vehicle T may be great, thereby increasing the danger of a collision. As with the previously described scenario, the trooper's vehicle's emergency lights, if engaged, may provide some warning to the operator of the other vehicle B, but do not warn the trooper of the impending danger.
[0015] In this second scenario, the trooper vehicle T again represents a primary vehicle, the detained vehicle, if any, represents a secondary vehicle, and the vehicle with which a collision potential exists represents the closing vehicle. In other scenarios such as this, a fire truck, ambulance, utility van, or maintenance truck may represent the primary vehicle.
[0016] Therefore, there is a need in the art for a system and method which provides detection of such possibly dangerous traffic conditions, and which provides an alerting function to a vehicle operator.
SUMMARY OF THE INVENTION
[0017] The present invention provides a detection and alerting system for the operator of a primary vehicle, preferably in conjunction with a Doppler Direction Sensing Radar (“DDSR”), and alternatively with other types of radar such as a pulsed time-of-flight radar or pulsed Doppler radar. Parameters regarding the state of a primary vehicle, such as speed and gear, as well as parameters regarding the status of a closing vehicle are determined using DDSR functionality. A logical process then determines if a dangerous condition may exist, as defined by one or more user preferences.
[0018] If the predetermined thresholds or conditions are found to exist, an alert such as an audible tone and/or a visual indicator is issued to the primary vehicle operator. By allowing a user to set various thresholds and preferences, the system can be inhibited from issuing alerts except for conditions which the operator considers to be dangerous. Such user preferences may include, but are not limited to, difference of primary vehicle and closing vehicle speeds, minimum distance from primary vehicle to closing vehicle, minimum time to collision, and automatic triggering methods and thresholds. Manual triggering of the traffic alert functionality is also provided in order to allow an officer to start a check for potentially dangerous traffic prior to executing or during a traffic maneuver.
[0019] The invention enhances safety for law enforcement officers during routine traffic maneuvers, while simultaneously allowing a common user interface (e.g. the radar gun controls and display) to be used by the officer, thereby minimizing training and learning requirements. Additionally, by integrating into typical DDSR units, the present invention can be provided at an attractive cost to public safety departments, and can be installed in a vehicle without additional equipment weight or power consumption.
[0020] As many jurisdictional agencies such as city, county, state and federal governments, often operate other, non-emergency vehicles in their fleets, there exists an economic advantage to considering equipping these other non-emergency vehicles with the traffic alert system, even though those vehicles do not need the equipment for other law enforcement purposes. For example, by purchasing enough traffic alert systems to equip a municipal police force as well as all street maintenance vehicles, city fire vehicles, and ambulances, the safety of the operation of all these vehicles can be enhanced. Use of the same equipment on all of these vehicles allows the city to realize economic and efficiency advantages due to common installation, maintenance, and training.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts in which:
[0022] FIG. 1 illustrates a common U-turn maneuver;
[0023] FIG. 2 illustrates a common maneuver performed when a vehicle returns to traffic following a standing period at the side of a road;
[0024] FIG. 3 shows an improved scenario during U-turn maneuvers according to the present invention;
[0025] FIG. 4 shows the improved scenario during maneuvers to return to patrol or the roadway after being stopped, according to the present invention;
[0026] FIG. 5 illustrates the general organization of a police Doppler Direction Sensing Radar unit;
[0027] FIG. 6 provides a more detailed perspective of a police DDSR unit;
[0028] FIG. 7 depicts a profile of vehicle speed versus time during U-turn maneuvers, which is employed as a trigger condition according to the present invention;
[0029] FIG. 8 depicts a profile of vehicle speed versus time during maneuvers to return to patrol after being stopped, which is employed as a trigger condition according to the present invention;
[0030] FIG. 9 shows one embodiment of a logical process for detecting preliminary alert conditions according to the present invention;
[0031] FIG. 10 shows one embodiment of a logical process for determining ancillary alert conditions according to the present invention;
[0032] FIG. 11 provides an architectural illustration of a traffic alert system according to the present invention; and
[0033] FIG. 12 shows a time-variant radar signal transmission frequency employed to provide range measurement from a primary vehicle to a closing vehicle.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The present invention is preferably realized as a functional enhancement to a police Doppler Direction Sensing Radar. The present invention may be embodied as software, hardware, or a combination of software and hardware. As such, we first present information regarding such DDSR units. Additionally, we will provide certain examples of usage of the present invention with respect to law enforcement vehicles, which we will collectively refer to as “trooper vehicles”. However, usage of the present invention is not limited to law enforcement vehicles, but also includes all types of vehicles which may benefit from improved safety during operation such as other emergency vehicles and non-emergency vehicles.
[0035] Enhanced Safety Scenarios using Our Traffic Alert System
[0036] Turning to FIG. 3 and revisiting the dangerous traffic scenario ( 10 ) discussed in conjunction with FIG. 1 , our enhanced DDSR with Traffic Alert function uses the rear looking radar capabilities of the DDSR to help detect ( 19 ) potentially dangerous oncoming traffic conditions following a U-turn maneuver ( 18 ). The enhanced scenario ( 10 ′) shown in FIG. 3 provides greater safety to the officer or operator of a primary vehicle equipped with our Traffic Alert System.
[0037] For example, in this improved scenario, the Traffic Alert system determines parameters regarding the operation of the primary vehicle (e.g. a trooper vehicle or other vehicle) such as speed variations indicating the execution of a U-turn maneuver. Such speed variations can be determined and tracked by use of a primary vehicle speed sensing (“VSS”) function within the police radar unit, by input from the speedometer of the primary vehicle, or both.
[0038] The Traffic Alert system also determines certain parameters regarding the state of a closing vehicle B, and then determines if a potentially dangerous situation exists according to the user's preferences and thresholds (e.g. is there enough time to avoid collision, is the closing vehicle approaching too fast, etc.). If so, an alert is issued to the operator of the primary vehicle, such as a beep or tone, visual indicator, or both. This alert may allow the operator of the primary vehicle to take evasive action to avoid the collision, such as pulling back onto the shoulder or median of the road, or changing lanes.
[0039] Now turning to FIG. 4 and revisiting the dangerous traffic scenario discussed in conjunction with FIG. 2 , the rear looking radar capabilities of the DDSR are utilized to help detect ( 19 ) potentially dangerous oncoming traffic conditions prior to or following a maneuver ( 23 ) to return to the roadway following a roadside stop or when returning to patrol. The scenario ( 20 ′) shown in FIG. 4 provides greater safety to the operator of the primary vehicle by detecting certain parameters with respect to the state of the primary vehicle T, such as transitioning from a stopped state to a moving state using the speed sensing capabilities of the police radar unit, and by determining certain parameters with respect to the state of the closing vehicle B, such as its speed, distance, time to collision, etc.
[0040] Then, the Traffic Alert system determines if any of the preferences or thresholds set by the user are met or exceeded, such as minimum time to collision or maximum speed difference between the primary vehicle and the closing vehicle. If any of these preferences or thresholds are met or exceeded, an alert is issued to the operator of the primary vehicle to enable evasive action.
[0041] DDSR Platform
[0042] FIG. 5 illustrates a high-level block diagram ( 50 ) of a typical Doppler Direction Sensing Traffic Radar. A typical DDSR includes a power source ( 55 ), such as the vehicle-battery or generator, a forward looking antenna ( 51 ), a rearward looking antenna ( 54 ), a radar core unit ( 52 ), and a set of displays (e.g. LCD panel, LED digits, indicators, annunciators, etc.) and controls (e.g. touch-screen panel, switches, knobs, etc) ( 53 ).
[0043] The directional antennas ( 51 , 54 ) transmit radar energy in front of and behind, respectively, the trooper vehicle, such that the energy may be reflected back to the trooper vehicle by vehicles in front of or behind the trooper vehicle. Changes in return signal amplitude, frequency (e.g. Doppler shift), and time for energy return are used to determine a target vehicle's speed and direction, which is displayed by the DDSR.
[0044] FIG. 6 provides a more detailed view ( 60 ) of such a typical DDSR unit, including one or two radar front end circuits ( 61 , 61 ′) and antennas ( 51 , 54 ), a microprocessor or digital signal processor (“DSP”) ( 62 ), and the user interface devices ( 65 ). The microprocessor or DSP ( 62 ) executes one or more firmware and software functions to receive radar data ( 64 , 64 ′) from the front ends, to control the transmission characteristics of the front ends ( 63 , 63 ′), to perform Fast Fourier Transforms (“FFT”) calculations, to determine if certain logical conditions exist, to execute other methods and processes, to produce visible and audible user alerts and indications ( 66 ), and receive user selections, preferences and controls ( 67 ).
[0045] While DDSR units such as these are employed in our preferred embodiment or in conjunction, the present invention may be realized in association and cooperation with other suitable DDSR units, as well.
[0046] Primary Vehicle Speed Sensing or Estimation
[0047] If the speed of a trooper vehicle or other primary vehicle is ascertainable, then the police radar can be used not only while the trooper vehicle is standing still, but also while it is in motion. Generally speaking, if a police radar unit is equipped with the capability of determining the speed of the trooper vehicle in which it is traveling, it can accurately determine the relative speed of a closing vehicle, and thus the absolute (real) speed of the closing vehicle. By determining the speed of the patrol unit, and adding or subtracting this value to the detected relative speed of a target vehicle (depending on the relative direction of the target vehicle), the actual speed of the target vehicle can be determined. This ability to determine the speed of the primary vehicle is useful to the present invention, as well, as the invention may examine the pattern of speed variations over time to determine if certain driving maneuvers are being executed such that a search for potentially dangerous closing vehicles should be performed.
[0048] Many methods for determining the speed of a vehicle or piece of equipment are well known in the art, such as the use of Global Positioning System information to determine rate of travel, or making inertial measurements to determine speed. In a simple method, a speedometer reading may be employed to determine speed of a vehicle in which a police radar unit is installed.
[0049] Some police radar units, however, use their own radar transmission and reception capabilities to sense the trooper vehicle speed, which then allows the unit to make speed measurements of target vehicles while the trooper vehicle is in motion.
[0050] In these existing police radars, the primary vehicle speed is determined by searching the Fourier components of the Doppler return signal for radar reflections from stationary objects such as billboards, trees, the ground, etc. Usually, the strongest signal component represented a return from the ground or another stationary object. However, that is not always true, and false patrol speed signals could be locked onto and tracked if another signal from, for example, a truck with a large radar cross section is the strongest signal in the spectrum. In other words, the fact that a radar return signal is the strongest signal in the spectrum does not guarantee that it is from a stationary object and represents the patrol speed.
[0051] To resolve that ambiguity, some of these radars use digital signal processing to examine the shape of the Fourier component spectrum around the peak which the radar thinks is the patrol speed return from a stationary object. Primary vehicle speed returns typically have an asymmetrical shape around the peak, and some other police radars take advantage of this fact by examining the shape of the spectrum around each peak which is suspected of being a primary vehicle speed return to determine if the characteristic asymmetric shape was present.
[0052] At least one method allows the police radar unit to self-calibrate itself with the assistance of input from the primary vehicle's speedometer, such as the system described in U.S. Pat. No. 6,501,418 entitled “Patrol Speed Acquisition in Police Doppler Radar” to Aker. In this system, speed pulses from the primary vehicle's speedometer are used to steer a search by a digital signal processor on a Fourier transform based police Doppler radar to find the correct patrol speed from stationary object returns. The system initially calibrates itself by finding the correct ratio between primary vehicle's speed sensor (e.g. speedometer) output frequency and true vehicle ground speed. By calibrating itself, it allows a portable police radar unit to be-moved easily from one car to another with different speed versus frequency characteristics of their speedometers. Alternatively, this system can skip or omit the self-calibration process, resorting to operation similar to other police radars to find the ground speed without any speedometer input at all.
[0053] Sensing Direction of a Closing Vehicle
[0054] Some DDSR units can determine the direction of a vehicle being monitored relative to the direction of travel of the trooper vehicle (e.g. same direction as patrol vehicle, opposite direction as patrol vehicle), as well as the lane of the vehicle being monitored (e.g. same lane, opposing lane). Methods for determining direction of a closing vehicle using radar signals are known in the art. The knowledge of the direction of a vehicle which is within view of the police radar unit is useful for the present invention in order to eliminate vehicles from consideration which are moving away from the primary vehicle, thus do not provide a collision danger to the primary vehicle.
[0055] One police radar unit which provides direction sensing is described in U.S. Pat. No. 6,198,427 entitled “Doppler Complex FFT Police Radar with Direction Sensing Capability”, issued to Aker, et al. In this unit, a quadrature front end which mixes received RF with a local oscillator to generate two channels of doppler signals is employed, with one channel being shifted by an integer multiple of 90 degrees in phase relation to the other channel by shifting either the RF or the local oscillator signal being fed to one mixer but not the other. The two Doppler signals are digitized. The digital samples from each-channel are then processed by a digital signal processor using a complex FFT resulting in a receding target spectrum and an approaching target spectrum of Fourier components. This particular patent discloses several single mode radars detailing the manner of processing the two half spectra of receding and approaching targets to find either the strongest target alone or the fastest target alone in various stationary, moving same lane or moving opposite lane operation, and it also discloses a multimode digital FFT, direction sensing, doppler radar where the operator can select between the following modes of stationary, strongest only, receding only; stationary, strongest only, approaching only; stationary, strongest and fastest, approaching only; stationary, strongest and fastest, receding only; moving, same lane only, strongest only; moving, same lane only, strongest and fastest; moving, opposite lane only, strongest only; and moving, opposite lane only, strongest and fastest.
[0056] According to the disclosed fastest search methods, samples are collected which were digitized at a known gain level by virtue of using the DSP to control the gain of an amplifier, and the two amplifiers in the two channels. A strongest search is performed first, preferably, maintaining a record of some number of the strongest signals in the spectrum such that the fastest target candidates can be screened to eliminate false fastest targets. A further degree of refinement in the fastest target screening process is provided by using the controlled gain amplifiers to amplify the Doppler signals before they are digitized. By knowing the gain that was in effect as each batch of samples were gathered, it is possible to calculate the true power of any signal in the spectrum from its apparent or relative power and the gain that was in effect when the samples were collected. This allows fastest target candidates to be not rejected even if they are at a frequency that is a double or triple of the trooper vehicle speed or a strong signal if the trooper vehicle speed or strong signal does not have a true power that exceeds an experimentally determined harmonic generation threshold.
[0057] Likewise, a fastest candidate that has a frequency that happens to be at the sum of the frequencies of two strong signals need not be eliminated if the true powers of the two strong signals do not exceed power thresholds which are experimentally determined to be likely to cause intermodulation products to exist. This has the significant advantage that it does not blind the radar to legitimate fastest targets if the underlying strong signals are not strong enough to have caused harmonics or intermodulation products.
[0058] Even though this particular unit is employed in our preferred embodiment, it is also possible to employ other known methods of closing vehicle direction sensing for the purposes of achieving the present invention.
[0059] Estimating Range from Primary Vehicle to Closing Vehicle
[0060] Methods and circuits for estimating the range or distance from a primary vehicle to a closing vehicle are also well known in the art, and are provided by the DDSR platform in our preferred embodiment. In alternate embodiments, the addition of a ranging function to a unit may be required to realize certain aspects of the present invention. Having a range estimate is useful to the present invention such that the invention may determine a predicted time to impact with the primary vehicle. By using the range and speed of the closing vehicle, coupled with the speed of the trooper vehicle, a determination can be made of how long the operator of the primary vehicle has to react to the closing vehicle. If the time prediction exceeds a user-set preference, then the closing car may not be considered a danger and an alert may not be issued. Otherwise, an alert is made to allow the operator of the primary vehicle maximum chances to take evasive action.
[0061] A variety of ranging techniques are available in the art, such as that described in U.S. Pat. No. 4,740,045 entitled “Multiple Parameter Doppler Radar” to Goodson, et al. As a ranging function is highly beneficial, but not critical, to realization of the present invention, we turn to FIG. 12 to discuss one known ranging technique. The radar Doppler signal is continuously transmitted while its frequency is varied by Δf between a first frequency f 1 and a second frequency f 2 , such that the signal ( 1210 , 1203 , 1202 , 1204 ) varies over time in two states, forming two signals which are reflected from a target to the DDSR unit.
[0062] For example, the radar signal frequency may be varied between 35.000 and 35.005 Ghz. The two reflected signals are down converted, and the Doppler components are recovered, using conventional means. Through a process of separation, filtering, and squaring, the approximate range to the target vehicle can be determined by measuring the magnitudes of the phase angle between the two recovered Doppler components.
[0063] A microprocessor or DSP control signal is employed by the software to vary the frequency of the radar signal transmission, a function which can alternately be performed by circuitry, as well. After determining the approximate range to the impending vehicle, the range value can be compared to a threshold value such as a user preference (e.g. minimum distance to vehicle alarm setting), and an alert can be issued if the threshold is met or exceeded.
[0064] Alternate, known techniques for ranging may be employed, as well, such as using return signal strength to estimate range. In our preferred embodiment of the invention, the resolution of the range needs only to be within several yards to allow for an approximate range determination, and subsequently for an approximate time to collision calculation.
[0065] Our Traffic Alert Function
[0066] As previously stated, the present invention is preferably realized as a software feature within a suitably configured microcontroller-based or digital signal processor-based police radar unit such as the aforementioned DDSR units.
[0067] FIG. 11 provides an architectural block diagram representing an enhanced police Doppler Direction Sensing Radar unit ( 200 ), such as the one previously described, which includes at least one radar antenna ( 201 ), a radar front end ( 202 ), a user interface ( 205 ) for control and display, and a target vehicle speed determination function ( 203 ). Some of these functions may be implemented entirely in hardware circuitry, entirely in software functionality, or in a combination of hardware and software.
[0068] Further according to a preferred embodiment, the enhanced DDSR unit ( 200 ) has direction sensing functionality ( 204 ) to measure speeds of vehicles moving in the same direction of orientation of the law enforcement vehicle (e.g. a rear looking radar), and optionally has the capability to measure speeds of vehicles moving in the opposing direction of orientation of the law enforcement vehicle (e.g. forward looking radar).
[0069] Additionally, the preferred embodiment includes any or all of the advanced functions previously described, including a primary vehicle speed determination function (“VSS”) ( 205 ), and target range finding function ( 206 ). Some of these functions may be implemented entirely in hardware circuitry, entirely in software functionality, or in a combination of hardware and software.
[0070] Further, the enhanced DDSR unit includes-certain logical processes for our Traffic Alert Function ( 208 ), preferably embodied in a firmware module which is executable by the microprocessor or DSP. Alternatively, the Traffic Alert Function may be realized in part or entirely in circuitry.
[0071] The logical processes of the present invention includes three phases:
(1) in the first phase, one or more parameters about the state of movement of the primary vehicle are determined and considered, which we will refer to as “preliminary conditions”; (2) in the second phase, one or more parameters about the state of movement of the closing vehicle are determined and considered, which we will refer to as “ancillary conditions”; and (3) in the third phase, an alert is issued to the operator of the primary vehicle if the preliminary conditions and the ancillary conditions indicate that a potentially dangerous situation exists with respect to the primary and closing vehicles, in consideration of a number of user preferences and thresholds.
[0075] First Phase: Detecting Preliminary Conditions Preceding an Alert
[0076] The preferred embodiment of the present invention detects and considers most or all of the following logical and physical preliminary conditions which indicate a traffic alert detection should be performed. However, it will be readily recognized by those skilled in the art that not all of the following conditions must be detected to realize the present invention, but that a subset of these conditions may be employed in alternate embodiments.
[0077] Further according to our preferred embodiment, a set of user preferences are established which control which conditions and their thresholds are detected for each individual Traffic Alert unit, thereby allowing a primary vehicle operator to customize the alerting function for his or her risk perception.
[0078] In a U-turn maneuver scenario as previously described and illustrated in FIG. 3 , the preliminary conditions include, but are not limited to:
(a) a relatively sudden slowing of a primary vehicle velocity V T(t) from an initial speed V 1 , to a speed V 2 , and subsequently rapidly accelerating or returning to a greater speed V 3 , especially when the subsequent speed V 3 is much greater than the initial speed V 1 indicating the start of a pursuit, a speed pattern which is characteristic of a U-turn maneuver as shown in FIG. 7 ; (b) the condition of the primary vehicle gear selector being in a “Drive” state during the velocity transitions, as shown in FIG. 7 ; or (c) activation of a “traffic alert check” control by a user (e.g. manual triggering of the traffic alert function).
[0082] In a common scenario involving a maneuver to return to the roadway following a period of standing or slow driving alongside the roadway as previously described and illustrated in FIG. 4 , the preliminary conditions include but are not limited to:
(d) an increase from a primary vehicle velocity V T(t) of initial speed V 4 which is stopped (or nearly stopped) at time t 6 , followed by acceleration or reaching a subsequent speed V 5 at time t 7 , indicative of a return to traffic speeds, as shown in FIG. 8 ; (e) a change from a primary vehicle transmission setting of “Park” or “Neutral” at time t 5 to a setting of “Drive” at time t 6 , indicative of returning to travel after a roadside stop or when beginning an interception of a vehicle traveling in the same direction at the primary vehicle; (f) recent radar acquisition ( 41 as shown in FIG. 4 ) of secondary vehicle C in either direction relative to the primary vehicle within a specified recent period of time; or (g) activation of a “traffic alert check” control by a user (e.g. manual triggering of the traffic alert function).
[0087] Primary vehicle speed changes may be detected by monitoring the speedometer of the primary vehicle, employing a Global Positioning System, monitoring an accelerometer unit, or using the previously described VSS function of a typical DDSR.
[0088] Changes in the transmission setting of the primary vehicle may be monitored via signal input from the primary vehicle's control computer or transmission controller, such as by input from a Controller Area Network (“CAN”) automotive control bus.
[0089] Determination of whether or not a radar target has been acquired within a recent period of time can be made using software timing loops or hardware timers commonly found on microcontrollers and DSPs, combined with signal conditions of the radar front ends and results of the target vehicle speed, range, direction, return strength, etc., functions.
[0090] Manual triggering may be made by depressing a button on the DDSR control panel.
[0091] Turning to FIG. 9 , one available embodiment ( 90 ) of a logical process according to the present invention for detecting the existence of one or more preliminary conditions is shown, which includes logic for both stationary and moving alerting modes. Alternate embodiments including stationary-only, moving-only, automatically-triggered only, and manually-triggered only processes may be realized through employing subsets of the steps shown. Choice of programming language and methodology can be made according to the target microprocessor or DSP of the DDSR which is to be enhanced with the invention.
[0092] The process starts ( 91 ) by determining ( 92 ) if the primary vehicle is moving or not (alternatively if it is in Park or Drive gear selection). If it is moving, then moving alert condition monitoring is performed ( 93 ), unless the user has disabled moving alert mode. If the primary vehicle is not moving, then stationary alert condition monitoring is performed ( 93 ), unless the user has disabled stationary alert mode.
[0093] When one or more stationary conditions are met (or exceeded) ( 96 ) according to the user preferences and threshold settings ( 95 ), processing proceeds ( 97 ) to ancillary condition consideration.
[0094] Second Phase: Detecting Ancillary Conditions Prior to an Alert
[0095] Before issuing a traffic alert indication to the operator of the primary vehicle, several other ancillary conditions are preferably determined and checked, either individually or in combination. However, as it will be readily recognized by those skilled in the art, not all of the following ancillary conditions must be detected to realize the present invention. Alternatively, a subset of the following conditions may be detected individually or in combination with others.
[0096] According to our preferred embodiment, additional user preferences are established which control the ancillary conditions and their thresholds. Our ancillary conditions include, but are not limited to:
(h) determination of the speed of the closing vehicle exceeding a maximum preferred real (e.g. absolute) speed; (i) determination of the speed of the closing vehicle exceeding a maximum preferred speed relative to the primary vehicle speed (e.g. maximum allowable closing speed); (j) determination of a distance to the closing vehicle from the primary vehicle position as being at or below a minimum preferred distance (e.g. a closeness threshold); and (k) determination that an estimated time to collision by the closing vehicle with the primary vehicle is below a minium preferred time for evasive maneuver by analyzing the estimated speed of the potentially dangerous-vehicle and its range to the trooper vehicle position (e.g. generally determining a closing speed by subtracting the speed of the trooper vehicle from the speed of the dangerous vehicle, and dividing the closing speed by the estimated range to the dangerous vehicle to yield a time-to-collision estimate).
[0101] Determination of the speed of the potentially dangerous vehicle is made in the customary manner by the usual DDSR functions, and this speed estimate is then compared by the new Traffic Alert function to a pre-determined threshold value.
[0102] Determination of the distance to the potentially dangerous vehicle is made using a typical radar ranging function and compared to a threshold value.
[0103] Determination of an approximate or estimated time to collision between the primary vehicle and the closing vehicle is made by dividing the difference of the closing vehicle speed and the primary vehicle speed by the approximate range to the closing vehicle, all calculations of course being scaled to compatible units of time and distance, and by comparing the distance value to a threshold value such as a user preference value (e.g. minimum time to collision alarm setting).
[0104] An example embodiment ( 1000 ) of ancillary condition processing is shown in FIG. 10 . Ancillary condition analysis ( 1001 ) is performed as previously described, and if ( 1002 ) any of the ancillary conditions or thresholds as set by the user preferences ( 95 ) are met (or exceeded), an alert is issued ( 1003 ) according to the user preferences (e.g. audible only, visible only, audible with visible, etc.).
[0105] Third Phase: Alerting the Operator of the Primary Vehicle
[0106] Upon determination that a traffic alert should be issued because at least one preliminary or trigger condition and at least one ancillary condition have been detected, the enhanced DDSR alerts the driver in one or more of the following manners:
(1) issues an audible alert such as a beep, buzz, chime, or voice warning through the annunciator of the DDSR; (2) issues a visible alert such as an illuminated indicator, a flashing indicator, or an icon on a display; or (3) issues both an audible alert and a visible.
[0110] According to a preferred embodiment, a manual alert cancellation control is provided on the user interface to allow the user to cease the alert indicator or sound, and an automatic cancellation is performed according to a user preference alert time period value if no manual cancellation is performed.
CONCLUSION
[0111] The present invention has been disclosed in general terms as well as with specific examples and descriptive illustrations. It will be recognized by those skilled in the art that the scope of the present invention is not limited to these illustrations and examples, and that the present invention may be realized in a number of alternate forms, and used in conjunction with a wide variety of vehicle types in order to enhance the safety of their operation. Additionally, the present invention may be realized in conjunction with other types of radar systems, such as pulsed time-of-flight or pulsed Doppler systems.
[0112] Further, certain details of preferred embodiments have been described, but it will be recognized by those skilled in the art that many substitutions and variations may be made from the disclosed embodiments without departing from the spirit and scope of the invention. Therefore, the scope of the invention should be determined by the following claims. | An enhanced police Doppler direction sensing radar detects possibly dangerous traffic conditions during certain vehicle maneuvers such as U-turns and returns to travel after roadside stops. By monitoring a host or primary vehicle speed, speed transitions, transmission state (e.g. gear selection), and the closing vehicle position, range and speed, a number of selectable conditions are detected, resulting in an alert indication to a primary vehicle operator. User preferences and thresholds allow the traffic alert function to be customized according to a primary vehicle operator's desire to suppress alerts in situations which the user does not deem dangerous. The traffic alert function may be automatically triggered under certain detected conditions, or manually initiated when the primary vehicle operator intends to make a driving maneuver. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a nonprovisional of, and claims the benefit of the filing date of, U.S. Prov. Pat. Appl. No. 61/074,418, filed Jun. 20, 2008.
BACKGROUND OF THE INVENTION
[0002] The present application relates to a processing system for processing a substrate comprising a process chamber for receiving said substrate in said processing chamber. The present application relates further to a method for processing a substrate comprising a step of providing a processing system as mentioned above.
[0003] In a number of technical applications, thin material layers are deposited on a substrate for generating a one-layer or multilayer system. For depositing the layers on a substrate, various methods may be used such as chemical vapor deposition (“CVD”), physical vapor deposition (“PVD”), evaporation, sputtering, etc.
[0004] A one-layer or multilayer electronic device, e.g. an organic light-emitting diode (“OLED”) device such as an OLED panel or screen, may be exposed to environmental influences. In order to protect the device against these influences, a protective element is provided on top of the layer and the layer system respectively. For example, a combination of a glass panel and a getter system for gettering humidity may be glued on top of the layer system.
[0005] Alternatively, for sealing the electronic device it is possible to deposit a protective layer stack on top of a functional layer and layer system respectively. the protective and/or barrier layer(s) may be deposited by use of a CVD deposition process. Sometimes, it may be required to form a structure or a pattern in the protective layer(s). Thus, shadow masks may be used for covering portions of the surface of the substrate during the coating process. A shadow mask is usually positioned and aligned relative to the substrate outside a coating chamber before the coating process, the substrate being positioned in a substrate carrier.
[0006] Because of the fact that a plurality of layers of different materials may have different patterns, a respective shadow mask may have to be removed after each deposition step and be replaced by another respective shadow mask. Manufacturing the protective layer stack may thus involve a lot of handling effort regarding the handling of the substrates, the shadow masks, and the substrate/mask carriers. Furthermore, handling of substrates is a source for the generation of particles, which may involve contamination of a layer and constrict the production of an effective protective layer stack.
BRIEF SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a coating system and method for processing a substrate requiring less handling effort, particularly when producing a patterned sealing layer stack.
[0008] This object may be achieved by providing a processing system and a method for processing a substrate. The processing system for processing a substrate comprises a process chamber for receiving the substrate in the process chamber, a patterning device installed within the process chamber, and a mechanism for transferring the substrate into the process chamber and for aligning the substrate relative to the patterning device.
[0009] The processing system may be a coating system for depositing a protective layer or a protective layer stack, such as on top of an OLED layer or layer system. The coating process may be any conventional process, such as CVD, PVD, evaporation, sputtering, etc. The process chamber may comprise a coating chamber for the respective coating process.
[0010] The patterning device may be a shadow mask, such as for use in a CVD coating process. According to embodiments of the present invention, the patterning device is installed and fixedly arranged within the process chamber. Before processing, the substrate is arranged in a substrate carrier and transferred into the process chamber. A carrier or a plurality of carriers may be transported into a particular coating chamber. Afterwards, the carrier and/or the substrate are moved towards the shadow mask and aligned in front of the shadow mask. A lifting device may be used to lift the carrier and/or the substrate towards the shadow mask. The substrate may be aligned relative to the patterning device, such as through the use pins and corresponding receivers for the pins provided at the carrier and in the coating chamber respectively. In the coating chamber, a layer of a particular material having a particular pattern is deposited on the surface of the substrate(s).
[0011] After the deposition of a particular layer, the substrate is removed from the shadow mask, such as by lowering the substrate, and removed from the process chamber. At this stage, the shadow mask remaining located within the coating chamber is cleaned by a plasma treatment within the chamber before the next coating process is carried out in the chamber.
[0012] With embodiments of the invention, it is possible to provide a patterned/structured layer, such as by using a CVD coating method, wherein the shadow mask remains in the coating chamber after the layer has been deposited on the substrate. There is not need in such embodiments to adjust a shadow mask relative to a substrate attached to a carrier and attach the mask to the carrier outside a coating chamber. Therefore, contamination of the protective layer stack by particles released from the mask during a handling step may be avoided.
[0013] In the meantime, the shadow mask remains within the coating chamber in a vacuum atmosphere after the particular coating step has been terminated. It is possible to clean the mask, such as by providing plasma in the vicinity of the patterning device, before processing another substrate. The cleaning process may be carried out as soon as the substrates have been removed from the coating chamber, such as into a lock chamber that may be evacuated and/or vented while cleaning the mask.
[0014] According to embodiments of the invention, the effectiveness of the system, such as measured by the cycle time/uptime of the system, may be improved. Furthermore, because of plasma cleaning of the mask between two coating steps, the quality of the pattern and the purity and perfection of the layer stack may be improved.
[0015] In one embodiment of the invention, the processing system comprises a plasma source for providing a plasma in the vicinity of the patterning device for cleaning the patterning device. The plasma source may be arranged within the process chamber. The plasma cleaning step is usually carried out between two processing/coating steps.
[0016] Particularly, the mechanism is configured to move the substrate relative to the patterning device at least from a transfer position into a processing position. A relative movement comprises moving the substrate and/or the patterning device to align the substrate relative to the patterning device. The transfer position may be a position inside or outside the process chamber. The processing position is a position inside the process chamber where the substrate is usually positioned close to the shadow mask for depositing a patterned layer on the surface of a substrate.
[0017] The mechanism may, in some embodiments, comprise at least a handling system for moving the substrate relative to the patterning device in the process chamber and to transfer the substrate from the transfer position into the processing position. Merely by way of example, the handling system may comprise a robot arm having a mechanism for engaging a corresponding mechanism provided at the substrate carriers for receiving, releasing, lifting, and/or lowering the substrate carrier and/or the substrate. The invention is not limited to a particular handling and/or transport system, but maybe implemented with any handling and/or transport system that provides a movement of a substrate from the transfer position into the processing position.
[0018] In one embodiment, the processing system comprises at least a substrate carrier for carrying at least a substrate. The substrate may be attached to a substrate carrier, particularly when it is outside the process chamber.
[0019] Particularly, the substrate carrier and/or the process chamber comprise the mechanism for aligning the substrate relative to the patterning device. Such a mechanism for aligning may comprise a guidance, pins and corresponding cavities for receiving the pins, etc.
[0020] In another embodiment of the invention, the mechanism for transferring the substrate comprises a mechanism for lifting and/or lowering the substrate. Such a mechanism for lifting and/or lowering the substrate may be provided in the form of a handling arm. For example, the mechanism may comprise a device for actuating lifting pins provided in the substrate carrier for lifting and/or lowering a substrate carrier and/or the substrate.
[0021] In another embodiment of the invention, the processing system may comprise a lock chamber coupled to the process chamber.
[0022] Methods for processing a substrate according to embodiments of the invention comprise (a) providing a processing system as described above; (b) transferring a substrate into the process chamber; (c) moving the substrate relative to the patterning device from a transfer position into a coating position; (d) processing the substrate; (e) removing the substrate from the process chamber; and (f) providing plasma cleaning of the patterning device arranged in the process chamber. Step (e) is usually carried out while the coated substrate is locked out of the coating system via a lock chamber and/or while a new substrate to be coated is locked in the coating system via a lock chamber. Therefore, time used for evacuating and venting the lock chamber may be used for plasma cleaning the mask.
[0023] In one embodiment, step (c) includes aligning the substrate relative to the patterning device.
[0024] In some embodiments, step (c) includes moving/lifting the substrate towards the patterning device to arrange the substrate in the vicinity of the patterning device in the coating position. the mask may be fixedly arranged within the chamber or it may be moveably arranged within the chamber. Either the substrate or the mask, or both the substrate and the mask, may be moved such that the substrate is finally in the processing position relative to the mask.
[0025] Particularly, step (e) may include moving the substrate away and/or lowering the substrate from the patterning device and/or transferring the substrate out of the process chamber.
[0026] Methods according to the invention may comprise repeating steps (b) to (e) to process another substrate. The may, in particular, comprise repeating steps (b) to (f) to process another substrate and clean the mask after every coating process in a cycle of n=0, 1, 2, 3, . . . repetitions of steps (b) to (f).
[0027] The features described above are meant to be protected by themselves or in any combination with the described device and/or method features.
BRIEF DESCRIPTION OF THE DRAWING
[0028] Further objects and advantages result from the following description of specific embodiments.
[0029] The drawing in FIG. 1 shows a schematic top view of an embodiment of a coating system according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The drawing illustrates an embodiment of a coating system 1 according to the invention.
[0031] The coating system 1 comprises a vacuum coating chamber 2 (recipient), a lock chamber 3 coupled to the vacuum coating chamber 2 , and a handling robot 4 for handling substrate carriers 5 . Further more, the coating system 1 may comprise a transport or conveyer system 6 for delivering substrates 7 to the coating system 1 and/or coated substrates 7 away from the coating system 1 . Moreover, the coating system 1 may comprise an inkjet printer 8 for printing a pattern, such as of a polymer material, on the surface of a substrate 7 .
[0032] The vacuum coating chamber 2 comprises a housing 21 defining an inner space 22 of the vacuum coating chamber 2 . In the inner space 22 of the vacuum coating chamber 2 a shadow mask 23 is fixedly installed. Furthermore, the vacuum coating chamber 2 comprises coating tools (not shown), such as for providing a CVD coating process in the inner space 22 of the vacuum coating chamber 2 .
[0033] The shadow mask 23 has pin holes 24 for receiving adjustment pins 51 provided at a substrate carrier 5 for adjusting a substrate 7 attached to a carrier 5 relative to the mask 23 in a coating position indicated by dashed lines 25 . According to embodiments of the invention, a coating system 1 comprises a plasma source 26 that is arranged in the inner space 22 of the coating chamber 2 . While there is no substrate in the inner space 22 of the coating chamber 2 , a plasma is generated in the vicinity of the shadow mask 23 for providing a cleaning process to clean the shadow mask 23 by use of a plasma chemical process. Particles removed from the mask 23 during the cleaning process are removed from inner space 22 of the coating chamber 2 before carrying out another coating process. The particles removed from the mask 23 in the cleaning process are gaseous reaction products, which may be removed from the inner space 22 of the coating chamber 2 by a vacuum pump system (not shown).
[0034] The lock chamber 3 is coupled with the coating chamber 2 via gate valves 31 . The lock chamber 3 provides for transferring substrates from an atmospheric pressure outside the lock chamber 3 into a vacuum atmosphere provided in the inner space 22 of the coating chamber 2 and vice versa. In dashed lines, a transfer position 32 is indicated in which a substrate is held during an evacuation and/or venting process of the lock chamber 3 .
[0035] The handling robot 4 comprises a drive (not shown) for driving a robot arm 41 that is connected with a support element 42 for supporting a substrate carrier 5 and/or a substrate 7 . The support element 42 has a lifting mechanism 43 for interacting with lifting pins 52 provided at the substrate carrier 5 in order to lift the carrier 5 (and thus the substrate 7 attached to the carrier 5 ) into the coating position 25 arranged in the inner space 22 of the coating chamber 2 .
[0036] Before the substrate carrier 5 is transported into the lock chamber by the handling robot 4 , a substrate 7 received from the transport conveyer 6 is attached to the substrate carrier 5 . As mentioned above, the substrate carrier 5 comprises adjustment pins 51 for engagement with corresponding pin holes 24 provided at the mask 23 , and lifting pins 52 for interacting with a lifting mechanism 43 provided at the handling robot 4 for lifting a substrate from a transfer position into the coating position 25 .
[0037] According to embodiments of the invention, the shadow mask 23 remains in the inner space 22 of the coating chamber 2 during a number of coating cycles. Between the coating steps, the mask 23 may be cleaned by a plasma cleaning system 26 that is also provided within the inner space 22 of the vacuum coating chamber 2 .
[0038] Therefore, it may be unnecessary to fix a mask to the carrier before starting the coating process, and thereby also to remove the mask from the carrier after terminating the coating process, thus avoiding handling steps and contamination of the substrate attached to the substrate carrier by particles released from the mask.
[0039] Having fully described several embodiments of the present invention, many other equivalent or alternative processing systems and methods of the present invention will be apparent to those of skill in the art. These alternatives and equivalents are intended to be included within the scope of the invention, as defined by the following claims. | A processing system for processing a substrate includes a process chamber for receiving the substrate, a patterning device installed within the process chamber, and a mechanism for transferring the substrate into the process chamber and for aligning the substrate relative to the patterning device. | 2 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to travel control methods and in particular to such methods which are used to control search vehicles.
(2) Brief Description of the Prior Art
When searching an area for an object such as a mine, it is often desirable to search an area using expendable units. These units should have a relatively low cost, but they should also be capable of searching an area in an efficient fashion.
One way of searching an area is by an ordered search algorithm such as a grid. Grids are not readily adaptable to rough terrain, and the party positioning the search object can optimize placement of search objects to reduce grid efficiency.
Another method of searching an area is by random dispersal. Random dispersal requires little control and accommodates any terrain type. The problem with random dispersal is that it is inefficient. Some areas go unsearched while other areas are subjected to multiple searches.
Various methods and apparatus are disclosed in the prior art for controlling robotic vehicles.
U.S. Pat. No. 5,321,614 to Ashworth, for example, discloses a control apparatus and method for autonomous vehicles. Obstacle sensors onboard each vehicle produce signals associated with obstacles used for navigation.
U.S. Pat. No. 5,329,450 to Onishi discloses a control method for multiple robots in which a central control station distributes remaining tasks to robots having no task.
U.S. Pat. No. 5,367,456 to Summerville et al. discloses a control system for automatically guided vehicles. A stationary control computer schedules the activities of individual robots.
U.S. Pat. No. 5,568,030 to Nishikawa et al. discloses a travel control method for a plurality of robots. Each destination route is searched for availability prior to being used to control a robot's travel path.
U.S. Pat. No. 5,652,489 to Kawakami discloses a mobile robot control system in which each robot emits a signal. The signal is used to stop movement of other robots about to traverse the same route.
None of these methods provides a control method using a decentralized method of controlling low cost robots.
SUMMARY OF THE INVENTION
The object of this invention is to define a control strategy framework that will improve the performance of multiple robots when searching an area. This framework builds on a random search strategy by introducing two kinds of phases: a disperse phase and an aggregate phase. During the disperse phase, the vehicles perform a random search, which will result in the group dispersing over the search area. During the aggregate phase, the vehicles will continue to search, but will also communicate with neighbors when they come into communication range of each other. This is referred to as an “encounter”. During an encounter, two vehicles exchange information and adjust their headings based on the current encounter strategy. The combination of these phases results in a group of robots performing a random search enhanced by intra-group communication that will provide better group cohesion and a more efficient search. The disperse, aggregate, and disperse combination is referred to as the DAD-Control Strategy. The DAD-Control Strategy framework allows variations in several fundamental ways: the duration of each phase, combination of the phases, (e.g., DADAD), and the selection of encounter strategies during the aggregate phases.
The present invention comprises a method for conducting a search of an area for targets by a plurality of vehicles. First each vehicle disperses from the other vehicles. Then during the aggregate phase each of the vehicles responds in a predesignated way to an encounter with one of the other vehicles.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will become apparent upon reference to the following description of the preferred embodiments and to the drawing, wherein corresponding reference characters indicate corresponding parts in the drawing and wherein:
FIG. 1 is a schematic drawing illustrating an encounter between two vehicles and a detection of a target in a preferred embodiment of the method of the present invention;
FIG. 2 is a schematic drawing illustrating a preferred embodiment of the method of the present invention, referred to hereafter as the north strategy;
FIG. 3 is a schematic drawing illustrating another preferred embodiment of the present invention referred to hereafter as the best finder strategy;
FIGS. 4 a and 4 b are schematic drawings illustrating another preferred embodiment of the present invention referred to hereafter as the best finder or north strategy; and
FIG. 5 is a schematic drawing illustrating still another preferred embodiment of the present invention referred to hereafter as the best finder and north strategy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The underlying philosophy in robot maneuvering logic is to keep the logic simple. A powerful and yet simple to implement control strategy for multiple vehicles searching as a group is a random search strategy. There is little to no dependency on neighbors in determining next position. Given enough time an area can be completely covered much in the way a gas will fill a volume. The robots in this simulation use random changes in heading and random number of steps forward. This allows the robot to wander in and out of an area. The goal is to improve the efficiency of this simple search scheme by allowing exchanges of information that will improve the efficiency of the next move decision logic of the robot. This establishes a minimal level of connectivity between group members. The connectivity is established when two members come into range, recognize each other and establish a communication link long enough to exchange a pre-determined packet of information. Once the information is transmitted, the connectivity is terminated.
The proposed control strategy is a combination of two types of maneuvering phases: a disperse phase and an aggregate phase. The natural side effect of a group of vehicles performing a random search is that the vehicles spread out or disperse over time. The disperse phase produces such an emergent behavior as each vehicle follows a random search with communication only present to avoid the other vehicles, and the group disperses over the search area. The aggregate phase maintains the random search maneuvering, but then introduces opportunities for two vehicles to exchange information through encounters. Information exchange is primarily focused on adjusting the heading of one or both vehicles based on the encounter strategy. Other information categories can be investigated along with new encounter strategies. By running a sequence of disperse, aggregate and disperse (DAD) phases, the overall performance should improve because the vehicles remain more concentrated or guided during the random search phases.
During the disperse phase, a random walk scheme is used. In this scheme, vehicles can randomly turn from −45 degrees to 45 degrees. Vehicles can also advance from 1 to 10 steps forward. The upper limit of the turn has been tested at ranges of ±45 degrees, ±90 degrees ±180 degrees. The value can be set according to the amount of dispersal and overlap for the particular application.
During the aggregate phase, vehicles also use the random walk scheme, but also communicate during encounters. An encounter occurs when vehicles are within a predetermined encounter distance to each other. This is defined as the variable encounter zone, which has a constant value of 70 (units of distance). The exchange of information is based on the current encounter strategy.
When two vehicles are within the encounter zone distance apart, the vehicles exchange information that impacts the heading of one or both vehicles. An encounter threshold variable is set that establishes to some degree the frequency with which vehicles change heading based on an encounter with the same vehicle. Sensitivity tests were made varying the encounter threshold variable by values of 0, 5 and 10. This signifies that two vehicles will not re-encounter for the number of simulation cycles specified by the encounter threshold after the initial encounter even if they remain in the encounter zone.
There are different strategies that were tested when two vehicles encounter one another. These strategies were motivated by operational requirements in littoral waters and studies of animal behavior in a foraging scenario.
Referring to FIG. 1 , a first vehicle 10 and a second vehicle 12 are illustrated. Also illustrated are three targets 14 , 16 and 18 . The first vehicle 10 has a detection range 20 and an encounter zone 22 . The second vehicle 12 has a detection range 24 and an encounter zone 26 . A detection occurs when one of the vehicles, such as vehicle 10 approaches one of the targets such as target 14 within the vehicle's detection range such as detection range 20 . An encounter occurs when two vehicles such as first vehicle 10 and second vehicle 12 approach within their respective encounter zones 22 and 26 . An encounter consists of a communication between vehicles 10 and 12 , which may result in adjusting the heading of one or more of the vehicles, based on one of the strategies described herein. The encounter threshold will also provide a delay (in simulation cycles) to avoid re-encountering the same vehicles.
A first strategy, the north strategy, uses a preferred direction to establish a new heading. In this strategy, upon encounter each vehicle's heading is compared to a preferred direction heading (i.e., north or 90 degrees) which specifies the overall group's heading. The vehicle with the heading closest to the preferred direction is used as the new heading for the other vehicle.
By setting the overall group's heading to impact the individual's heading adjustment, the group should eventually advance in a sweeping motion in the direction of the overall group's heading. In addition, following is introduced at a small scale when two vehicles encounter and one adapts the heading of the other. This creates a short instance of following until the follower vehicle again adopts the random search scheme. Another net affect should be the consolidating of group members in the operational space or at least in clusters.
Referring to FIG. 2 , the north strategy is further illustrated. In this strategy, the first vehicle 10 has an initial heading 28 , and the second vehicle 12 has an initial heading 30 . A comparison of these initial headings 28 and 30 is made with the north or preferred direction 32 . Since the second vehicle 12 has an initial heading 30 which is closer to the preferred direction 32 than the initial heading 28 of the first vehicle 10 , the first vehicle 10 changes direction to new heading 34 . The second vehicle 12 remains at its initial heading 30 .
A variation on the north strategy involves switching the preferred direction when a preselected condition occurs. This preselected condition can be the elapse of a period of time, the finding of a predefined number of targets, or the occurrence of a set number of encounters with other vehicles. This will result in the overall group moving back to its point of origin. This strategy is a slight variation on the north strategy, which would allow a second pass over already explored area. This variation may compensate for targets that are missed and supports running multiple passes over the same area.
Another strategy, the best finder strategy, compares the number of targets found by each vehicle and uses the direction of the vehicle finding more targets. The heading of the vehicle with the most targets found is used as the heading for the other vehicles in the encounter. Based on observations from social animals, there are members in a group that show higher success at discovering food, and other members can be seen to mimic the actions of this best finder. This strategy allows the vehicle that has found the most targets to influence the heading of the second vehicle during an encounter. This could be interpreted as the best finder leading the second vehicle to a concentration of targets. This strategy should improve target finding when the targets have a clustered or patch distribution given successful exchange between the best finder and second vehicle.
Referring to FIG. 3 , the best finder strategy is illustrated in which the vehicle with the most targets T found sets the heading for the second vehicle. For purposes of illustration, the first vehicle 10 has located four targets and the second vehicle 12 has located six targets. The first vehicle 10 has an initial heading 36 and the second vehicle 12 has an initial heading 38 . The first vehicle 10 has a new heading 40 which conforms to the initial heading 38 of the second vehicle 12 since the second vehicle 12 has located more targets.
Yet another strategy is the best finder or north strategy. This strategy is a combination the north strategy and the best finder strategy such that if both vehicles have found no targets or have the same number of targets, the vehicles use the north strategy since no one vehicle has out performed the other. If there is a discrepancy in number of targets between the two vehicles, the vehicles use the best finder strategy.
Referring to FIGS. 4 a and 4 b , the best finder or north strategy is illustrated. In FIG. 4 a the first vehicle 10 has an initial heading 42 and the second vehicle 12 has an initial heading 44 under conditions where the first vehicle 10 has located four targets, T=4, and the second vehicle 12 has located six targets, T=6. Because the second vehicle 12 has located more targets, the first vehicle 10 assumes a new heading 46 that conforms to the initial heading 44 of the second vehicle 12 . If both vehicles have located the same number of targets T, or if no targets have been located, FIG. 4 b is applicable. In FIG. 4 b , the first vehicle 10 has an initial heading 48 and the second vehicle 12 has an initial heading 50 . Since the initial heading 50 of the second vehicle 12 is closer to the preferred direction or north 52 , the first vehicle 10 will assume a new heading 54 which conforms to the initial heading of the second vehicle 12 .
The best finder and north strategy is a variation of the best finder strategy. The variation consists of setting the best finder vehicle's heading to the preferred direction that in this case is north 60 . The other vehicle receives the best finder's heading as its new heading. The motivation for this strategy is to introduce some degree of delegating one vehicle's actions to another. The vehicle with the most targets found will send the second vehicle in the same direction since targets have been found there to continue the local search. The vehicle with the most targets will continue the global search by heading in the preferred direction to locate other concentrations of targets.
Referring to FIG. 5 , the best finder and north strategy is illustrated in which the best finder strategy applies except as the best finder adjusts its heading to the overall group heading of north or the preferred direction. In this example, the first vehicle 10 has located four targets and the second vehicle 12 has located six targets. The first vehicle 10 has an initial heading 56 and the second vehicle 12 has an initial heading 58 . Since the second vehicle 12 has located more targets T, it assumes a new heading 60 that is in a preferred direction or north 62 . The first vehicle 10 , which has located fewer targets T, assumes a new heading 64 in the same direction as the initial heading 58 of the second vehicle 12 .
Another strategy concerns varying the vehicle's velocity based on the search outcome. The logic behind this strategy is that a vehicle should slow down and make a slow search if it finds a high ratio of targets to time searched. Otherwise, the vehicle should increase its velocity to advance to other areas more rapidly.
In order to perform this strategy, each vehicle is preprogrammed with an estimate, E, for the target density in the search area. This is weighted by a selected estimate weight, E_wt. Each vehicle has a value for experience, Exp, related to The number of targets found T, for an elapsed time, t, and weighted by E_wt, a weighting factor. Velocity, V, can then be changed in accordance with the following equations, where ΔV is the change in velocity:
Exp = T * Exp_wt t ( 1 ) Δ V =( E −Exp)* E — wt (2)
Using these equations, it was observed that often the velocity, V, increases rapidly, and the vehicle exits the search area. Therefore, a maximum velocity can be set in the vehicle so that the velocity of the vehicle plus the change in velocity is set to the maximum if the maximum velocity would be exceeded. Likewise, a minimum velocity can be set if the change in velocity would bring the velocity below the minimum.
It will be appreciated by those skilled in the art that this velocity adjusting algorithm can be applied to any of the previous search strategies.
While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims. | A method for conducting a search of an area for targets by a number of vehicles. First each of the vehicles randomly disperses from the other vehicles. Then during an aggregate phase, each vehicle responds in a predesignated way to an encounter with one of the other vehicles. A number of specific search strategies may be followed which tend to direct the search in a particular designated direction or allow a successful searching vehicle to set the direction of the search. This method results in improved performance in conducting searches by robots or other vehicles. | 5 |
FIELD OF THE INVENTION
This invention relates generally to earth moving equipment and more particularly to improvements in land leveling apparatus.
BACKGROUND OF THE INVENTION
Apparatus for leveling and smoothing land has heretofore been used for a variety of agricultural and industrial applications for maintenance and tillage operations. In humid areas this equipment has been used to correct surface drainage and for seed bed filling, and on rolling fields to fill and erase small washes and gullies, smooth terraces and benches, and shape up waterways. For industrial applications land levelers are used to work and smooth the land for landscaping and by contractors.
In U.S. Pat. Nos. 2,994,977 and 3,090,141, assigned to the assignee of the present invention, there is disclosed land leveling apparatus having automatic leveling features that maintain the cutting blade on the field grade plane independently of the vertical travel of the rear tractor wheels. The present invention provides advances in implements of the land leveling type and more particularly in apparatus capable of smoothing a wider area with each pass over a field while maintaining the cutting edge in a horizontal plane. In providing a land leveling apparatus of increased width the land leveler apparatus of the present invention is capable of handling greater weights, supporting a wider span, providing required widths during travel on the highway, and avoiding any tendency of the outer extremities of the scraper blade to dip and gauge the ground on turns.
Accordingly, it is an object of the present invention to provide novel and improved apparatus generally of the earth moving type.
Another object of the present invention is to provide a novel land leveling apparatus having a substantially greater leveling capacity.
Still another object of the present invention is to provide a novel land leveling attachment having articulated side blade sections that fold up for transport purposes, have upper and lower level adjustments and are positively locked in the lowered working position.
A further object of the present invention is to provide a novel and improved hitch for a land leveling attachment that affords efficient coupling and decoupling with a conventional hydraulically powered tractor linkage and allows both vertical and twisting motion of the tractor independently of the leveling attachment.
Yet another object of the present invention is to provide a novel and improved automatic leveling assembly for a land leveling apparatus that adjusts as the tractor moves up and down to maintain the scraping edge of the scraping blade in the ground plane of the rear leveler frame wheels and front tractor wheels independently of the vertical movement of the rear tractor wheels.
Still a further object of the present invention is to provide a novel and improved land leveling attachment that is readily adapted to different categories of tractor linkages.
SUMMARY OF THE INVENTION
The land leveling apparatus disclosed includes a land leveling attachment releasably hitched to the hydraulically operated three-point linkage on a tractor. The attachment has articulated side blade sections pivotally connected to a central blade section that are hydraulically moved via linkage arms between raised and lowered positions and are positively locked in the lowered position by an over-center linkage lock together with upper and lower level adjustments for the side blade sections. A hitch on the leveling attachment includes a pair of lower hitch arms that are pivotally connected at their rear ends to said central blade section to provide a rotary or twisting motion of the lower hitch arms relative to said central blade section about both a longitudinal axis and a lateral axis. The lower hitch arms have downfacing receiving sockets at the forward ends which cooperate with an adjustable-length crossbar secured to the rear links of the tractor linkage. The lower hitch arms are adjustable to more than one hitch category. An automatic leveling frame with rear wheels connects at the front end to the central blade section and the hitch, central blade section, and tractor linkage form a four-bar leveling linkage with pivot points at each corner that maintains the scraping blade edge in a grading plane contacted by the front wheels of the tractor and the leveling frame rear wheels independently of the vertical movement of the rear wheels of the tractor. A setting of the caster and camber on the rear wheels avoids undue digging in of the scraping edge at the ends on turns.
Other objects, advantages and capabilities of the present invention will become more apparent as the description proceeds, taken in conjunction with the accompanying drawings in which like parts have similar reference numerals and in which:
FIG. 1 is a rear perspective view of land leveling apparatus embodying features of the present invention with the articulated side blade sections in the raised transport position;
FIG. 2 is a rear perspective view of the land leveling apparatus shown in FIG. 1 with the articulated side blade sections in a lowered working position;
FIG. 3 is a top plan view of the apparatus shown in FIG. 2 with only the rear portion of the pulling tractor shown;
FIG. 4 is a sectional view taken along lines 4--4 of FIG. 3;
FIG. 5 is a side elevational view of the land leveling apparatus shown in FIGS. 1-4 on a flat or level grade plane with positions of the apparatus illustrated generally and some portions removed for clarity;
FIG. 6 is a side elevational view of the apparatus shown in FIG. 5 with the rear wheels in a recess and the front wheels raised as they move over a hump;
FIG. 7 is a side elevational view of the apparatus shown in FIG. 5 with the rear wheels raised to be on the hump;
FIG. 8 is a front elevational view of a central portion of the land leveling attachment shown in FIGS. 1-7 with the side blade sections in the lowered working position and the lower hitch arms in the raised, non-hitch position;
FIG. 9 is a front elevational view of the central portion of the land leveling attachment shown in FIG. 8 with the side sections in the raised inboard transport position;
FIG. 10 is a rear elevational view of a lower level adjustment between the central and side blade sections with portions shown in section;
FIG. 11 is a side elevational view of one of the lower hitch arms connected to the tractor linkage with a range of pivotal movement in the raised position shown in dashed lines;
FIG. 12 is a sectional view taken along lines 12--12 of FIG. 11;
FIG. 13 is an enlarged sectional view of the ball connector pivotally securing the rear end of each of the lower hitch arms to the central blade section;
FIG. 14 is a side elevational view of one of the leveling frame wheels; and
FIG. 15 is a rear end view of one of the leveling frame wheels.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, there is shown a prime mover 9 in the form of a farm tractor to which is releasably hitched a land leveling implement or attachment 10 that is pulled by the tractor in a land leveling operation. The tractor 9 shown has a pair of front wheels 11, two pairs of rear wheels 12, and a rear axle housing 13. The hitching linkage shown attached to the rear axle housing 13 of the tractor 10 is a conventional arrangement for the releasable attachment of the tractor to a three-point hitch implement and is hydraulically powered by the hydraulic power equipment on the tractor.
This three-point hitching linkage carried by the tractor includes an adjustable upper link 15 arranged along a longitudinal center line of the attachment and a pair of laterally spaced lower links 16 on opposite sides of a longitudinal center line of the attachment each articulated or pivotally connected to the rear axle 13 at its forward end and releasably connected to a crossbar 17 of a particular construction at its rear end. The pivotal connection of the upper link 15 to the rear axle housing 13 is referred to as the upper link point 18 and the pivotal connection of each of the lower links to the tractor is referred to as a lower link point 19. Each of the lower links is moved up and down relative to the lower link points 19 by means of a link 21 connected at one end to an intermediate position on lower link 16 at a pivot 22 and at the other end to a link 23 at a pivot 24. A two-way hydraulic cylinder 25 is connected to link 23 at a pivot 26 and to link 16 at a pivot 27. Cylinder 25 is coupled to the hydraulic system of the tractor to raise and lower the lower links relative to the lower link points 19 in response to hydraulic fluid being supplied to cylinder 25.
The land leveling attachment 10 in general includes a blade assembly 28, a hitch assembly 29 secured to and extending forwardly of the blade assembly, and a leveling assembly 31 secured to and extending rearwardly of the blade assembly.
The blade assembly 28 has a sectional scraping blade SB and includes a central blade section A which in turn has two articulated left and right side blade sections B anc C, respectively, pivotally connected at forward and rear pivots 32 and forward and rear pivots 33, respectively, these pivots being on the upper part at the opposite ends of the central blade section A. The side blade sections B and C pivot relative to the central blade section between a lowered working position (FIG. 2) in which the side blade sections extend laterally out from the ends of the central blade section and a raised inboard position (FIG. 1) in which they extend up from the ends of the central section.
The central blade section A has a supporting frame including a tubular cross frame member 35 of square cross section with three laterally spaced knee frames 36 at an intermediate and end positions each connected to the back side of the cross frame member 35 and extending rearwardly and downwardly therefrom. An arcuate scraping blade member 39 is mounted in a depending manner from the underside of a horizontal portion of each of the knee frames and is affixed at the back to an upright portion of each of the knee frames and has a lower scraping edge 39a. An upper crossbar 41 and a lower crossbar 42 extend across the back of the upper and lower portions, respectively, of the blade and intermediate back braces 43 are provided between the knee frames along the back side for additional strength.
Each of the side blade sections B and C is of an identical construction arranged for left and right side operation and is of a construction similar to the central blade section A. Each side blade section has a tubular cross frame member 45 of square cross section with knee frames 46, one at an intermediate position and another at an inner end position, and an outer end plate 49 that also forms a structural support like a third knee frame at the outer end. Each side section has an arcuate scraping blade member 51 aligned with scraping blade member 39 mounted in a depending manner affixed to the back of the knee frame 46, an upper crossbar 52, a lower crossbar 53, and back braces 54. Scraping blade members 51 and 39 arranged end-to-end in the working position form the composite scraping blade designated SB.
An identical linkage assembly 56 is connected between each side blade section B and C and the central blade section A which in general serves to lock the associated side section in the lowered working position and is responsive to the linear movement of a common two-way hydraulic actuator 58 to simultaneously raise and lower the side blade sections and to hold the side blade sections in the raised position. Each linkage assembly 56 includes a lever arm 59 fulcrumed at a pivot 61 between a front support plate 62 and rear support plate 63 that is secured to and projects up from the cross frame member 35. An adjustable line 64 has one end pivotally connected at pivot 65 to one end of the lever arm 59 and the other end is pivotally connected at a pivot 66 on a bracket plate 67 projecting up from the top of the associated side blade section.
In the lowered working position for the side blade sections shown in FIG. 8, the adjustable link 64 and lever arm 59 are substantially end-to-end and substantially in line with the pivot 65 at a slight over-center position below a horizontal line passing through pivots at 61 and 66. This over-center arrangement locks the side blade sections in the lowered working position. A stop 68 is provided on the lever arm 59 against which the free end of the adjustable link 64 will abut to prevent the link 64 and lever arm 59 from going too far past the over-center position.
The opposite ends of the two-way hydraulic actuating cylinder 58 are pivotally connected at a pivot 71 on each lever arm 59 opposite pivot 65 and offset to one side of a line passing through pivots 61 and 65 so that, as the actuating cylinder 58 is expanded to increase the effective length between the ends thereof, both lever arms 59 rotate or swing simultaneously from a generally laterally outwardly extending position to an upright position, which pulls the adjustable link 64 from a horizontal to an upwardly and inwardly inclined position forming an acute inside angle between the lever arm 59 and the associated link 64, causing the side blade sections B and C to pivot to the upright position about their respective pivots 32 and 33. The side sections B and C are then held in the upright or folded position by the pair of linkage assemblies 56 and hydraulic actuator 58 powered by the hydraulic system of the tractor.
An identical lower level adjustment 76 is provided for each of the side blade sections B and C for their adjustment relative to the central blade section A. As best seen in FIG. 10, the lower level adjustment 76 includes an externally threaded member 78 affixed at one end to the central blade section A as by welds 79 and further by a bracket 81 secured to the knee frame 36 and to the threaded member at welds 82. The threaded member 78 projects laterally out and terminates in a narrowed stepped end portion 83 that is slidably inserted into an aperture in sleeve 84 affixed to the knee frame 46 of blade section B by welds at 85 and to a bracket 86 as by welds indicated at 87.
An adjustment nut 88 threads on the end of the threaded member against the bracket 86 so that threading in one direction will raise the side blade section B slightly and in the other direction will lower the side blade section B slightly. A lock nut 89 threads on the threaded member 78 against nut 88 to lock the level adjustment at a particular setting. The lower level adjustment is normally set with the side blade section B level and does not require further adjustment. The upper level adjustment is provided by threading the adjustable links 64 in the linkage 56 used for raising and lowering the side blade sections, as above described.
The hitch assembly 29 includes an upright mast plate 96 affixed to the front support plate 62 and further supported by an inclined brace 97 connected between mast plate 96 and knee frame 36. The mast plate 96 shown has two laterally spaced, parallel, forwardly projecting flanges 101 and 102 provided with three pairs of vertically spaced apertures 104, 105 and 106 each adapted to slidably receive an upper hitch pin defining a pivot 107. The rear end of the upper link 15 inserts between flanges 101 and 102 and has an aperture that aligns with a pair of aligned apertures in the mast plate flanges and the hitch pin 107 slide-fits in one of the three aligned apertures to pivotally and releasably connect the rear end of the upper link 15 to the mast plate 96 at a pivot 107.
The hitch assembly 29 further includes two laterally spaced lower hitch arms 108 each pivotally connected at its rear end to the central blade section A at a side pivot connection. Each side pivot connection is of a universal-type joint with a ball connector 111 mounted on a lateral shaft 113 supported in a housing 115 affixed to blade section A. Each ball connector 111 is provided with an outer spherical race 111a inserted into and held in an aperture 119 in the rear end of arm 108 and an inner ball portion 111b movable in the race that is affixed to shaft 113 so that each hitch arm 108 rotates relative to blade section A about both a longitudinal axis and a lateral axis at its pivotal connection, providing for limited up and down movement and also twisting movement about a longitudinal axis of the tractor independently of the position of the blade sections. Optionally, a single common center point pivotal connection may be used in place of the two side pivot connections wherein the rear ends of both hitch arms are secured to and pivot with a common crossbar pivoted at its center by an enlarged version of fixed center pivot pin 129 described hereinafter.
Each housing 115 has a back wall portion 115a and a lower wall portion 115b on which the associated hitch arm 108 rests in a lowered position, as shown in dashed lines in FIG. 11. The housing 115 shown is constructed with an intermediate wall portion 115c providing a section for a category II hitch and a section for a category III hitch.
For the side pivot connection each hitch arm 108 is secured against lateral movement during turns by a cross link 127. Cross link 127 is pivotally connected to pivot in a vertical plane at an inside end at a common center fixed pivot pin 129 on a bracket 131 affixed to the center frame member 35. Each cross link 127 is provided with a second aperture 133 to facilitate adjustment for a category II hitch.
The outer end of each cross link 127 is pivotally connected to an associated lower hitch arm 108 by a ball connector 132 having a pivot pin 134 connected to a bracket 136 secured to the inside of the hitch arm 108 between the front and rear ends of the hitch arm. No cross links 127 or associated structure is required for the center pivot hitch connection. Each hitch arm 108 is normally held in the upper position, shown in FIG. 11, during transport by a pin 141 on a bracket 142 and a pin 143 on front plate 62. The same link 144 with holes at the opposite ends preferably is used as that which releasably holds the crossbar 17 to the lower hitch arms 108.
Each of the hitch arms 108 has a down-facing socket 151 at its front end that slidably receives an end portion of cross-bar 17 carried by the lower draft links 16 and 17 of the tractor. Each hitch arm 108 is of a bifurcated construction including a pair of laterally spaced arm plate portions 108a and 108b joined at their rear ends which carry the ball connector 111 and open at the front ends to slidably receive the rear end portion of a lower draft link 16.
The two bifurcated plate portions 108a and 108b are each provided with a down-facing slot alined with one another having rounded corners to form the socket 151 at the front end that slidably receives the crossbar 17. In use the crossbar 17 is normally lowered under the sockets and raised into position by actuating cylinder 25. The plates are wider at the front end and have a notched area 158 at the rear that fits up against the frame member 35 in the raised transport position, as shown in dashed lines in FIG. 11. The link 144 with holes at each end is releasably supported across the slot opening on arm 108 by pins 161 and 162 to releasably fasten the crossbar to the lower hitch arms.
The crossbar 17 has a lengthwise adjustment feature to facilitate its use with either a category II or a category III hitch. The hitch is shown in a category III setting. The adjustable crossbar 17 includes a central tubular member 164 in which end tubular members 165 and 166 are telescopically and slidably received. Adjustment bolts 167 and apertures in members 164, 165 and 166 facilitate the shortening of the effective length thereof. Each end tubular member has an external guide flange 168 that guides the crossbar into position between the plates 108a and 108b of the bifurcated lower hitch arms 108. Each end tubular member 166 carries an end shaft 171 with an external diameter that slides into a ball connector 172 in the lower link 16 and an end section 173 of reduced diameter that extends beyond the associated lower hitch arm 108. In the adjusting of the hitch assembly for a category II hitch, the crossbar 17 is shortened in length and the base connectors 111 are positioned in the inside sections of housing 115.
The automatic leveling assembly 31 includes a generally open, box-shaped, leveling frame including two laterally spaced, parallel, hollow side members 175 on opposite sides of a longitudinal center line, a hollow front cross member 176, and a hollow rear cross member 177. Each side member has a downturned front end portion 178 pivotally connected to the rear outer end portion of cross frame member 35 at a pair of laterally spaced pivots 30 on opposite sides of a longitudinal center line of the attachment. The rear end of the leveling frame is supported for vehicular movement on a pair of laterally spaced wheels 181 mounted on end extensions of the rear cross member 177.
Referring now to FIGS. 14 and 15, each wheel 181 is carried by a caster bracket 182 with a stub shaft 183 rotated in a journal 184. The journal 184 is secured to the end extension of the cross member 177. The wheels are set on a selected caster designated by angle E and a camber designated by angle F in FIGS. 14 and 15 to avoid a digging in at the ends of the side blade sections during a turning movement. A preferred caster angle E is about three degrees and a preferred camber angle F is about one-half degree.
The depth of the scraper blade may be selectively, manually adjusted by means of a four-sided or four-bar linkage arrangement including a link 188 connected at a pivot 189 to the cross member 176 having one end connected to one end of a two-way hydraulic cylinder 191 at a pivot 192. The other end of the cylinder 191 is connected at a pivot 193 to the mast plate 96. An adjustable link 194 is connected at a pivot 195 to the other end of link 188 and to the mast plate at a pivot 196 below pivot 193. Pivots 193 and 195 are positioned at spaced locations on the back side of the mast plate. When the cylinder 191 is retracted a vertical downward force is exerted on link 188 and in turn member 176 to move the scraper blade down, and when the cylinder is extended the scraper blade in turn is raised. This four-bar blade depth adjustment above described as well as inclined brace 97 and pivots 30 rigidly affixes the forward end of the leveler frame 31 to the mast plate 96 and central blade section A so they move up and down together during the leveling operation.
The automatic level-adjusting assembly 31 hitched to the tractor as above described is shown to comprise an essentially four-sided or four-bar leveling linkage with opposite bars non-parallel to one another and with a pivot at each corner and functions to maintain the cutting blade assembly on a grade line designated P contacted by the front wheels 11 of the tractor and the trailing wheels 181 independently of the movement of the rear tractor wheels 12, as shown in FIGS. 5-7. This automatic leveling linkage is comprised of the upper link 15 pivotally connected to the tractor at pivot 18 and lower link 16 pivotally connected to the tractor at pivot 19, these links 15 and 16 being opposite and non-parallel to one another, as well as the rear axle housing 13 between pivots 18 and 19, and the rigid structure between pivots 107 and 113. The rigid structure between pivots 113 and 107 is one bar of the linkage that generally extends at a downward and rearward incline and is non-parallel to the opposite bar between pivots 18 and 19 that extends at a downward and forward incline. Pivot 107 is an upper rear control pivot and is adjustable up and down by virtue of the vertically spaced apertures in the mast plate. Pivot 113 is a lower rear pivot, pivot 18 is an upper front pivot and pivot 19 is a lower front pivot.
In the operation of this leveling linkage, as the front wheels 11 move up over a hump and/or the rear wheels move down in a depression for an upward tilt of the tractor, the tractor pivots counterclockwise about pivot 19, pivot 18 moves rearwardly to push link 15 and control pivot 107 rearwardly and upwardly about pivot 113 with pivot 113 and leveling frame 31 raising and in turn raising and tilting the mast plate slightly forward and raising and tilting the scraping blade SB slightly forward so that the scraper blade edge remains in the grade line or plane contacted by the front wheels of the tractor and the rear wheels of the leveling frame, and soil in the blade SB fills the depression R.
Conversely, when the rear wheels 12 of the tractor rise over the hump and the front wheels 11 move down so that there is a downward tilt of the tractor, as shown in FIG. 7 the tractor pivots in a clockwise direction about pivot 19, pivot 18 moves forwardly to pull link 15 and control pivot 107 downwardly and forwardly about pivot 113 with pivot 113 and leveling frame 31 lowering and in turn lowering and tilting the mast plate slightly back and lowering the scraper blade edge to cut off the hump, again with the position of the blade edge remaining in the plane P contacted by the front wheels of the tractor and the rear wheels 181 of the leveling frame.
The automatic leveling assembly apparatus and operation may be further understood by considering the upper rear control pivot 107 as a common pivot at the apex of a bridge-like structure having one forwardly and downwardly inclined bridge portion extending from the pivot 107 along the tractor through approximately the front wheels of the tractor and another rearwardly and downwardly inclined bridge portion extending generally along the leveling frame from pivot 107 through the center of the rear wheels 181 with the scraping blade SB being supported in a depending manner from these bridge portions and moving up and down as the control pivot 107 moves up and down. As the control pivot 107 is raised as shown in FIG. 6, the scraping blade is raised, and as the control pivot 107 is lowered as shown in FIG. 7 the scraping blade is lowered, but again at all times the triangulation of this bridge-like structure retains the scraping blade edge on a grade line or plane P contacted by the rear wheels 181 and front tractor wheels 11.
In this way, in the operation there is a cutting off of high spots and a filling of depressions, with the grade established by the front wheels of the tractor and the rear trailing wheels located a considerable distance apart with the movement of the rear wheels of the tractor not materially affecting the position of the blade.
In the event a lowering or raising of the scraping blade SB is required, hydraulic fluid is admitted to cylinder 191 which when retracted increases the depth and when extended raises the scraping blade SB.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof. | Land leveling apparatus includes a leveling attachment drawn by a tractor with the attachment having pivotally connected side blade sections on a central blade section affording a substantially greater leveling capacity. The side blade sections fold up to reduce width during transport and have a power-driven linkage arrangement for each blade section that moves and positions the blade sections and locks them in the lowered working position, together with upper and lower level adjustments for the side blade sections. A hitch assembly facilitates quick coupling to a crossbar carried by the lower links of the tractor linkage and is pivotally joined to the central blade section so as to facilitate rear tractor wheel movement independently of the scraper blades. A leveling frame is connected at the front end to the central blade section and the pivotal attachments of the hitch assembly to the tractor linkage with the central blade section provide a four-bar linkage leveling structure that automatically moves in response to tractor movement to maintain the scraping edge substantially in a ground plane of the rear leveler frame wheels and front wheels of the tractor independently of the vertical movement of the rear wheels of the tractor. | 4 |
FIELD OF THE INVENTION
The present invention relates to a roll for a paper or board machine, and in particular to a roll of the type having a number or openings extending through the mantle.
BACKGROUND OF THE INVENTION
In paper or board machines, a web forming section employs mainly suction rolls which usually comprise a perforated roll mantle attached to end flanges at the ends of the roll. The end flanges are in turn journalled rotatably on attachment flanges situated at the ends of the roll and attached to the frame of the machine. Inside the roll mantle. there may be a static suction box attached to the attachment flanges enabling suction to be applied to a given sector of the suction roll. The interior of the roll may also be empty, in which case suction is applied to the entire circumference of the roll mantle. The ends of the roll are provided with ducts by which an external source of negative pressure can be connected to the roll. Moreover, bores extending through the roll mantle are normally provided. in the outer surface of the mantle, with countersinks by means of which the unbroken connecting portions surrounding the holes of the bores in the outer surface of the roll mantle are made smaller and the open area of the outer surface of the roll mantle is increased.
The press section of paper or board machines in turn employs rolls which have a roll mantle that is perforated or provided with blind-drilled bores. In that case, the interior of the roll is not necessarily connected to a separate source of negative pressure. In a press nip, water is sucked into the holes, blind-drilled bores or other recesses of the roll mantle and removed from them after the press nip by means of the centrifugal force. In order to reduce the contact pressure, the mantle of press section rolls is normally coated with a material that is softer than steel, for example, with some rubber-like material. The blind-drilled bores in a roll provided with a coated mantle may extend some distance into the steel mantle or merely into the coating depending on a desired volume of the bores. Moreover, both through bores and blind-drilled bores are normally provided with countersinks in the outer surface of the mantle for reducing the size of the unbroken connecting portions that surround the holes or recesses in the outer surface of the roll mantle and for enlarging the open area of the outer surface of the roll mantle.
Around the perforations of the roll mantle on the outer surface of the roll mantle, despite holes. blind-drilled bores or recesses, there remain relatively large unbroken connecting portions at which the suction effect is weaker. For this reason, said unbroken outer surface of the roll mantle causes marking in the paper web.
One solution to this marking problem has been to provide the roll mantle, for example, with a coarse wire net, by which the open surface of the outer face of the roll mantle has been increased. The wire net or a wire sock is mostly made of plastic and it is attached in place by shrinking to form the outermost layer of the roll. The manufacture of such a wire sock and its fitting to the outer face of the roll mantle constitute an additional work stage in the manufacture of the roll. In addition, the wire sock wears in use and thus it has to be replaced at certain intervals.
It is also known to mount on the roll mantle a separate honeycomb arrangement made of metal by means of which the open surface of the outer face of the roll mantle is enlarged. It is difficult to fasten this kind of metal honeycomb to the face of the roll mantle and it may become detached in use.
DE patent 21 40 776 discloses a suction roll of a paper machine comprising a mantle stiffened against bending and a perforation extending through the mantle of the roll and forming a certain pattern. Additionally, the mantle surface of the roll is provided with grooves that connect a row of holes so that a symmetrical embossed pattern of the surface is formed in practice. The hole area in the surface of the roll mantle is over 50% and it may be nearly 90% of the total area of the roll mantle. It is also stated in the publication that some of the above-mentioned holes may be blind-drilled bores or that, in addition to the above-mentioned holes, blind-drilled bores are made into the surface of the mantle for improving the water retention capacity of the roll. In this arrangement, the connecting surface of the walls between two adjacent grooves in the surface of the mantle forms a solid connecting portion supporting the wire or equivalent.
The problem in this arrangement of DE patent 21 40 776 is the solid connecting portions at which the suction effect of the roll is weaker. These solid connecting portions constitute an obstruction to the free flow of water into the holes or blind-drilled bores.
OBJECTS AND SUMMARY OF THE INVENTION
The roll in accordance with the invention provides a very good and even flow of water into the holes extending through the mantle of the roll and/or into the blind-drilled bores and/or equivalent openings situated in the outer surface of the roll mantle. Moreover, in the roll in accordance with the invention, no separate wire sock is needed on the outer surface of the roll mantle. The open area of the outer surface of the mantle of the roll in accordance with the invention is about 70-90% depending on the application.
The arrangement of the invention may be used in a roll of a paper or board machine which comprises either openings extending through the roll mantle, e.g. through bores, or recesses formed into the outer surface of the mantle, e.g. blind-drilled bores, or a combination of them. Such rolls are used, for example, in a web former and in a press section. The invention may be used in a suction roll where suction is applied to the circumference of the entire mantle or in a suction roll having a static suction box by means of which suction is applied to a given sector of the roll. The arrangement in accordance with the invention may also be used in a roll which employs no external source of negative pressure, by which a negative pressure is maintained in the interior of the roll. In that case, the water that is being removed from the web is transferred into the holes and/or blind-drilled bores of the roll mantle at the point of compression by the action of a pressure difference produced in the wire or equivalent supporting the web.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention will be described in more detail with reference to the figures in the accompanying drawings, to the details of which the invention is, however, not intended to be exclusively confined.
FIG. 1 is a schematic sectional view of a suction roll.
FIG. 2 shows one embodiment of a surface pattern in a mantle of a roll in accordance with the invention.
FIG. 3 shows a variant of the embodiment of FIG. 2 .
FIG. 4 shows a second embodiment of a surface pattern in a mantle of a roll in accordance with the invention.
FIG. 5 shows a third embodiment of a surface pattern in a mantle of a roll in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a view of principle of a suction roll where the arrangement in accordance with the invention may be used. The suction roll comprises a roll mantle 11 , which is rotatably journalled on axle journals 13 A and 13 B connected to the roll mantle 11 through end flanges 12 A and 12 B. The roll mantle 11 has perforations 15 which are formed of numerous holes 15 extending through the roll mantle 11 . The figure shows only some of the perforations 15 of the mantle 11 . The interior of the roll is here empty, but inside the roll there may also be a suction box by means of which suction is guided to a given sector of the roll mantle. At least one 13 B of the axle journals comprises ducts which lead to the interior of the roll and to which an external source of negative pressure (not shown in the figure) can be connected. Air is sucked out (arrow P 2 ) by means of the source of negative pressure from the entire interior of the roll or at the sector formed by the suction box, in which connection a corresponding amount of air (arrow P 1 ) flows into the roll through the perforations 15 of the roll mantle. The perforations 15 of the roll mantle 11 may be composed of bores extending with the same diameter through the entire mantle 11 or countersinks may have been made into the bores in the outer surface of the mantle 11 . whereby the area of the holes 15 opening into the outer surface of the mantle 11 has been enlarged. The perforations 15 of the roll mantle 11 are advantageously formed to be spiral-shaped so that the holes are not situated in rows in the axial direction of the roll. By this arrangement, the emptying of the holes 15 of water and the subsequent filling of the holes with air can be arranged to take place stepwise in terms of time, whereby the noise caused by this can be reduced. The diameter of the holes 15 is generally about 2-5 mm and the diameter of the countersinks is generally about 2-15 mm.
FIG. 2A shows one embodiment of a pattern in an outer surface of a mantle of a roll in accordance with the invention. The holes and/or blind-drilled bores or their countersinks 15 situated in the roll mantle form a regular pattern in the outer surface of the roll mantle. Through a line formed by the centres of the holes and/or blind-drilled bores 15 , it is possible to draw a curve which extends spirally along the outer surface of the roll mantle and whose angle of spiral relative to the axis X—X of the roll is α. In this figure, said angle α is about 45°, but in practical applications the angle of spiral α is, however, considerably smaller than 45° in order that the holes and/or blind-drilled bores 15 shall not be placed in rows parallel to the axis X—X of the roll. In the example of FIG. 4, which shows another embodiment of the invention, the angle of spiral α is about 10°. The arrangement in accordance with the invention may in itself be used at any angle of spiral α and with any regular pattern formed by holes and/or blind-drilled bores.
The row formed by the holes and/or blind-drilled bores 15 in a first direction S 1 in FIG. 2A is connected by means of a first groove 16 formed into the outer surface of the roll mantle and the row formed by these holes and/or blind-drilled bores 15 in a second direction S 2 is connected by means of a second groove 17 formed into the outer surface of the roll mantle. This figure depicts only two adjacent grooves 16 running in the first direction S 1 and two adjacent grooves 17 running in the second direction S 2 . The width of the crossing grooves 16 , 17 in the outer surface of the roll mantle corresponds substantially to the diameter of the holes and/or blind-drilled bores or their countersinks 15 in the outer surface of mantle. When the first grooving 16 is made into the outer surface of the mantle on the holes and/or blind-drilled bores 15 , a solid connecting portion 16 ′ is formed between the adjacent grooves 16 in the outer surface of the mantle, which connecting portion prevents a free flow of water into the holes and/or blind-drilled bores 15 . This solid connecting portion 16 ′ is broken by means of the second grooving 17 situated crosswise with respect to the first grooving 16 and formed on the holes and/or blind-drilled bores 15 . In that case, between four holes and/or blind-drilled bores or their countersinks 15 closest to one another, there remains a square-shaped support point 18 for a wire or an equivalent support member of the web running on the surface of the roll, which support point is situated on a level with the original outer surface of the mantle.
By means of the arrangement shown in FIG. 2A, the open area of the outer surface of the roll mantle can be enlarged at its maximum by about 90% so that only the small square-shaped support points 18 support the wire running on the surface of the roll. From the edges of the square-shaped support points 18 , the surface of the mantle inclines into the mantle and opens into the holes and/or blind-drilled bores 15 of the mantle, in which connection the water removed from the web is able to flow freely and evenly into the holes and/or openings of the mantle.
FIG. 2B shows a cross section of the roll mantle at the support points 18 . The cross section shows a profile of the grooves 16 , 17 which is advantageously in the shape of a cone widening upwards to the outer surface of the mantle. The support points 18 are depicted here such that their outer surface constitutes a plane, which is the most preferable arrangement from the point of view of the manufacturing technique. In the arrangement that is the most preferable from the point of view of operation, the outer surface of the support points is hemispherical so that the edges of the square-shaped support points will not form a sharp angulation for the wire. The hemispherical surface provides a smooth support surface for the wire moving on the surface of the roll. The depth of the grooves 16 , 17 is advantageously about 1.5-2 mm and they may be made into the outer surface of the roll mantle, for example, by turning, milling or knurling.
FIG. 3 shows a variant of the embodiment of FIG. 2 . In FIG. 3, grooves 40 , 41 formed in first S 1 and second S 2 directions are provided between rows of holes and/or blind-drilled bores 15 such that the edges of the grooves 40 , 41 form a tangent to the holes and/blind-drilled bores or their countersinks 15 in the outer surface of the mantle. In this arrangement, around each hole and/or blind-drilled bore or their countersink 15 , there remain, in the outer surface of the mantle, four support points 42 for a wire or an equivalent member supporting the web. The open area of the outer surface of the mantle provided by this embodiment is not as large as that of the embodiment illustrated in FIG. 2, but in this case, too, water moves relatively efficiently and evenly into the holes and/or blind-drilled bores 15 .
FIG. 4 shows a second embodiment of a pattern in an outer surface of a roll mantle in accordance with the invention. The holes and/or blind-drilled bores or their countersinks 15 situated in the roll mantle are shown in the figure as completely filled circles. In addition to the holes and/or blind-drilled bores or their countersinks 15 , circular grooves 30 are formed into the outer surface of the roll mantle. The grooves 30 are made such that the centre of each groove 30 coincides with the centre of the holes and/or blind-drilled bores 15 and the centre radius of the grooves 30 is equal to the distance between the centres of the holes and/or blind-drilled bores 15 . The centres of the holes and/or blind-drilled bores 15 are situated in this example at the apices of an equilateral triangle. The outer surface of the mantle surrounding the holes and/or blind-drilled bores or their countersinks 15 can be opened by means of said grooves 30 . Connecting channels extending to the depth of the grooves 30 are thus formed between the holes and/or blind-drilled bores or their countersinks 15 in the outer surface of the mantle. In this embodiment, the wire or equivalent is supported by triangular support points 31 . The open area of the outer surface of the roll mantle can be regulated in this embodiment by regulating the width of the grooves 30 . This embodiment, too. provides an efficient flow of water into the holes and/or blind-drilled bores 15 .
FIG. 5 shows a third embodiment of a pattern in an outer surface of a mantle of a roll in accordance with the invention. In this embodiment, blind-drilled bores 50 are provided between holes and/or blind-drilled bores or their countersinks 15 such that each blind-drilled bore opens a connection to the closest holes and/or blind-drilled bores or their countersinks 15 surrounding it. By this means, the open area of the roll mantle can be enlarged. The size of the open area of the outer surface of the mantle depends in this embodiment, among other things, on what kind of pattern the holes and/or blind-drilled bores 15 form in the outer surface of the mantle. If blind-drilled bores 50 are made to the hole pattern shown in FIG. 4, a relatively large open area can be achieved, and if blind-drilled bores 50 are made to the hole pattern shown in FIG. 5, a slightly smaller open area is achieved. The support points supporting the wire are here denoted with the reference numeral 51 .
The claims are presented in the following and the details of the invention may vary within the inventive idea of said claims and differ from the disclosure given above by way of example only. | The invention relates to a roll for a paper or board machine comprising axle journals on whose support the roll is arranged to revolve, end flanges with which the axle journals are connected, and a mantle which is connected with the end flanges. The mantle is provided with a number of openings extending through the mantle and/or recesses formed into the outer surface of the mantle, which openings and/or recesses form a regular pattern. Solid connecting portions in the outer surface of the mantle around said openings and/or recesses are opened to that, from each opening and/or recess, there is a connection, provided in the form of a groove or an additional recess extending into the outer surface of the mantle, with at least each of the openings and/or recesses adjacent to it. | 3 |
BACKGROUND OF THE INVENTION
Continuous or fan-folded computer forms are well known and have a computer print out applied to sheets which are interconnected at reverse folds along top and bottom edges of the sheets. The side edges of the sheets are perforated to receive cogs or drive belts of tractor devices which are adapted to transport the fan-folded form.
From time-to-time, it is desired that a duplicate or plural copies of the computer print out form be made, but manual handling of the folded form is time-consuming and unwieldy.
It has been proposed that an attachment be provided for use with copying machines, the attachment having drive means for the form enabling the form to be progressively fed beneath the platen of the copier in responses to the traverse of the scan light of the copier, so that the form can be copied and refolded. While such an attachment has general applicability to copiers, by adaptation of the supporting means, there remains a need for a fan-folded form feeder which can be readily applied to existing copiers or incorporated into new copiers and which is compact, reliable and easy to use.
SUMMARY OF THE INVENTION
An object of the present invention is to provide improved fan-folded form feeding apparatus for copying machines.
Another object is to provide such apparatus which can be easily installed on the copying machine and adapted to transport fan-folded forms of different widths and/or lengths.
In accomplishing the foregoing, apparatus is provided which includes a mounting plate applicable to the rear of a copying machine and having a pair of laterally spaced form tractors supported on the plate for relative lateral adjustment, the tractors being driven by a power source under control of selective means operable to move a selected length of the form over the copying machine from a form receiver to a refold tray.
Since the form feeder may not be desired at all times, the receiver tray and refold tray are foldable to a compact state, enabling the copying machine to be located closely adjacent to a wall, for use of the copier in the usual manner.
The drive means for the tractors, according to this invention are driven by an electric motor which drives the tractor drive shaft through a slip clutch and the shaft is stopped by a stop mechanism to assume correct registry of the form on the copying machine.
In addition, the angular travel of the drive shaft for the tractors is determined by selected cam operated switches which control operation of the motor and stop mechanism.
This invention possesses many other advantages and has other purposes which may be made more clearly apparent from a consideration of the forms in which it may be embodied. The preferred form is shown in the drawings accompanying and forming part of the present application. It will now be described in detail, for the purpose of illustrating the general principals of the invention; but it is to be understood that such detailed description is not to be taken in a limiting sense.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation showing the form feeder applied to a copier of FIG. 3;
FIG. 2 is a top plan;
FIG. 3 is a rear elevation;
FIG. 4 is an enlarged fragmentary section on the line 4--4 of FIG. 3;
FIG. 5 is a fragmentary view on the plane of the line 5--5 of FIG. 4, showing the form transport means;
FIG. 6 is a vertical section on the line 6--6 of FIG. 5;
FIG. 7 is a vertical section on the line 7--7 of FIG. 5;
FIG. 8 is a section on the line 8--8 of FIG. 7, showing the tractor open;
FIG. 9 is a diagram of the control system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Fan-folded form copying apparatus, as seen in the drawings, comprises a copier C for making successive copies of original sheets, a platen P pivotally mounted on the copier, a form receiving tray 10 disposed horizontally above and rearwardly of the platen, and a form refolding tray 11 disposed horizontally below the platen and rearwardly of the copier. Means are provided for guiding the form, as shown in FIG. 1, from said receiving tray across the platen and beneath the platen to the rear of the copier. Intermittently operable drive means D (FIG. 5) are provided for progressively feeding the form beneath the platen to the rear of the copier for gravitation to said refolding tray.
The drive means includes laterally spaced drive tractors T including driven members 12 having pins 13 engageable in perforations in the side edges of the form, and as later described, the tractors are laterally adjustably mounted for adjustment to drive forms of different widths.
The drive means has selective control means shown in FIGS. 5 and 6 to cause intermittent feeding of different lengths of said form as also later described.
Referring to FIG. 5, the tractors T are mounted upon a square shaft 20 and an upper guide shaft 21. The square shaft 20 is driven by a motor M under the control of the system shown in FIG. 9.
Referring to FIG. 7, each tractor T will be seen to comprise a body 22 containing sprockets over which a drive belt 12 extends, the drive belt having the above described pins 13. The lower sprocket 22 is driven by the square drive shaft 20, whereby the form engaged by the pins 13 is transported from the receiving tray 10, moving upwardly over an upstanding transversely extending bail 24 thence forwardly and downwardly beneath a rod 25 extending horizontally just above the rear portion of the platen P, the form then extending beneath the platen for reproduction, thence engaging the tractors, at the rear of the copier, from which the form moves gravitationally onto the rear flat tray 11, all as seen in FIG. 1.
The right hand tractor T of FIG. 5 is laterally adjustable along the shafts 20 and 21, when a cam lock 27 on the tractor is released from engagement with the guide shaft 21. This enables the pair of tractors to engage forms of different widths. In this connection, it will also be seen in FIG. 2 that the platen has a fixed marginal guide 28 on its upper surface opposed by a laterally adjustable marginal guide 29, whereby to guide the forms of different widths, one of which is seen in full lines and one of which is seen in broken lines.
Referring to FIGS. 4 and 5, means are shown for stopping movement of the drive shaft 20 at fixed locations coinciding with the spacing of the perforations in the margins of the form. The stop means includes a cog wheel 30 on shaft 20 for rotation therewith, the wheel having a number of lugs providing radial faces 31 engageable by a pivoted pawl or detent 32. The pawl is adapted to be disengaged from the cog wheel by a solenoid 33. This stop means positively stops rotation of shaft 20, and a slip clutch 30' is mounted on the drive shaft 20 to normally drive the latter through motor driven gearing 31' when the pawl is released from the cog wheel, but when the pawl engages the cog wheel, the slip clutch 30' permits the motor to overrun without changing the location of the form.
In addition, as best seen in FIGS. 5 and 6, means are provided for causing the drive shaft 20 to be stopped following different degrees of angular travel whereby different lengths of the form can be transported through the copier.
A pair of gears 40 and 41 are in mesh with gears 42 and 43 on the drive shaft 20 to drive a pair of switch actuator cams 44 and 45. The ratio of the gears 40, 42 and 41, 43 is such that the cams 44 and 45 revolve differentially. Switch arms 46 and 47 are actuated by the cams 44 and 45, respectively, to close the switches or to allow the switches to open following one revolution of the cam. As will later become apparent, opening of these control switches de-energizes the motor M and the pawl solenoid so that the drive shaft is instantaneously stopped, but as pointed out above, the motor can overrun.
From the foregoing, it will be apparent that the number of cogs in cog wheel 30 and the angular extent of rotation of the switch operating cams are so related to the tractor pin spacing that precise lengths of form will be transported with each shaft revolution.
The cycling or intermittent operation of the transport is timed to the copy cycle of the copying machine. Referring to FIG. 9, a diagrammatic illustration of the control system is shown wherein the scanning lamp voltage of the copier is employed to energize a normally closed relay 50. When relay 50 is closed, current is supplied through a time delay device 51 to a normally closed relay 52, and through one of the selective cam operated switches 46 and 47 to the motor and to the pawl solenoid 33. The time delay 51 enables the motor to be started by current supplied through normally closed relay 52, thereby causing the selected cam operated switch 46 and 47 to be activated to the closed condition, whereby current is continued to the motor after normally closed relay 52 opens.
From the foregoing, it will be apparent that the invention provides a compact and simple form feeder to be combined with the copier to facilitate the reproduction of the fan-folded form.
When the form feeder is not in use, the copier can be used in a conventional manner, at which time an outer tray section of the refold tray 11 can be pivoted upwardly to an out-of-the-way position. Likewise, the receiver tray 10 can be pivoted to a position on top of the transport housing. | A continuous fan-folded form feeder is applied to a copying machine and has a receiver for the folded form from which the form is trained over the top of the copying machine platen and then beneath the platen to the rear of the copying machine for engagement by form tractors to be progressively fed in stages beneath the platen to a re-fold tray. Drive means for the tractors feeds the form step-by-step in selected increments of length. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to electronic ballasts used for powering gas discharge lamps. More particularly, the present invention pertains to methods and circuits for providing overvoltage protection and automatic lamp re-striking in an electronic ballast.
Electronic ballasts for gas discharge lamps, e.g. fluorescent lights, are well known in the prior art. Electronic ballasts can provide, among others, the means to ignite and operate the gas discharge lamps.
Gas discharge lamps are lit through a variety of methods. For exemplary purposes, one method requires the lamp, having an elongated tube with a phosphor coating on the inside surface, to be subjected to a large voltage differential between its terminals. This large voltage differential is sufficient to generate an electrical pathway between the terminals (the voltage differential is greater than the breakdown voltage between the lamp terminals). The resultant current flowing between the terminals excites gaseous atoms, already present in the tube of the lamp, which in turn causes the gaseous atoms to release photons. These photons are outside of the visible spectrum, typically, in the ultraviolet range. These ultraviolet photons bombard the atoms comprising the phosphor coating of the tube and cause the phosphor coating to release photons which are in the visible spectrum. In this way visible light is produced.
The ballast occupies an integral role in this process. The ballast supplies the means to ignite the lamp through the process detailed above. Once the lamp is ignited, the ballast also regulates the electrical current that flows through the lamp. Without the regulation efforts of the ballast, the current demanded by the lamp would be significant because once the lamp begins to operate it presents very little electrical resistance. If there was not a mechanism to curtail the current demanded by the lamp, the lamp would be impractical to use.
Of particular import is the ability of the ballast to reliably ignite, or re-ignite, the lamp after the lamp malfunctions or is replaced. Ideally, the ballast should successfully ignite the lamp with only one attempt but it is not unusual for a ballast to make a series of ignition attempts before the lamp actually ignites. This succession of ignition pulses engenders the ballast ignition system with a degree of robustness.
However, it is also desirable for the ballast to recognize when a lamp is faulty and cannot be lit or when no lamp is present. In either case it would be advantageous for the ballast to appreciate that further ignition attempts will be fruitless. Unfettered re-ignition attempts can pose safety risks to those exposed to the lamp fixture because the ballast must generate a significant voltage to induce the lamp to ignite. Moreover, continuous ignition or re-ignition attempts needlessly stress the ballast and can lead to premature component fatigue and eventual failure. Consequently, a ballast that can generate a series of ignition pulses to effectively ignite a lamp and can also diagnose when further ignition attempts are ill advised is desirable.
No less crucial than ignition concerns is a the ability of the ballast to guard against potentially damaging overvoltage conditions, such as when the lamp experiences input arcing or unsuccessful ignition attempts. To effectively forestall damage from overvoltage conditions, the ballast must expeditiously recognize and suppress the overvoltage condition before irreparable damage occurs. As with unnecessary ignition attempts, overvoltage conditions are deleterious to the ballast because the ballast's components are stressed. Prolonged and/or excessive overvoltage conditions can stress the components until they fail.
As discussed above, when a ballast attempts to ignite a lamp, a large voltage differential is presented across the lamp terminals. Typically, this voltage differential is applied across the terminals by an inverter. For a myriad of reasons a lamp may not ignite even with a sufficient voltage differential across its terminals—alternatively, ignition may not even be possible if no lamp is present. If the differential were allowed to build beyond this point the ballast may be damaged, in addition to posing dangers for individuals working around these ballasts. To prevent this from happening the ballast needs an overvoltage protection mechanism to disable the inverter or otherwise safely dissipate the accumulated voltage differential. Additionally, to effectively protect the ballast, the overvoltage protection mechanism must rapidly address this overvoltage condition.
Thus, a contentious relationship exists between providing a voltage differential large enough to effectively ignite the lamp, overstressing the ballast by exposing the ballast to extreme voltages or high voltages for prolonged periods of time, and mitigating potential hazards to persons dealing with the ballast. As such, a ballast capable of expertly managing these concerns, particularly any associated overvoltage conditions that may arise, is paramount to safe and reliable ballast operation.
The prior art has not left these concerns unaddressed. Conventional ballasts disclosed in the prior art handle overvoltage conditions by completely disabling the inverter or retarding the output of the inverter. Prior art ballasts also teach systems having multiple re-strike ignition capabilities that can be limited to a predetermined number of attempts. For example U.S. Pat. No. 7,015,652 issued to Shi discloses one such ballast. Shi teaches a ballast having an overvoltage protection system with multiple re-strike capabilities that can be controlled. However, the prior art does not include a ballast that has a reliable, safe, automatic re-striking capability following an overvoltage shutdown condition, an overvoltage protection mechanism that responds with sufficient speed to protect the ballast regardless of the cause of the overvoltage condition, and the ability to recognize when further re-ignition attempts should cease, e.g. a faulty lamp.
What is needed, then, is a ballast that provides overvoltage protection and re-ignition systems that cooperate to produce an effective, reliable ballast in a simple implementation so that measured automatic re-ignition attempts are made after the ballast has reacted to an overvoltage condition.
BRIEF SUMMARY OF THE INVENTION
The present invention is an electronic ballast for a gas discharge lamp having an overvoltage protection system and an automatic re-striking function. The electronic ballast has an inverter, a shut-down circuit, a safety circuit, a monitoring circuit, and an overvoltage protection circuit. The inverter provides an appropriate alternating current power supply to operate the lamp. The shut-down, safety, monitoring, and overvoltage protection circuits are coupled to the inverter and provide the overvoltage protection and automatic re-striking functions.
The overvoltage protection circuit is able to detect an overvoltage condition in the inverter. In one embodiment, this detection is accomplished by a sensor magnetically coupled to a resonant circuit of the inverter. The overvoltage may be the result of a ballast or lamp failure condition. If an overvoltage condition is detected, the overvoltage protection circuit will temporarily disable both the inverter and the monitoring circuit via the shut-down circuit, which is operably connected to the power supply for the inverter. This temporary disablement allows the overvoltage condition to dissipate. When the overvoltage condition is no longer present the overvoltage protection circuit will permit the inverter to institute re-ignition efforts.
The safety circuit operates to permanently disable the inverter when a safety threshold has been exceeded. The safety threshold is exceeded if the inverter experiences more than a predetermined number of overvoltage events or conditions. This threshold can be adjusted by the selection of ballast circuit components. The threshold corresponds to a state indicating that the ballast has failed, the lamp has failed, or no lamp is present. Thus, when an overvoltage condition is present, or immediately thereafter, and the safety threshold is exceeded, the safety circuit, via the shut-down circuit, will prevent the inverter from attempting to re-ignite the lamp. Subsequent to this scenario, the ballast will function only after the lamp has been replaced or the power to the ballast has been recycled. Accordingly, the final state of the inverter, i.e. its ability to attempt re-ignition, hinges on whether, during the overvoltage event, the safety threshold was exceeded.
To ensure that the safety circuit does not prematurely or inadvertently disable the inverter, the monitoring circuit prevents the safety circuit from functioning under normal inverter operating conditions. Thus, in order for the safety circuit to activate, the overvoltage protection circuit must first disable the monitoring circuit, as occurs during an overvoltage condition, and the safety threshold must be exceeded. The interaction between the safety, monitoring, shut-down, and overvoltage protection circuits engender the ballast with the ability to rapidly detect and correct overvoltage conditions, re-ignite the lamp after an overvoltage condition, and recognize that an anomaly exists with the ballast or lamp and cease re-ignition attempts.
For example, if a new lamp is inserted into the ballast and the lamp is not lit by the first attempt, the inverter may encounter an overvoltage condition. To prevent damage to the lamp or the ballast, the overvoltage protection circuit, via the shut-down circuit, will temporarily disable the inverter and the monitoring circuit until the overvoltage condition passes. After the overvoltage condition subsides the inverter will be free to attempt to ignite the lamp again, assuming the safety threshold was not exceeded. If a re-ignition attempt is successful and the inverter is within normal operating parameters, the monitoring circuit will obviate the safety circuit's ability to disable the inverter.
Now consider that the ballast contains a faulty lamp. In this scenario, the inverter will unsuccessfully attempt to light the lamp, which results in an overvoltage condition that that is corrected by the overvoltage protection circuit. During each overvoltage condition, the overvoltage protection circuit disables the monitoring circuit, in addition to the inverter, so that the safety circuit may evaluate the state of the ballast and/or lamp. After some number of unsuccessful attempts, and during or immediately after the overvoltage event, the safety threshold will be exceeded and the safety circuit will permanently disable the inverter. The inverter will be disabled, or locked-up, until either the power to the ballast is cycled or the lamp is removed.
Accordingly it is an object of the invention to provide an electronic ballast having an overvoltage protection circuit.
It is another object of the invention to provide an electronic ballast with an automatic re-striking capability.
It is yet another object of the invention to provide an electronic ballast with an overvoltage protection circuit that temporarily disables the inverter to correct overvoltage conditions and permanently disable the inverter after predetermined number or sequence of ignition attempts.
It is still another object of the invention to provide an electronic ballast that can rapidly respond to overvoltage conditions to avoid damage to the ballast.
It is also an object of the invention to provide an electronic ballast that can reliably re-start after an overvoltage condition has subsided.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a block diagram of one embodiment of the present invention.
FIG. 2 is a schematic drawing of one embodiment of the invention shown in FIG. 1 .
FIG. 3 is a flow chart describing a sequence of steps implemented by the method of the invention to address overvoltage conditions.
DETAILED DESCRIPTION OF THE INVENTION
I. Functional Overview
FIG. 3 illustrates a sequence of steps in which the method of the invention evaluates and corrects overvoltage conditions and provides automatic re-striking capabilities. Initially, it is determined if an overvoltage condition exists, as shown in step 100 . If no overvoltage condition is detected then step 102 instructs that no action is taken. However, if an overvoltage condition is detected step 104 then determines if the safety threshold has been exceeded. If the safety threshold has been exceeded, indicating that an anomaly with the lamp or ballast exists, then the inverter is disabled, as depicted in step 106 . Conversely, if the safety threshold has not been exceeded then step 108 proffers that the inverter be temporarily disabled so that the overvoltage condition may subside. Finally, after the overvoltage condition has dissipated, the inverter will automatically attempt to ignite or re-ignite the lamp, as described in step 110 .
Now referring to FIGS. 1 and 2 , the electronic ballast 10 for a gas discharge lamp has an inverter 12 that receives a rectified DC rail voltage and generates a relatively high frequency AC voltage suitable to operate a gas discharge lamp. The ballast 10 also includes a shut-down circuit 14 coupled to the inverter 12 . Preferably, the shut-down circuit 14 is coupled to the power supply node 16 of the inverter 12 so that when the shut-down circuit 14 is activated, the shut-down circuit 14 will deny the inverter 12 sufficient power to operate—causing the inverter 12 to be disabled. It is also envisioned that the shut-down circuit 14 may be connected to an enabling node on the inverter 12 , which must be set for proper operation, thereby permitting the shut-down circuit 14 to prevent the inverter 12 from continuing to supply power to the lamp.
It is further contemplated that the shut-down circuit 14 may indirectly control the operation of the inverter 12 by manipulating ballast circuit components that condition and supply the signals received by the inverter 12 or otherwise facilitate the operation of the inverter 12 . For instance, a power factor correction circuit (not shown) may supply the inverter 12 with a conditioned signal and if the shut-down circuit 14 disables the power factor correction circuit the inverter 12 is also restricted from properly functioning. Regardless of the mechanism, the shut-down circuit 14 superintends the inverter 12 .
The ballast 10 also includes a safety circuit 18 coupled to the inverter 12 and the shut-down circuit 14 . The safety circuit 18 evaluates the state of the inverter 12 and functions to instruct the shut-down circuit 14 to disable the inverter 12 if a safety threshold is exceeded. Once the inverter 12 has been disabled at the direction of the safety circuit 18 , the inverter can only be restarted if the ballast 10 is reset. This may occur if the power to the ballast 10 is cycled or a lamp is removed and replaced in the ballast 10 .
The safety circuit 18 is designed to permanently disable (until the ballast power is cycled or a lamp is replaced) the inverter 12 when the safety threshold has been exceeded. The safety threshold may be exceeded if the ballast or lamp is faulty or if no lamp is connected to the ballast 10 . As will be discussed in greater detail below, the inverter 12 will attempt to ignite, or re-ignite the lamp in any of the preceding conditions, i.e. faulty lamp, ballast, or no lamp. At some point it is desirable to prohibit any further attempts by the inverter 12 to re-strike (re-ignite) the lamp. The safety threshold serves to set this point. The safety threshold correlates to a predetermined number or cumulative duration of overvoltage conditions/events or a similar measure.
The desirability to restrict re-ignition attempts stems from the inexpedient results that may accompany limitless re-ignition efforts. These results include, among others, unnecessary stress on the ballast circuit components and shock hazards to individuals associating with the ballast. The crux of these undesirable effects is the significant voltage that must be developed by the inverter 12 to successfully ignite the lamp. The safety circuit 18 recognizes when additional ignition attempts are ill advised and stifles any such efforts by the inverter 12 .
The monitoring circuit 20 is operably engaged to the inverter 12 , the shut-down circuit 14 , and the safety circuit 18 . The monitoring circuit 20 prevents the safety circuit 18 from activating, and permanently disabling the inverter 12 , during normal operating conditions (or normal inverter operating conditions). Normal operating conditions are those conditions in which the ballast 10 is functioning within acceptable parameters. More specifically, normal operating conditions are those other than overvoltage conditions/events and, potentially, immediately thereafter. An overvoltage condition may occur when the lamp or ballast malfunctions or no lamp is present and the inverter 12 generates a large voltage differential in an endeavor to re-strike or re-ignite the lamp. Thus, as long as the inverter 12 , or the ballast 10 in general, is operating within acceptable limits, the monitoring circuit 20 will preclude the safety circuit 18 from activating.
The overvoltage protection circuit 22 is capable of detecting overvoltage conditions in the inverter 12 or ballast 10 . Furthermore, once an overvoltage condition has been detected, the overvoltage protection circuit 22 will temporarily disable the inverter 12 via the shut-down circuit 14 . By temporarily disabling the inverter 12 , the overvoltage protection circuit 22 allows any unwanted overvoltage conditions to dissipate. Following the elimination of the overvoltage condition, the overvoltage protection circuit 22 will allow the inverter 12 to attempt re-ignition of the lamp or otherwise resume normal operation.
The overvoltage protection circuit 22 will also disable the monitoring circuit 20 during overvoltage conditions thereby allowing the safety circuit 18 to evaluate the state of the inverter 12 and ascertain if a permanent shut-down is in order, i.e. has the safety threshold been exceeded? If the threshold has been exceeded the safety circuit 18 will instruct the shut-down circuit 14 to disable the inverter 12 . If the safety threshold was not exceeded and the overvoltage condition has ended, the overvoltage protection circuit 22 will permit the monitoring circuit 20 to reactivate which, in turn, disables the safety circuit 18 and allows the inverter 12 resume its operation.
In sum, the interaction between the shut-down circuit 14 , the safety circuit 18 , the monitoring circuit 20 , and the overvoltage protection circuit 22 bestow the present invention with the ability to provide rapid overvoltage protection, automatic re-strike capabilities, and the faculties to recognize when to permanently disable the ballast because further re-strike attempts would be detrimental to the ballast or persons around the ballast.
Particularly, when the overvoltage protection circuit 22 detects an overvoltage it temporarily disables the monitoring circuit 20 and the inverter 12 through the shut-down circuit 14 until the condition has subsided. While the monitoring circuit 20 is disabled the safety circuit 18 is free to evaluate the state of the inverter/ballast and if the safety circuit 18 determines that the safety threshold has been exceeded, it will permanently disable the inverter 12 via the shut-down circuit 14 . If the threshold has not been exceeded, the safety circuit will permit the inverter 12 , and the monitoring circuit 20 , to activate. Once activated, the monitoring circuit 20 will frustrate any efforts by the safety circuit 18 to disable the inverter 12 as long normal operating conditions persist. However, if the overvoltage protection circuit 22 detects another overvoltage, the above sequence repeats giving the safety circuit 18 another chance to determine if the safety threshold has been exceeded and disable the inverter 12 .
II. Detailed Circuit Operation
The inverter 12 may have an inverter power supply node 16 (Vcc) with an operating supply potential, a potential sufficient to allow the inverter 12 to properly function. In one embodiment shown in FIG. 2 , the inverter drive circuit (IC) 28 is powered by capacitor C 15 , which is charged through power supply node 16 (Vcc). Power supply node 16 is fed by V_rail through resistors R 20 , R 21 , R 16 , R 19 , R 1 , diode D 12 and lamp filaments Rf_ 1 and Rf_ 3 . When C 15 is sufficiently charged, the inverter drive circuit 28 will generate inverter switching signals, allowing inverter 12 to commence normal operation.
The ballast 10 may also have a disabling node 32 with a potential lower than that of the operating supply potential. The disabling node potential does not meet the demands required to power the inverter 12 . As shown in FIG. 2 , the shut-down circuit 14 includes a switch 30 , Q 5 , having a pair of terminals. One of the pair of terminals is coupled to the power supply node 16 , and consequently C 15 , and the other of the pair of terminals is coupled to the disabling node 32 , electrical ground in this embodiment.
Once the shut-down circuit 14 has been activated, by the monitoring circuit 20 or the safety circuit 18 , the shut-down circuit 14 , via switch 30 , will rapidly discharge capacitor C 15 through the disabling node 32 (essentially short circuiting C 15 to ground). This will effectively disable the inverter 12 by deactivating the inverter drive circuit 28 . As long as switch 30 is activated, i.e. the gate threshold voltage of Q 5 is exceeded, C 15 will not charge up and power the inverter drive circuit 28 . Although the shut-down circuit 14 has been described through a transistor implementation, it would be obvious to one of ordinary skill in the art that a plethora of other implementations may serve to satisfy the same or similar ends.
The overvoltage protection circuit 22 may include a sensor 24 coupled to the inverter 12 . The sensor 24 is capable of sensing overvoltage conditions in the inverter 12 . In one embodiment shown in FIG. 2 , the sensor 24 is a magnetically coupled secondary winding, T_resonant_A, of the inductor T_resonant. However, capacitive and resistive coupling are also within the scope of the invention as is the location of the coupling. T_resonant is coupled to the parallel resonant LC tank circuit (C_preheat and T_preheat). Any overvoltage conditions in the tank circuit will be reflected in the sensor 24 . The overvoltage protection circuit 22 also includes Zener diodes D 30 and D 29 , resistor R 14 , and capacitor C 14 (protecting capacitor) depicted in FIG. 2 .
As the voltage across T_resonant_A increases, such as from an overvoltage condition in the tank circuit, the voltage will cause D 30 to break down and start conducting. Accordingly, D 30 sets the overvoltage condition for the circuit. This will allow C 14 to begin to charge through D 30 and D 22 . Once the voltage across C 14 reaches the turn-on threshold of switch 30 , i.e. Q 5 , the switch 30 will conduct and discharge C 15 . As C 15 is discharged, the inverter 12 will be disabled. As the inverter 12 is not contributing to the overvoltage condition, the condition will subside.
Eventually, D 30 will stop conducting, because the biasing voltage relayed through T_resonant_A will fall in accordance with the dissipation of the overvoltage condition, and C 14 will begin to discharge through R 14 . With C 14 no longer supplying an adequate turn-on voltage for the switch 30 , it will stop conducting and allow C 15 to start charging. Once sufficiently charged, C 15 will allow drive circuit 28 to start the inverter 12 and lamp ignition efforts will begin.
The actions of the overvoltage protection circuit 22 also impact the operation of the monitoring circuit 20 . The monitoring circuit 20 includes a monitoring switch 34 , also referred to as a second switch (Q 4 in FIG. 2 ). Referring to FIG. 2 , the gate of Q 4 , i.e. the control terminal, is coupled to C 15 (and hence Vcc). Accordingly, during the response of the overvoltage protection circuit to an overvoltage condition, i.e. discharging C 15 , Q 4 turns off. This occurs because as C 15 is being discharged through Q 5 , the gate voltage on Q 4 is pulled down below the gate threshold voltage thereby turning off Q 4 . As with the inverter 12 , once the overvoltage condition is over, and C 14 cannot bias Q 5 , C 15 will charge up and eventually turn on Q 4 . Consequently, Q 4 will be conducting during normal operating conditions.
The ballast 10 also includes a safety circuit 18 operably coupled to the monitoring circuit 20 , the inverter 12 , and the shut-down circuit 14 . As shown in FIG. 2 , the safety circuit may include a capacitor C 6 . One terminal of C 6 is coupled to the gate of Q 5 so that when C 6 is sufficiently charged, it may activate Q 5 so that C 15 will discharge—disabling the inverter 12 . The charge level at which the voltage across C 6 is adequate to turn on transistor Q 5 is referred to as the safety threshold or activation level. However, C 6 is only permitted to charge when Q 4 is turned off. When Q 4 is conducting it will prevent C 6 from charging because Q 4 presents a less resistive path than that offered by path including C 6 . Thus, C 6 will be prevented from turning on Q 5 to disable the inverter 12 while Q 4 is conducting. This prevents the safety circuit 18 from permanently disabling the inverter 12 during normal operating conditions.
As the overvoltage protection circuit 22 reacts to an overvoltage condition and turns Q 4 off, C 6 is allowed to charge through R 13 , D 25 , and D 18 . When the overvoltage condition has passed and C 15 sufficiently charges to turn Q 4 on, C 6 will once again be precluded from further charging. As long as the safety threshold has not been exceeded, the inverter 12 will be able to attempt re-ignition of the lamp after the overvoltage condition has been corrected. However, after a predetermined sequence of overvoltage correction cycles C 6 will incrementally charge to the extent that it is able to turn on Q 5 and permanently disables the inverter 12 . This sequence can be determined by careful selection of the ballast circuit components. The inverter 12 will be permanently disabled because once C 6 is charged beyond the safety threshold, the inverter 12 will only reactivate if the power to the ballast 10 is cycled or the lamp is removed and replaced.
Thus, although there have been described particular embodiments of the present invention of a new and useful OVER-VOLTAGE PROTECTION AND AUTOMATIC RE-STRIKE CIRCUIT FOR AN ELECTRONIC BALLAST, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims. | The present invention is an overvoltage protection and automatic re-strike circuit for an electronic ballast. The electronic ballast has an inverter, a shut-down circuit, a safety circuit, a monitoring circuit, and an overvoltage protection circuit. The inverter provides an appropriate alternating current power supply to operate the lamp. The shut-down, safety, monitoring, and overvoltage protection circuits are coupled to the inverter and provide the overvoltage protection and automatic re-striking functions. During an overvoltage condition, the overvoltage protection circuit will temporarily disable the inverter. Subsequent to the overvoltage condition, the overvoltage protection circuit permits the inverter to attempt to re-ignite the lamp. After a predetermined number of unsuccessful re-ignition attempts, the safety circuit will permanently disable the inverter to avoid damage to the ballast. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of the filing date of provisional application 60/837,924, filed Aug. 16, 2006.
BACKGROUND OF THE INVENTION
This invention relates to a system for improving the combustion efficiency of internal combustion engines.
The present invention improves combustion efficiency and reduces polluting combustion by-products of internal combustion engines by reforming the hydrocarbon fuel to render it more readily and completely combustible. This is accomplished by a pre-ignition fuel treatment system in which large, complex hydrocarbon molecules are “cracked” or broken down into smaller, simpler molecules. These simpler hydrocarbons are more readily combustible and produce fewer combustion by-products. Reformed or “cracked” hydrocarbons are also rich in ions and free radicals, which are highly reactive and hence highly combustible. Hydrocarbon “cracking” is a highly endothermic reaction, which means it requires a large amount of energy to complete the reaction. Therefore, hydrocarbon cracking must take place under conditions of high temperature and high pressure. The cracking process is facilitated by the presence of a catalyst.
The present invention takes advantage of the high temperature, high pressure environment of the engine's exhaust gases to create a reaction zone in which the hydrocarbon molecules of the fuel are cracked. The hydrocarbon cracking reaction is facilitated by the insertion into the reaction zone of an iron rod. Under the high temperature conditions of the reaction zone, the surface of the iron rod becomes oxidized. It is known that iron oxides act as catalysts for various hydrocarbon cracking processes, as for example, in the hydrocarbon reforming processes taught by Setzer, et al., U.S. Pat. No. 4,451,578. As ionized fuel molecules and atoms are produced during the cracking process, moreover, their motion around the rod generates an electromagnetic field which magnetizes the iron in the rod. As the iron rod itself magnetizes, the rod generates its own magnetic field, which further ionizes the fuel and accelerates the motion of the ionized particles. These accelerated ions then generate a still stronger electromagnetic field, which in turn induces even greater magnetism in the iron rod. Thus, the electrical-magnetic interaction of the ionized fuel and the iron rod becomes a feedback loop that drives the process toward ever greater ionization until the fuel is transformed into a plasma.
The prior art contains two patents which teach the use of a reactor rod in pre-ignition reformation of hydrocarbon fuel. These are Pantone, U.S. Pat. No. 5,794,601, and Jonson, U.S. Pat. No. 7,194,984. While both of these patents have superficial similarities to the present invention, they are both riddled with technical misconceptions which lead to fatal design flaws. In Pantone, a hydrocarbon fuel is volatilized and the vapor is drawn through a thermal preheater mounted inside an engine exhaust pipe. The thermal preheater is configured as a reactor tube having a reactor rod mounted concentrically within it, so that the vapor flows through an annular plenum around the rod. The downstream side of the reactor tube is pneumatically connected to the engine's intake manifold, such that the partial vacuum of the intake manifold extends through the reactor tube and draws the fuel vapor into the intake manifold.
Although the inventor of this apparatus speculates that some type of molecular cracking takes place in the reactor tube, he candidly admits to being clueless as what is taking place and why. While the inventor has apparently stumbled upon some things that work, he stumbles over some other things that don't. He states, for example, that the composition of the reactor rod is of no consequence, and he asserts that even a generic ceramic reactor rod will do (4:35-39). But if the reactor rod serves no catalytic function, then the supposed “cracking” process must be purely thermal cracking, which requires an extremely elevated level of temperature and pressure far above the range found in automobile exhaust.
And, in fact, the inventor's own observations confirm that no cracking takes place in his reactor tube, but instead the volatized fuel is partially combusted. The inventor relates that his reactor tube becomes quite a bit hotter than could be attributed to the heat transfer from the exhaust gases (5:25-43). This means that an exothermic reaction—one that releases heat—is taking place. Cracking is an endothermic reaction—one that absorbs heat. It follows that the Pantone apparatus does not render the fuel more combustible by cracking it, but instead renders it less combustible by partially burning it in the reactor tube.
The reason that the performance of Pantone's apparatus is indifferent to the composition of the reactor rod is that he makes the annular plenum between the reactor rod and the reactor tube too large. The patent specifies a range of 0.035-0.04 inches for this annular plenum (6:6-9), which is more than twice as wide as what is needed. A much more constricted annular plenum is necessary for two reasons: (1) to bring more fuel molecules into direct contact with the surface of the reactor rod, so as to maximize the electro-chemical interaction between the rod and the fuel, and (2) to accelerate the fuel molecules, thereby increasing their kinetic energy to a level at which molecular cracking can occur. On the other hand, the wider annular plenum in Pantone's reactor tube is more conducive to the partial combustion process which, unbeknownst to the inventor, is actual going on there.
In the Jonson patent, we have another instance of an inventor groping in the dark because he doesn't understand the underlying science. Consequently, although Jonson corrects some of Pantone's errors, he goes on to make some errors of his own which equally frustrate the purpose of the invention. While Jonson baldly asserts that his treated fuel has “characteristics of a cold plasma” (3:6-7), it becomes clear from reading the specification that he has no idea what a “plasma” actually is. Unable to credibly claim that his process yields an actual plasma, in the scientific sense of that word, Jonson creates his own totally circular definition: “the term plasma fuel as used herein is simply used as a title to refer to fuel produced as described herein” (3:9-11). In other words, the treated fuel is “plasma”, provided that “plasma” is defined to mean the treated fuel.
Unfortunately for Jonson, the enormity of his logical fallacies is matched by that of his technical fallacies. According to his specification, fuel enters one end of his reactor tube as liquid droplets and exits the other end as plasma (3:32-39). Since plasma is an ionized vapor, a liquid can only become a plasma if is first vaporized and then ionized. Yet Jonson's “plasma fuel” is neither ionized nor vaporized. In fact, the patent asserts that cavitation of the “plasma fuel” occurs in a low pressure area of the reactor tube (4:10-15), which necessarily implies that the “plasma fuel” remains in a liquid state, since cavitation can only occur in a liquid. And the patent claims clearly designate the “plasma fuel” as being in a liquid state, since they repeatedly describe the final step of the patented process as “introducing the droplets to the combustion process” (8:35, 9:10, 9:28, 9:51, 10:1, 10:18, 10:36, 10:59).
Although the Jonson patent states an unsupported belief that the treated fuel is provided to the engine “in a significant state of ionization”, it describes no process by which such ionization can occur. Moreover, since the treated fuel remains in a liquid state, the only way it can be “ionized” (loosely speaking) is in the sense that its droplets acquire an electrical charge. But electrically charged liquid fuel droplets are no more combustible than electrically neutral droplets. Ionization must occur at the molecular-atomic level in order to affect chemical reactivity and combustion characteristics of the fuel.
While Jonson, unlike Pantone, gets it right in requiring that the reactor rod be a magnetic material and specifying a narrowly constrained annular plenum between the reactor rod and reactor tube, he still finds other ways to go wrong. His specification calls for lowering the temperature inside the reactor tube, even to the extent of using refrigeration (3:56-65, 12:22-23). The specification also calls for reducing the pressure within the reactor tube to 250 mmHg (less than one-third of atmospheric), even using a vacuum generator to that end (5:45-48, 6:7-10, 8:18-20, 8:5-63). Both of these features completely negate any potential for hydrocarbon cracking to occur in Jonson process, since cracking requires high temperature and high pressure.
Jonson's disclosure superficially resembles the present invention insofar as it uses the magnetic field induced in the reactor rod and the constrained annular plenum in the reactor tube to accelerate the fuel flow around the reactor rod. But the big difference is in what is being accelerated in each case. The Jonson process is designed to accelerate liquid droplets of fuel (see claims 1 - 3 ). But acceleration of liquid droplets has no effect on molecular energy within the droplets, and hence contributes nothing to the chemical reformation of the fuel hydrocarbons which is the ostensible goal of the process. In the present invention, on the other hand, it is the ionized molecules of the fuel that are accelerated, and this has the immediate effect of increasing molecular kinetic energy and temperature, thereby inducing molecular cracking of the fuel hydrocarbons.
The most important distinction between the present invention and the Pantone and Jonson patents is the total absence in the prior art reactor rods of a catalytic material. Without such a catalyst, hydrocarbon cracking simply cannot occur in the temperature range of engine exhaust gases. Consequently, the prior art fails to disclose an apparatus and process capable of cracking hydrocarbon fuel and converting it into a genuine plasma so as to truly improve the fuel's combustibility and increase the overall combustion efficiency of the internal combustion engine in which the fuel is burned. As will now be explained in some detail herein, the present invention offers precisely these capabilities.
SUMMARY OF THE INVENTION
It is an object of the present invention to create a reaction zone in a motor vehicle wherein the hydrocarbon fuel is reformed at high temperature and pressure, such that large hydrocarbon molecules are “cracked” to produce smaller, more readily combustible molecules.
It is another object of the present invention to crack the hydrocarbon fuel molecules in such a manner as to generate plentiful free radicals and ions, which are highly reactive and hence highly combustible.
It is a further object of the present invention to take advantage of the high temperature, high pressure environment of the engine's exhaust gases by locating the reaction zone within the exhaust pipe, such that some of the energy of exhaust gases is transferred to the fuel molecules and helps induce molecular cracking.
It is yet another object of the present invention to create a reaction zone containing a reactor rod composed of a material having catalytic properties, such that the reactor rod acts as a catalyst to promote the hydrocarbon cracking process and to enable that process to take place at a lower temperature and pressure than would otherwise be feasible.
It is yet a further object of the present invention to utilize a reactor rod composed of a material that also has magnetic properties, such that when ions from the cracking process flow around the reactor rod, the rod becomes magnetized and generates a magnetic field which interacts with ionized hydrocarbon molecules, causing them to accelerate.
It is still another object of the present invention to create in the reaction zone a positive feedback loop between the magnetization of the reactor rod and the acceleration of the hydrocarbon molecules, such that the accelerated motion of the ionized molecules induces a progressively stronger magnetism in the rod, which in turn generates a stronger magnetic field that further accelerates the molecules.
It is still a further object of the present invention to utilize the electromagnetic feedback loop created in the reactor zone to accelerate the hydrocarbon fuel molecules to such an elevated energy level that the fuel is transformed into a gaseous plasma.
These and other beneficial objects are achieved by a process in which a reaction zone is established in within the outflow of exhaust gases downstream of the exhaust manifold of an internal combustion engine. The reaction zone comprises a reactor vessel that is installed within the exhaust pipe, such that the exhaust gases flow around the reactor vessel on all sides. Within a reactor enclosure is a reactor rod, which is axially positioned within the reactor vessel such that a uniform annular plenum is formed between the surface of the reactor rod and the walls of the reactor enclosure. The reactor rod is centrally located along the length of the reactor vessel, and it is composed of a material that has both catalytic and magnetic properties.
On the distal end of the reactor vessel (i.e., the end furthest from the exhaust manifold) is an injection assembly, comprising one or more fuel injection ports and one or more air injection ports. The fuel injection ports are hydraulically connected to a fuel line, through which a hydrocarbon fuel flows from a fuel tank. The air injection ports are pneumatically connected to the external atmosphere through an air inlet. At the proximal end of the reactor vessel (i.e., the end closest to the exhaust manifold), is a vacuum conduit which pneumatically connects the reactor vessel to the engine's intake manifold at a location downstream of the throttle plate, thereby creating a pressure drop from the distal end to the proximal end of the reactor vessel. This pressure drop draws fuel and air through the injection assembly, then through the reactor vessel from the distal end to the proximal end, and then into the vacuum conduit. From the vacuum conduit, the fuel-air mixture is drawn into the intake manifold and from there into the engine cylinders where it is combusted.
The fuel-air mixture flows within the reactor vessel in the opposite direction to the flow of exhaust gases around the reactor enclosure. At the distal end of this cross-flow process, the fuel-air mixture is heated by the exhaust gases to a temperature at which the fuel is completely vaporized. The vaporized fuel-air mixture then encounters the reactor rod at its distal end, which has a convex shape to promote laminar flow around it. As the vaporized fuel-air mixture enters the annular plenum around the reactor rod, its flow path becomes constricted, which causes its pressure and velocity to increase. The increased pressure and kinetic energy of the vaporized fuel-air mixture is further augmented by its absorption of thermal energy from the exhaust gases, which are becoming progressively hotter as the exhaust manifold is approached.
As the temperature and pressure of the vaporized fuel-air mixture becomes progressively elevated, some of the vaporized fuel molecules reach a sufficient energy to undergo catalytic cracking reactions at the surface of the reactor rod. The cracking reactions produce ionized molecules, the motion of which generates an electromagnetic field around the reactor rod, and this electromagnetic field magnetizes the reactor rod itself. As the reactor rod becomes magnetized, it generates its own magnetic field which causes the motion of the ionized fuel molecules to accelerate. The accelerated motion of the ionized fuel molecules has two effects. First, the accelerated ionic flow generates a stronger electromagnetic field around the reactor rod, which causes the reactor rod to become more strongly magnetized, which then further accelerates the ionic flow. Second, the accelerated flow increases the kinetic energy of the fuel molecules, thereby increasing the temperature and pressure of the vaporized fuel, so that an increasing number of molecules undergo catalytic cracking along the surface of the reactor rod.
As more fuel molecules crack, more ions are produced and their increasing number and acceleration generates a progressively stronger electromagnetic field around the reactor rod. This strengthening electromagnetic field, in turn, progressively increases the magnetization of the rod. The progressively stronger magnetic field generated by the reactor rod then further accelerates the molecular flow, further increasing the kinetic energy of the molecules and causing more of them to crack and ionize
Thus, a positive feedback loop is established which drives the hydrocarbon molecules to progressively higher kinetic energy levels. This is an endothermic process that increasingly draws energy from the cross-flow of exhaust gases as those gases become hotter toward the proximal end of the reactor vessel. This positive feedback loop continues until the vaporized fuel-air mixture reaches the proximal end of the reactor rod and has been ionized to a degree corresponding to the physical state known as plasma.
The plasma of cracked fuel and air then passes through the proximal end of the reaction vessel and into the vacuum conduit. From there it enters the intake manifold below the throttle plate and is drawn into the engine cylinders where it is combusted. Since the cracked plasma is much more chemically reactive than un-cracked non-plasma fuel, its combustion releases more energy per unit of fuel and leaves fewer combustion by-products as potential air pollutants.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the pre-ignition fuel treatment system according to the preferred embodiment of the present invention.
FIG. 2 is a cross-sectional view of the reaction zone with the reactor vessel installed in an exhaust pipe according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , a pre-ignition fuel treatment system 10 is installed in a motor vehicle 11 having an internal combustion engine 12 , a fuel tank 13 , an exhaust pipe 14 , an air inlet 15 , an engine control module (ECM) 16 , and one or more engine/emissions sensors 17 . The fuel tank 12 stores a hydrocarbon fuel that is mixed with air to make a fuel-air mixture 33 that is combusted in the engine 12 . Optionally, water or steam can also be added to the fuel-air mixture 33 . Combustion by-products and excess air, collectively referred to as exhaust gases 33 , exit from the vehicle to the external atmosphere through an exhaust pipe 14 . The engine/emissions sensors 17 monitor the air-to-fuel ratio and/or the amount of oxygen in the exhaust gases 34 .
The engine 12 comprises a plurality of cylinders 18 , an intake manifold 19 , an air filter 20 , a throttle plate 21 , and an exhaust manifold 22 . In the cylinders 18 the fuel-air mixture 33 is combusted and the exhaust gases 34 are expelled into the exhaust manifold 22 , which then expels the exhaust gases 34 into the exhaust pipe 14 . The cylinders 18 move with a reciprocating action that has the effect of creating a partial vacuum in the intake manifold 19 , which draws air from the external atmosphere into the engine 12 through an air filter 20 . The amount of air drawn into the intake manifold 19 is regulated by a throttle plate 21 that is located between the air filter 20 and the intake manifold 19 . The throttle plate 21 is a butterfly valve that opens wider as the vehicle operator depresses the gas pedal. The opening of the throttle plate 21 is controlled by the ECM 16 , which is a microprocessor that computes the optimal air-to-fuel ratio based on the readings of the engine/emissions sensors 17 .
Referring now to both FIG. 1 and FIG. 2 , the present invention 10 establishes a reaction zone 23 in the exhaust pipe 14 by inserting into a section of the exhaust pipe 14 a reactor vessel 24 . The reactor vessel 24 is an oblong plenum formed by a rigid reactor enclosure 25 , which is non-contiguously affixed to the exhaust pipe 14 . In the preferred embodiment 10 , the reactor vessel 24 is a tubular structure fabricated of a material having a high thermal conductivity that can withstand a high temperature, high pressure environment. The reactor vessel 24 is axially installed within the exhaust pipe 14 such that the exhaust gases 34 flow around the entire perimeter of the reactor vessel 24 . In the preferred embodiment 10 , the longitudinal axis of the reactor vessel 24 is aligned with that of the section of exhaust pipe 14 into which it is inserted.
In addition to the reactor enclosure 25 , the reactor vessel 24 comprises a reactor rod 26 , an annular plenum 27 , and an injection assembly 28 . The reactor rod 26 is an elongated cylindrical structure axially positioned within the reactor enclosure 25 , such that the annular plenum 27 formed between the reactor rod 26 and the reactor enclosure 25 is of uniform width. In the preferred embodiment, the width of the annular plenum 27 is approximately 0.015 inches, and the diameter of the reactor rod 26 is approximately 0.856 inches. Optionally, the reactor rod 26 , may have a slightly tapered diameter in the midsection of the rod, tapering down to a diameter of approximately 0.732 inches. The length of the reactor rod 26 is in the range of 4 to 10 inches, depending on the size of the engine 12 .
The material composition of the reactor rod 26 is crucial importance to the process of cracking the hydrocarbon fuel and transforming it into a plasma. The reactor rod 26 must serve the dual roles of providing a catalyst for the cracking process and participating in the “feedback loop” electromagnetic interaction with ionized fuel molecules, as described hereinabove, which drives the fuel-air mixture 33 toward a plasma state. In order to fulfill both of these roles, the reactor rod 26 must contain materials that are both highly magnetic and good catalysts for the hydrocarbon cracking process. While the preferred embodiment 10 uses an iron reactor rod 26 , other suitable material are steel, nickel, cobalt, rare-earth metals, alloys of the foregoing metals, and magnetic ceramics. Nickel, cobalt and rare-earth metals have known applications as catalysts in hydrocarbon cracking, as disclosed in Cornelius et al., U.S. Pat. No. 4,101,376, Sie, U.S. Pat. No. 4,579,986, and Kumar et al., U.S. Pat. No. 5,248,642, respectively. The reactor rod 26 can also consist of a magnetic core with a catalytic coating or plating. For example, a reactor rod 26 with a steel core covered by a layer of platinum plating is also suitable.
The shape of the reactor rod 26 is also plays an important role in the cracking and plasma-formation processes. The distal end of the reactor rod 26 (i.e., the end furthest from the exhaust manifold 22 ) has a convex shape, so that the flow of the fuel-air mixture 33 around the end of the rod is laminar. The goal in forcing the fuel-air mixture 33 into the constrained annular plenum 27 is to accelerate the flow rate and thereby increase the velocity and kinetic energy of the fuel molecules so that some of them will attain the energy level needed for cracking to begin. Therefore, turbulent flow around the reactor rod 26 is to be avoided, since turbulence dissipates the molecular kinetic energy and thus retards the cracking process. Accordingly, the proximal end of the reactor rod 26 (i.e., the end closest to the exhaust manifold 22 ) has a concave shape, which has the effect of creating an area of reduced pressure downstream of the reactor rod 26 . This area of reduced pressure has the effect of drawing the flow of fuel-air mixture 33 evenly along the surface of the reactor rod 26 , so that energy-dissipating areas of turbulent flow are avoided.
On the distal end of the reactor vessel 24 is the injection assembly 28 , comprising one or more fuel injection ports 29 and one or more air injection ports 30 . The fuel injection ports are hydraulically connected to a fuel line 31 , through which the hydrocarbon fuel flows from the fuel tank 13 . The air injection ports 30 are pneumatically connected to the external atmosphere through the air inlet 15 . At the proximal end of the reactor vessel 24 , is a vacuum conduit 32 , which pneumatically connects the reactor vessel 24 to the engine's intake manifold 19 at a location downstream of the throttle plate 21 , thereby creating a pressure drop from the distal end to the proximal end of the reactor vessel 24 . This pressure drop draws fuel and air (and, optionally, water or steam) through the injection assembly 28 , then through the reactor vessel 24 from the distal end to the proximal end, and then into the vacuum conduit 32 . From the vacuum conduit 32 , the fuel-air mixture 33 is drawn into the intake manifold 19 and from there into the engine cylinders 18 where it is combusted.
The location at which the vacuum conduit connects to the intake manifold is very important to maintaining a constant pressure drop across the reactor vessel 24 . In the prior art cited hereinabove, this connection is made upstream of the throttle plate 21 . Consequently, in the prior art systems, the pressure drop across the reactor is variable, becoming much diminished when the throttle plate is closed during engine idling or downhill coasting. For this reason, the prior art systems both have a tendency to stall during idling, because the diminished pressure drop is no longer sufficient to draw the fuel-air mixture through the reactor. In the present invention 10 , on the other hand, the vacuum conduit 32 connects to the intake manifold 19 downstream of the throttle plate 21 , such that the pressure drop across the reactor vessel 24 remains constant.
The flow direction of fuel-air mixture 33 through the reactor vessel 24 is in the opposite direction to the flow direction the exhaust gases 34 through the exhaust pipe 14 , thus creating a cross-flow that optimizes the transfer to thermal energy from the exhaust gases 34 to the fuel-air mixture 33 . As the fuel-air mixture 33 is drawn into the reactor enclosure 25 through the injector assembly 28 , the cross-flow heats the fuel-air mixture to the point at which the fuel component is vaporized. As the vaporized fuel-air mixture 33 enters the annular plenum 27 around the reactor rod 26 , its flow path becomes constricted, which causes its pressure and velocity to increase. The increased pressure and kinetic energy of the vaporized fuel-air mixture 33 is further augmented by its absorption of thermal energy from the exhaust gases, which are becoming progressively hotter as the cross-flow approaches the exhaust manifold 22 .
As the fuel-air mixture 33 flows through the annular plenum 27 , it undergoes the process of cracking and plasma-formation described hereinabove. The cracked plasma fuel then is drawn into the intake manifold 19 through the vacuum conduit 32 . At this juncture, the engine control module (ECM) 16 will determine how far to open the throttle plate 21 , thereby making the air-to-fuel ratio either richer (lower ratio) or leaner (higher ratio). Since, the ECM 16 bases its determination of air-to-fuel ratio on the stoichiometry of conventional fuel (gasoline or diesel) combustion, its operations must be modified to account for the higher energy content of the cracked plasma fuel generated by the present invention 10 . Therefore, the preferred embodiment of the present invention 10 includes an auxiliary microprocessor 35 , which interfaces with the ECM 16 so as to adjust the air-to-fuel ratio to reflect the stoichiometry of cracked plasma fuel combustion.
An example will illustrate the need for the auxiliary microprocessor 35 . Because of the higher energy content of the cracked plasma fuel, less of it will be consumed to release the same amount of energy as conventional fuel. Therefore, its combustion will consume less oxygen, causing the concentration of oxygen in the exhaust gases 34 to rise. This rise will be reflected in the readings of the engine/emissions sensors 17 and communicated to the ECM 16 . Since the ECM 16 does its calculations based on the energy content of conventional fuel, its normal response would be to infer from the rise in oxygen concentration in the exhaust gases that the air-to-fuel ratio is too lean. Therefore, the ECM 16 standing alone would, under the circumstances of this example, signal the engine 12 to increase the concentration of fuel being sent to the cylinders 18 . In so doing, however, the ECM 16 would undo the fuel economy advantage of the cracked plasma. When the auxiliary microprocessor 35 interfaces with the ECM 16 , however, the air-to-fuel ratio is adjusted to account for the higher energy content of the cracked plasma fuel, thus enabling the present invention 10 to achieve real savings in fuel consumption.
While this invention has been described with reference to a specific embodiment, the description is not to be construed in a limiting sense. Various modifications of the disclosed embodiment, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments that fall within the true scope of this invention. | A method and apparatus for reforming a hydrocarbon fuel which increases the efficiency with which said fuel's energy content may be extracted resulting in improved combustibility and reduction of by-products produced. The hydrocarbon fuel is cracked and ionized in a reactor vessel by means of a feedback loop of electro-chemical interactions with a reactor rod comprised of materials which are both magnetic and catalytic. | 5 |
This application is a division of copending application Ser. No. 196,807, filed Nov. 8, 1971, which is in turn a continuation-in-part of application Ser. No. 823,164, filed May 8, 1969, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a type of controlled release capsules, i.e. capsules with permeable or semi-permeable walls which have the ability to release a solute or a volatile liquid or the like at a predetermined rate. The release of solute is an effect resembling osmosis, while the release of the volatile liquid is an effect produced by partial pressure differences across the capsule walls. An aspect of this invention relates to a process for making the capsules.
There is considerable utility in the art of encapsulation for a means which permits the release of an encapsulated chemical over a predetermined period of time. For example, it is desirable to make one application of agricultural chemicals (fertilizers, pesticides, herbicides, etc.) which is effective for a complete growing season, rather than several successive applications. Also, it is desirable to apply only the necessary amount of fertilizer, thereby preventing ground water pollution.
Various types of coatings (U.S. Pat. No. 3,223,518) and porous packaging films (U.S. Pat. No. 3,059,379) have been suggested for encapsulating solid agricultural chemicals. However, the coatings cannot be utilized to contain aqueous solutions, while the flexible packaging films are not practical for encapsulating liquids. U.S. Pat. No. 2,791,496 discloses the impregnation of exfoliated vermiculite with liquid agricultural chemicals, but this product does not provide a controlled release rate. U.S. Pat. No. 3,423,489 discloses crystalline polyolefin capsules for encapsulating liquids, but these capsules are not suitable for controlled release of the contained liquid.
Accordingly, this invention contemplates providing liquids such as agricultural chemicals in a form which permits release of the chemical over a predetermined period of time. This invention also contemplates a means and method for introducing a controlled amount of microporosity into a membrane which serves as the wall or shell of a capsule.
SUMMARY OF THE INVENTION
This invention provides capsules which have permeable or semi-permeable walls, i.e. walls having microscopic passages or interconnecting pores providing a release route which permits an osmosis-like effect to occur at a controllable or predetermined rate. The observed effect resembles osmosis in that the amount of liquid contained within the capsule walls does not appear to diminish significantly, but any solute dissolved in the encapsulated liquid passes out of the capsules when a moist environment (e.g. soil) containing a lower concentration of solute exists outside the capsules. The capsules also can be used to release liquids volatile at the temperature of use, provided that, a partial pressure driving force is present as in the case when water-containing capsules are placed in a low humidity environment. The capsules are durable, crush resistant, uniformly small, substantially spherical, and non-tacky, and they are particularly suited for providing controlled release of dissolved chemicals from encapsulated aqueous solutions. Among the suitable dissolved chemicals are fertilizers, pesticides, herbicides, and other agents with agricultural utility, but the invention is generally useful for encapsulating liquids or solutions of any desired type. The release rate can be controlled so as to prevent ground water polution in agricultural applications. The filled capsules are dry and can be readily handled and shipped.
It has been found that a microporous capsule wall can be obtained when certain critical phase relationships are observed during the manufacture of the capsules. The capsule shell- or wall-forming material should comprise at least a first material which melts at elevated or moderately elevated temperatures and is capable of forming a single phase when admixed with a second material (which also melts at elevated or moderately elevated temperatures). A small amount of a high-boiling solvent or plasticizing material can be used, if desired, to facilitate this single phase formation step. After the first and second materials have been blended, heated, and formed into a homogeneous molten phase, the wall forming composition is brought into contact with a fill material (preferably an aqueous liquid) by means of the biliquid column technique disclosed in U.S. Pat. Nos. 3,423,489 and 3,389,194, the disclosures of which are incorporated by reference. Contact with the liquid fill rapidly cools the homogeneous wallforming phase, and as this molten phase approaches a solidified state and becomes an incipient capsule wall or shell, one of the materials present in this incipient wall begins to separate out as a discontinuous, solid phase dispersed throughout a substantially continuous wall matrix. The resulting dispersed particles are normally considerably smaller than the thickness of the capsule wall which ultimately results. The dispersed particles preferably contract, upon further cooling, at a rate which is faster than the contraction rate of the continuous matrix, but any disparity between the matrix and dispersed phase with regard to their respective rates or degrees of contraction can assist in the formation of cracks or pores in the capsule walls. Since the dispersed phase is present in a significant quantity, e.g. at least 5 parts by weight of the total composition, the resulting capsule is characterized by microporous walls having a porosity (determined by mercury porosimetry) of at least about 3 volume percent. The "microporosity" (this term being used herein to include sub-microscopic porosity) imparts permeability or semi-permeability to the capsule walls, and effects similar to osmosis are observed when a concentration gradient across the capsule wall is present. However, these osmosis-like effects are not necessarily limited to the diffusion of solutes; emulsoids and dispersoids also appear to pass through the capsule walls, indicating a variety of transport mechanisms may be operating. It will be understood, in any event, that this invention is not bound by any theory.
The capsules of the present invention are on the order of about 100 to about 10,000 microns, preferably about 1,000 to about 3,000 microns, in diameter. Capsules of this size are readily packaged, stored, and shipped, while larger capsules are weak, fragile, and subject to breakage during packaging, handling, or shipping. Capsules smaller than 100 microns in diameter have a large shell or wall volume in comparison to liquid fill volume and are excessively expensive for most uses. The capsule shell wall thickness varies from about 0.85 to about 10 microns for a 100 micron capsule diameter, from about 35 to about 400 microns for a 4,000 micron capsule diameter, and from about 85 to about 1,000 microns for a 10,000 micron capsule diameter. These capsule shells provide a volume ratio of contained fill to shell sufficiently high for efficient economical use.
The preferred capsules comprise an aqueous fill and a microporous (including sub-microscopic porosity) capsule wall wherein the capsule wall comprises three or more phases, i.e.: a solid, crystalline olefinic polymer phase, an amorphous phase (e.g. a hydrocarbon resin), and a second crystalline or semi-crystalline phase, e.g. a natural, paraffinic or microcrystalline petroleum wax. In this preferred composition, the wax ordinarily separates out first upon cooling, thus forming a crystalline or semi-crystalline phase dispersed throughout a continuous matrix of the other phases. Microporosity results upon further cooling, due apparently to one or more phenomena, including differences in the rate of degree of contraction between two or more phases and shear forces created by the disparity in structure between the different crystal types or between the polyolefin/amorphous resin and wax phases.
DETAILED DESCRIPTION AND EXAMPLES
As pointed out previously, an important factor contributing to the formation of microporous capsule walls involves differences in rates or extent of contraction of materials used to form the capsule wall or shell. A convenient method has been devised for characterizing the extent of the contraction upon cooling the various materials preferred for use in this invention. Briefly summarized, the method comprises filling a test tube or equivalent container to a given measured volume with a sample of the material in a molten state. The molten sample is kept in an oven at a standard temperature, e.g. 230° C. (a typical capsule-forming temperature when the biliquid column technique of U.S. Pat. No. 3,423,489 is used), and permitted to equilibrate, so that the melt is at a uniform temperature. Upon equilibration, an excess of sample material, as compared to the original measured volume, will have resulted due to expansion with heat. This excess is removed with a pipet. The oven is then turned off and the sample is allowed to slowly cool to room temperature, e.g. 25° C. The volume at room temperature (V 25 ) is measured for comparison with the volume at 230° C. (V 230 ). The ratio of ##EQU1## represents a fractional change in volume hereinafter referred to as the "fractional volume contraction" or "V"; 100V is the percentage of change in volume and is hereinafter referred to as the "% volume contraction".
In the preferred embodiments of this invention, the capsule wall-forming material is a blend of crystalline olefinic polymer; an amorphous, thermoplastic organic resin; and a wax. If X represents the weight fraction of polyolefin, Y represents the weight fraction of amorphous resin, and Z represents the weight fraction of wax; and V x represents the fractional volume contraction (defined previously) of polyolefin, V y represents the fractional volume contraction of amorphous resin, and V z represents the fractional volume contraction of the wax, the expression ##EQU2## will be greater than one when at least some wax is included in the composition, as is preferred. The expression, of course, approaches 1.0 as the wax concentration approaches zero. Zero wax concentrations result in very low mercury porosimeter readings at the low end of measurable pore size, particularly for the walls of perfect capsules. Grosser pores are sometimes evident in these wax-free capsule walls, but this is a much less preferred type of pore structure. (The solute diffusion rate can be conveniently measured by placing a given weight of capsules in a container with a given volume of water and monitoring the increasing concentration or weight gain of solute in the water, as will be described in detail subsequently.
It will be apparent that the above-noted expression compares the contraction of the total system to the contraction of the polyolefin/amorphous portion of the system. For convenience, this mathematical expression will be hereinafter referred to as the volume contraction ratio, or VCR. Although capsules with a measureable release rate can be obtained when the VCR is 1.0 (see Examples 1 -III, set forth subsequently), significant improvements in reproducibility and controllability of the capsule wall porosity and solute release rate are obtained when the VCR is greater than 1, preferably greater than 1.2. Apparently, a slight microporosity-creating phase separation effect can occur even when there is only one crystalline and one amorphous phase in the wall-forming system. However, at least three phases provide additional, readily controllable microporosity-creating effects. Crystal structure studies indicate that as the three-component melt cools from the temperature of capsule manufacture, the major (preferably continuous) polyolefin/amorphous resin phase comes out of solution last, leaving dispersed zones of a crystalline or semi-crystalline wax. Further loss of heat from the capsule wall or shell causes the polyolefin/amorphous portion and the wax portion to continue to contract. The aforementioned volume contraction ratio being greater than 1, microscopic (probably including some sub-microscopic) flaws, cracks, pores, channels, or the like are created in the capsule wall with no significant detrimental side effects, e.g. no noticeable increase in weak, imperfect, excessively frangible, or leaky capsules. At least some of the microscopic cracks, pores, etc. will completely traverse the capsule wall, either by a straightforward passage or a torturous route, and capsules with microporous walls are obtained. The existence of microporosity is confirmed by porosimeter studies, using an Aminco-Winslow mercury porosimeter, Model S-7107 or S-7108.
The presence of solute in the capsule walls can be demonstrated by analysis, using a scanning electron microscope having an x-ray detecting feature. One set of analyzed capsules originally contained an aqueous copper sulfate fill solution (25% by weight cupric sulfate-pentahydrate) and were used in a solute release rate test (3 days of leaching into water). The capsules were dried and cut in half. Copper was analyzed for, and detected at, four points in the capsule wall cross-section, ranging from the interior of the wall to its exterior, indicating an actual pass-through of cupric ion from the interior of the capsule toward the exterior.
Based on all the available evidence, one can envision a phase comprising amorphous resin molecules intimately associated with large polyolefin crystals, this polyolefin/amorphous resin phase surrounding a paraffin wax crystal. As the two crystalcontaining phases contract, a shearing action takes place between the two crystal types. When the second crystalline phase (i.e. the wax) is omitted, differential rates of contraction are still possible, but the aforementioned shearing action will probably be lost. Crystalline materials such as polyolefin exhibit a greater percent volume contraction than the amorphous materials. In the context of this invention, the present volume contraction of the polyolefin will ordinarily be at least 1.2 times greater, and preferably about 2 to 3 times greater than the amorphous resin contraction.
Thus, the capsule membrane (wall or shell) material of this invention, which provides the controlled release feature, is a multi-component blend, preferably a blend of resins and wax. The resin/wax mixture can be prepared so as to tailor the release rate of the encapsulated active ingredient to its desired application. A wide variety of adjustments in the release rate can be made by varying the composition of the capsule walls, both as to the physical properties of the selected ingredient and its weight fraction in the shell-forming melt. Since primarily physical rather than chemical phenomena are involved in the practice of this invention (in fact, chemical interaction between components is not preferred), capsule release rates can be controlled or adjusted by reference to easily calculated or observed criteria. Among these criteria are the volume contraction ratio (VCR, described previously) and the individual fractional volume contractions (V x , etc.), the degree of compatibility of the various wall-forming components at various temperatures, the melting points (or melting ranges) of the individual capsule wall-forming components, eutechtic points and liquid-solid curves or tie-lines for component mixtures, the phase relationships (continuous, discontinuous, homogeneous, etc.) as between any plurality of components, and the like. Some of the phase relationships and the like are best determined empirically as well as by reference to known compatibility data, melting points, etc. In many instances, these properties can be determined without first making capsules. Needless to say, however, it is also useful to determine various gross properties of the capsules themselves, including their release rates, crush strength, membrane (i.e. wall or shell) porosity, size, etc. Materials used in this invention for the formation of capsule walls are preferably selected with a view toward providing durable crush-resistant, non-tacky capsules. Microscopic observation techniques have been devised for determining when a capsule bursts or leaks due to compressive forces. For example, two 25 × 75 mm microscope slides with capsules sandwiched between them can be carefully pressed together with the aid of suitable electric motor and clutch arrangement. This crush testing configuration can be calibrated to determine the pounds per square inch (psi) or kilograms per square centimeter force on capsules viewed through the microscope slides. Using this technique, capsule crush strengths in psi ranging from about 5 to about 20 psi have been observed.
As pointed out previously, the volume contraction ratio (VCR) for capsule wall-forming systems of this invention is preferably greater than 1.0, more preferably greater than 1.2. The VCR cannot be indefinitely increased, however. Excellent porosity of capsule walls has been obtained in practice with a VCR greater than 2.0, but the weight fraction of wax (Z) approaches a very high level as the VCR approaches 3.0. Generally speaking, between 2.0 and 3.0, the amount of wax must be increased to the point where the phase relationship can become inverted, and the wax can become the continuous phase upon cooling. In a typical polyethylene/amorphous hydrocarbon resin/wax blend, this inversion point can be reached at VCR values as low as 2.2. At these high VCR or high wax content levels, the wax becomes the continuous phase and the polyolefin/amorphous resin becomes the discontinuous phase upon cooling of the capsule walls. Relatively low porosity in the capsule walls appears to be a consequence of this phase inversion.
Once the various physical factors (compatibility, melting points, phase relationships, etc.) are properly specified, VCR values for a given range of systems can be made to correlate fairly well with porosity values and/or solute release rates. Anamolous results are likely to be observed, of course, when the capsule wall-forming system is: at a eutechtic point, so rich in wax as to produce the wax phase inversion described previously, capable of forming a plurality of dispersed phases, or incapable of forming a continuous matrix for a dispersed phase. These anamolous results may entail a decrease in capsule wall microporosity or some other poorly correlated or undesirable effect, but not necessarily a loss of the solute release feature of this invention.
The preferred components of the multi-component composition used to form the capsule walls of this invention will now be described.
CRYSTALLINE OLEFINIC POLYMERS
The crystalline polyolefins found useful in the capsule shells of this invention are those which have a specific gravity of about 0.90 to about 0.98, preferably about 0.91 to about 0.95, as determined by the density gradient technique (ASTM Test D 1505-63E). These polyolefins have been found to have molecular weights of about 1,000 to about 4,000, preferably about 1,500 to about 3,500, and exhibit an average viscosity of less than 500 cps at 140° C. (Brookfield viscometer, Model LVT). Polyolefins of higher specific gravity do not appear to be capable of producing as high a porosity in the capsule wall, while polyolefins of lower specific gravity are not sufficiently self-supporting to provide strong capsules. The preferred polyolefins are highly crystalline. The term "crystalline", as used herein, characterizes those olefin polymers which have a definite visible crystal structure as observed through a petrographic microscope. This crystallinity is at least partly responsible for the high fractional volume contraction (V x ) of these polymers, e.g. about 0.15 to about 0.25.
The term "polyolefin" or "olefin polymer" is intended to include homopolymers and those copolymers (including terpolymers, etc.) which have polyolefin character, particularly those which have some crystallinity. Generally speaking, copolymerization interferes with crystal structure; however, if at least about 50 weight percent of the polymer comprises repeating alkylene units (e.g., units derived from ethylene, propylene, 1-butene, or the like) where the polymer consists of at least 75 mole percent of such repeating alkylene units, some crystallinity will be retained, permitting the use of up to 25 mole percent of comonomers such as vinyl acetate, acrylic acid, acrylate ester, vinyl chloride, etc. Higher mole percentages of the monomers vinyl fluoride, vinyl alcohol, and carbon monoxide, are permissible in polyethylene copolymers.
The following is a list of typical commercially available ethylene polymers useful in the invention and their fractional volume contractions (V x ). All of these polymers are manufactured by Allied Chemical Plastics Division and have "AC" commercial grade numbers. Polymer grades AC 617, AC 7, and AC 8 are non-emulsifiable polyethylenes. Grades AC 656, AC 629, and AC 655 are emulsifiable polyethylenes. Grades AC 400, AC 401, and AC 405 are ethylene-vinyl acetate copolymers.
______________________________________ Melt. pt. DensityGrade (° C.) (g/cc) V.sub.x______________________________________AC 617 102 0.91 0.180AC 7 107 0.92 0.227AC 8 116 0.93 0.223AC 656 96 0.92 0.193AC 629 101 0.93 0.180AC 655 104 0.93 0.197AC 400 95 0.92 0.165AC 401 -- -- 0.183AC 405 -- -- 0.180______________________________________
AMORPHOUS THERMOPLASTIC RESINS
The amorphous organic resins utilized in the capsule shells of this invention can be one or more of a broad group of materials which are compatible at elevated temperatures at the desired ratio with the polyolefin. By "elevated temperatures" is meant the temperature of capsule manufacture which normally is at least above the melting point of the highest-melting component of the capsule wall-forming composition, preferably at least 100° C. above this highest melting point. The melting points or melting ranges of the preferred amorphous thermoplastic resins are normally in the range of about 50° to about 150° C., preferably between about 85° to about 115° C. It is preferred that the amorphous resins be selected to have a melting point or melting range near the melting point of the polyolefin. The preferred resins belong to a class of materials referred to in industry by the term "hydrocarbon resins". "Hydrocarbon resins" are defined by the Kirk-Othmer Encyclopedia of Chemical Technology, Second Edition, Volume 11, John Wiley & Sons, New York, New York, 1966, page 242 et seq., as the readily thermoplastic polymers of low molecular weight derived from coal-tar fractions, from deeply cracked petroleum distillates, and from turpentine. These "hydrocarbon resins" (which are not hydrocarbon in the strictest sense of the term, since they may contain minor amounts of oxygen or other elements occurring in these natural materials) generally have a molecular weight of about 800 to about 4,000, preferably about 1,000 to about 2,000. Typical hydrocarbon resins (as defined by Kirk-Othmer) useful in the practice of this invention include coumarone-indene resins, indene resins, natural and synthetic terpene-based resins, alkyl-aromatic thermoplastic hydrocarbon resins, vinyl arene resins (based on polymers and copolymers of vinyl toluene, styrene, vinyl naphthalene, etc.), wood resins, asphaltic resins, and other resins described by Kirk-Othmer. Natural and synthetic polyterpene is particularly useful and is commercially available as "Wing-Tack 95" (Goodyear Tire and Rubber Co.), and the various "Piccolyte" resins available from Pennsylvania Industrial Chemical Corporation. From the standpoint of obtaining high compatibility with polyolefins and high porosity in capsule walls, the Piccopale resins (Pennsylvania Industrial Chemical Corporation) have been found to be particularly suitable. The Piccopale resins are produced by high temperature cracking of petroleum, which produces a mixture of monomers averaging about 90 in molecular weight, including dienes and reactive olefins. Polymerization of this olefinic material produces resins with substantially straight-chain hydrocarbon backbones and some cyclic content, but little or no aromatic content.
The amount of hydrocarbon resin and crystalline polyolefins in the capsule wall-forming material are variable but to some extent interrelated. To avoid an excessive contraction rate in the polyolefin/amorphous resin phase, the polyolefin content should not exceed about 95% by weight of the capsule shell or wall composition. The amount of hydrocarbon resin is preferably at least about 5% by weight of the total composition for the same reason. It is permissible to lower the polyolefin content to about 15 or 20% by weight, provided that the previously described phase relationships can be properly maintained. These phase relations are most easily obtained when the ratio of polyolefin to amorphous resin is at least 1:1. The amount of wax which can be added is somewhat limited, as will be explained subsequently. It is therefore generally true that drastically decreasing the polyolefin content may require increasing the hydrocarbon resin content and losing some of the diversity in crystal structure between at least two predominantly crystalline phases.
These hydrocarbon resins used in this invention exhibit a fractional volume contraction (V y ) which is less than the V x and is preferably in the 0.10 - 0.15 range.
The preferred amount of amorphous hydrocarbon resin ranges from about 5 to about 45% by weight of the total capsule wall-forming composition.
Other commercially available amorphous thermoplastic hydrocarbon resins include the following materials available from Pennsylvania Industrial Chemical Corporation: "Piccoumaron" resins (polyindine type), "Piccovar" resins (alkyl-aromatic type), "Piccotex" resins (vinyl toluene copolymers), and "Piccolastic" resins (low molecular weight polystyrene type). The fractional volume contraction (V y ) of the aforementioned "Wing-Tack 95" is 0.102.
The fractional volume contractions (V y ) of the aforementioned Piccopale and Piccolyte resins vary slightly depending on the melting points or ranges of the resins. The density of all the common available grades (Piccopales 70 SF, 85 SF, and 100 SF melting at about 70°, 85°, and 100° C., respectively, and Piccolytes S-40, S-85, S-100, and S-135, melting at about 40°, 85°, 100°, and 135° C., respectively) is in the range of 0.96 - 0.98 gram per cubic cm (g/cc) and the V y values are as follows:
______________________________________"Piccopale" "Piccolyte" V.sub.y______________________________________70 SF -- 0.113385 SF -- 0.1200100 SF -- 0.1333-- S-40 about 0.13-- S-85 0.120-- S-100 0.1333-- S-135 about 0.12______________________________________
THE WAX COMPONENT
The third component of the preferred composition comprises a wax or mixture of waxes, including the natural and/or petroleum and/or synthetic waxes. Again, the wax should be compatible with the other two components at the capsule manufacturing temperature, which temperature will normally be higher than the melting point of the highest-melting component of the mixture used to form the capsule wall. Crystalline paraffinic or other highly crystalline waxes are preferred, the microcrystalline petroleum waxes, the animal and vegetable waxes, the synthetic ester or amide-type waxes, etc. being less preferred. The weight fraction of wax in the capsule wall-forming composition preferably ranges from about 2 to about 25 weight percent. Generally speaking, increasing amounts of wax produce increasing porosity, up to the phase inversion condition described previously. Accordingly, the upper limit of wax concentration is not numerically fixed, but may vary to some degree with the system selected. Stated another way, the quantity of wax should be selected such that the volume contraction ratio (VCR) is at least about 1.2, but preferably not significantly greater than about 2.5. Capsule wall porosities (determined by mercury porisimetry) of at least 3% can be obtained when the wax content is at least 10% by weight.
Typical preferred waxes have a density ranging from about 0.9 to about 1.05, melting points ranging from about 50° to about 90° C., molecular weights ranging from about 300 to about 1500, preferably about 400 to about 800, and fractional volume contractions (V z ) of at least about 20%. The wax component thus has a rate or extent of contraction slightly greater than the preferred polyolefins, and considerably greater than the amorphous thermoplastic resins; hence the wax contraction can be significantly greater than the contraction of a polyolefin/amorphous resin phase.
Data on suitable commercial paraffin grade waxes ("Shellwax" 100, 200, 300, and 700, available from Shell Chemical Company) are set forth below:
______________________________________Grade Melting Pt.("Shellwax") (° C.) Density V.sub.z______________________________________100 51.4 0.91 0.260200 60.8 0.92 0.257300 70.6 0.93 0.250700 83.9 0.94 0.242______________________________________
______________________________________ Wax Grade MixturesWt % 100 / Wt % 700 V.sub.z______________________________________10/90 0.23720/80 0.24050/50 0.24380/20 0.250______________________________________
Among the suitable microcrystalline grades are Shellmax 400 (m.p. 80.6° C., density 0.94 g/cc, V z : 0.223) and 500 (m.p. 60.6° C., density 0.93 g/cc, V z : 0.200).
Other suitable wax grades are:
______________________________________Grade m.p. (° C.) Density (g/cc) V.sub.z______________________________________Carnauba 82.5 - 86.1 0.996 - 0.998 0.228Ouricury 82.5 - 84.4 0.97 - 1.050 0.2133Montan 83.0 - 89.0 1.020 - 1.030 0.200______________________________________
OTHER ADDITIVES
It is within the scope of this invention to add high boiling solvents and/or plasticizers to the capsule wall-forming composition. The plasticizer or flexibilizer materials lower the melt viscosity of a capsule wall-forming composition and increase capsule flexibility, thus resistance to breakage. Among the suitable plasticizers are: mineral oil, soya oil, peanut oil, and safflower oil. Anti-oxidants include octadecyl 3-(3',5'-di-t-butyl-4'-hydroxyphenyl) propionate and other compounds containing stearically hindered phenolic hydroxyls.
Typical water-soluble liquid agricultural chemicals which may be encapsulated for release of the active ingredient are aqueous solutions of urea; ammonium phosphates, sulfates, or nitrates; salts of 2-4, dichlorophenoxy acetic acid, trichloroacetic acid, trichlorobenzoic acid, or dichloropropionic acid; copper salts; potassium salts; salts of 3,6-endoexohexahydrophthalate, disodium and potassium salts being especially preferred; and salts of 1:1'-ethylene 2:2 dipyridylium, the dibromide being especially preferred. Suitable emulsifiable chemicals include the organo-phosphorous compounds disclosed in U.S. Pat. Nos. 3,317,636 and 2,578,652. Solutes or emulsoids which have the ability to chemically or physically attack the capsule walls should be avoided. But virtually any solute, emulsoid or dispersoid which does not have this undesirable property can be used in solution or emulsion form as a fill material for capsules of this invention. Thus, the fill material can be a solution, emulsion, or dispersion comprising fertilizers or pesticides (i.e. economic poisons), such as algicides, herbicides, and plant growth regulators.
In general, the capsules are formed and filled by forcing a jet of fill liquid through a body of molten capsule shell material, the jet being directed to follow a desired trajectory which causes a concentric shell to form around the liquid fill material. Cooling the molten capsule shell causes it to solidify and form capsules containing liquid fill solution, the capsules being non-tacky and dry on their exterior. See U.S. Pat. No. 3,423,489 (Arens et al), issued January 21, 1969. Other suitable methods of capsule formation are described in the Arens et al patent and in U.S. Pat. Nos. 2,799,897, 2,911,672, and 3,015,128.
The ability of the capsules to release the contained solute over a period of time is readily demonstrated by extraction techniques. Twenty grams of filled capsules are placed in a sealed bottle together with 100 ml of distilled water and allowed to stand for 24 hours at 25° C. A 10 ml aliquot is thereafter withdrawn, evaporated to dryness, the amount of solid residue determined, and the percent of active ingredient released during the 24 hour period calculated. The remaining solution is decanted and 100 ml of fresh distilled water added, the bottle resealed and allowed to stand for a second 24 hour interval, another aliquot removed, and the percent of active ingredient released is calculated. The procedure is then repeated at various intervals.
The following non-limiting Examples, in which all parts are by weight unless otherwise indicated, illustrate preparation of the capsules of this invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE I
An apparatus as illustrated in FIG. 1 of U.S. Pat. No. 3,423,489 was used to form capsules filled with an aqueous fertilizer solution. The apparatus contained a submerged, generally upwardly pointed nozzle for discharging fill liquid to be encapsulated. The nozzle was supplied by a conduit means provided with a needle valve to control the flow, and was immersed beneath the surface of a bath of hardenable liquid encapsulating material. The level of the liquid encapsulating material was maintained at an even distance above the nozzle orifice by means of a constant level overflow reservoir provided with a recirculating pump. Air pressure was applied to the reservoir of fill liquid and the nozzle was provided with tip windings of an electrical resistor to minimize congealing of encapsulating material around the nozzle.
The capsule shell comprised 85 parts polyolefin and 15 parts compatible hydrocarbon resin. The nozzle was inclined at an angle of 30° from the vertical, was provided with an orifice of 0.74 mm in diameter, and was immersed in the bath to a depth of 2 mm. The full liquid had the following composition:
______________________________________ PartsWater 34.0Urea 27.611-37-0 analysis fertilizer (TVA liquidbase solution) 12.010% solution of an interpolymer of methyl vinylether and maleic anhydride ("Gantrez" AN-169,General Analine and Film Corporation) 25.325% solution of the sodium salt of alkyl arylpolyether sulfonate ("Triton" X-200, Rohm andHaas Company) 1.1______________________________________
The shell composition was as follows:
______________________________________Polyolefin, 1,500 molecular weight, 102° C. softening 85.0point, 0.91 specific gravity, 145 cps viscosityat 140° C. (Polyethylene AC617A, Allied Chemical Co.)Hydrocarbon resin, 95° C. softening point, 0.93 15.0specific gravity ("Wing-Tack" 95, GoodyearTire and Rubber Company).______________________________________
Four liters of filtered fill solution were placed in the reservoir to which 0.34 atmospheres gauge pressure was applied. The temperature of the fill liquid was 22° C. The shell composition temperature was 250° C., and the tip winding was heated to about 700° C. The needle valve was opened and the fill solution was discharged at a rate of 133 cm per minute. The polyolefin-hydrocarbon shell composition solidified at a distance approximately 100 cm from the orifice, this time being sufficient to permit the biliquid column to form a string of capsules and then to separate into individual discrete capsules. Capsules were produced at the rate of about 40,000 per minute. The total trajectory length was about 10 feet after which the capsules were allowed to fall into water filled collecting trough. The capsules collected were 2125 microns in average diameter and had a shell wall thickness of about 120 microns. The fill liquid comprised about 79% of the total capsule weight and the shell material about 21%. The release properties of these capsules were demonstrated by extraction as previously described, the results being shown in TABLE I.
EXAMPLE II
This Example illustrates encapsulation of liquid fertilizer solution in a capsule shell comprising 70 parts of the polyolefin used in Example I and 30 parts of the hydrocarbon resin of Example I. The temperature of the fill solution was 20° C., and the shell composition temperature was 230° C. The fill solution and capsule mixture were discharged at a rate of 149.5 cc/min. Capsules were produced at the rate of about 40,000 per minute. The capsules collected were 2360 microns in average diameter and had a shell wall thickness of about 140 microns. The fill liquid comprised about 75% of the total capsule weight and the shell material about 25%. These capsules were extracted as previously described, the results being shown in TABLE I.
EXAMPLE III
This Example illustrates encapsulation of liquid fertilizer solution in a capsule shell comprising 60 parts of the polyolefin used in Example I and 40 parts of the hydrocarbon resin of Example I. The nozzle angle and trajectory length were substantially the same as utilized in Example I. The temperature of the fill liquid was 22° C. and the temperature of the shell composition was 240° C. Capsules were produced at the rate of about 40,000 per minute. The capsules collected were 2360 microns in average diameter and had a shell wall thickness of about 140 microns. The fill liquid comprised about 75.6% of the total capsule weight and the shell material about 24.4%. These capsules were extracted to demonstrate fertilizer release, the results being shown in TABLE I.
EXAMPLE IV
This Example illustrates the encapsulation of liquid fertilizer in a capsule shell comprising 60 parts of the polyolefin of Example I, 37.5 parts of the hydrocarbon resin of Example I, and 2.5 parts of hydrocarbon wax having a melting point of 84° C., and a specific gravity of 0.94 at 15° C. (Shellwax 700, Shell Chemical Company).
Four liters of filtered fill solution were placed in the reservoir to which 0.34 atmospheres gauge pressure was applied. The temperature of the fill liquid was 20° C. The temperature of the shell composition was 241° C. and the temperature of the tip winding was about 700° C. The needle valve was opened and the fill solution was discharged at a rate of 149.5 cm/min. Capsules were produced at the rate of about 40,000 per minute. The capsules collected were about 2360 microns in average diameter and had a shell thickness of about 140 microns. The fill liquid comprised about 75.6% of the total capsule weight and the shell material about 24.4%. These capsules were extracted as previously described, the results being shown in TABLE I.
EXAMPLE V
This Example illustrates encapsulation of liquid fertilizer in a shell comprising the components used in Example IV, except that the ratio was 60 parts polyolefin, 35 parts hydrocarbon resin, and 5 parts wax. The machine operating conditions were the same as those used in Example IV. The capsules collected were 2360 microns in average diameter and had a shell thickness of about 140 microns. The fill liquid comprised about 75.6% of the total capsule weight and the shell material about 24.4%. These capsules were extracted as previously described, the results being illustrated in TABLE I.
EXAMPLE IV
This Example illustrates encapsulation of liquid fertilizer in a shell comprising the components used in Example IV, the ratio of components being 60 parts polyolefin, 30 parts hydrocarbon resin, and 10 parts wax. Machine operating conditions were the same as those utilized in Example IV. Capsules were produced at the rate of about 40,000 per minute. The capsules collected were 2360 microns in average diameter and had a shell thickness of about 140 microns. The fill liquid comprised about 75.6% of the total capsule weight and the shell material about 24.4%. These capsules were extracted as previously described, the results being shown in TABLE I.
EXAMPLE VII
This Example illustrates encapsulation of a liquid herbicide in a capsule of the invention and illustrates incorporation of a mineral oil plasticizer in the capsule shell. The nozzle was inclined at an angle of about 30° from the vertical, was provided with an orifice 0.74 mm in diameter, and was immersed in the bath to a depth of about 2 mm. The fill liquid was 61.5 parts of a 65% aqueous solution of 1:1' -ethylene `2:2` dipyridylium dibromide ("Diquat", Chevron Chemical Company), 20.6 parts water, and 25.3 parts of a 10% aqueous solution of an interpolymer of methyl vinyl ether and maleic anhydride ("Gantrez"AN-169, General Aniline and Film Corporation).
The shell composition was 59.8 parts of the polyolefin used in Example IV, 21.4 parts of the hydrocarbon resin used in Example IV, 14.5 parts of the hydrocarbon wax used in Example IV, and 4.3 parts mineral oil ("Nujol" liquid petrolatum).
Four liters of filtered fill solution were placed in the reservoir to which 0.27 atmospheres gauge pressure was applied. The temperature of the fill liquid was 22° C. The shell composition temperature was 284° C., and the temperature of the tip winding was about 700° C. The needle valve was opened and the fill solution was discharged at a rate of 106 cc/min. The capsule solidified at a distance of approximately 120 cm from the orifice which was one second travel time of the capsule in the trajectory path. This time was sufficient to permit the biliquid column to first form a string of capsules and then to separate into individual discrete capsules. Capsules were produced at the rate of about 35,000 per minute. The total trajectory length was about 8 feet after which the capsules were allowed to fall into a water filled collecting trough. The capsules collected were 2360 microns in average diameter and had a shell thickness of about 82 microns. The fill liquid comprised about 81.3% of the total capsule weight and the shell material about 18.7%.
The results indicated in TABLE I show that the capsules of this example released less than 5% of their contents during the first 24 hours and released less than 10% of the contents in five days. This was considered to be a release rate sufficient to provide an adequate initial dosage of herbicide to the plants and also allow steady release of more herbicide for a definite period of time.
EXAMPLE VIII
This Example illustrates the practical utility of these capsules for use with live tomato plants. An 18-4-4 fertilizer comprising 40.5 parts urea, 5.95 parts NH 4 H 2 PO 4 , 5.8 parts KCl, 47.25 parts water, and 0.5 part surfactant ("Pluronic" L-64) was encapsulated and applied to plants. This fertilizer was encapsulated in the manner utilized in Example I, the capsule shell composition being 59.8 parts of the polyethylene used in Example I, 21.4 parts of the hydrocarbon resin used in Example I, 14.5 parts of the hydrocarbon wax used in Example I, and 4.3 parts non-hydrogenated peanut oil. The shell material comprised 35% of the total weight of the capsule and the fill solution was correspondingly 65%
Six 6-inch flower pots were filled with vermiculite, another six 6-inch flower pots filled with a low nutrient content soil, and a healthy started tomato plant transferred to each pot. The above fertilizer filled capsules were uniformly incorporated in two pots of vermiculite and in two pots of soil at the rate 11/2 tablespoons per pot (i.e., about 2 lbs. of nitrogen per cubic yard of planting media). One and one-half tablespoons of capsules was also added by top dressing to each of the two other pots of vermiculite and to two pots of soil. Two pots of vermiculite and two pots of soil were left as controls without any fertilizer. The plants were all watered with 1/2 to 1 liter of water per day, the progress of plant growth being noted at two week intervals.
Those tomato plants having fertilizer-filled capsules either incorporated in the pot contents or top dressed thereon showed normal growth, bore fruit, and showed no nutrient deficiencies until after 31/2 months. Those plants in pots not containing any encapsulated fertilizer showed nutrient deficiencies after 4 weeks and did not bear fruit.
TABLE I__________________________________________________________________________Cumulative Total Percent of Fill Solution Extracted at Various IntervalsExample1 Day 2 Days 3 Days 4 Days 5 Days 6 Days 7 Days 8 Days 9 Days 10 Days__________________________________________________________________________ 41 9.36 11.74 12.36 13.08 -- -- 14.53 15.01 15.53 15.902 3.76 5.51 5.73 6.09 -- -- 7.42 7.87 8.40 8.843 5.13 5.5 5.81 5.96 -- -- -- -- -- --4 1.37 1.68 1.79 1.90 -- -- -- -- -- --5 7.76 9.30 10.07 10.61 -- -- -- -- -- --6 9.81 11.52 12.35 12.86 -- -- -- -- -- --7 1.69 2.75 4.04 -- -- 10.27 13.79 17.73 21.78 26.188 7.95 11.05 12.92 14.24 -- -- 16.61 17.49 18.24 --__________________________________________________________________________
EXAMPLES IX - XX
The method of manufacture of these capsules was substantially as in Example I. All capsules had a polyolefin component (polyethylene "AC 617"), a hydrocarbon resin component (Wing Tack 95 described in Example I), and a wax component (Shellwax 700, described in Example IV). Two parts mineral oil were added in Examples XI and XV. The compositions, mercury porosimeter determinations, and the calculated volume contraction ratio (VCR) values of Examples IX - XX are set forth below in TABLE II. The fractional contraction values for the individual components have been given previously. The average daily percent of solute extracted by the standardized water leach test described previously stabilized after the first three days of leaching and was found to be substantially constant for all these Examples, indicating a uniform shell wall porosity as opposed to random gross flows in capsule walls. Further evidence of capsule wall integrity was provided by crush strength data (which also is maximized by the regularity of the capsule shape and the physical strength of the capsule walls). In the crush strength test described in the body of this specification, capsule failure was considered to occur when the tested capsule was observed to leak fluid or burst. The crush strength measurements in all of these Examples were in the range of 11 - 18 psi. A stain test (described subsequently) indicated that the capsules of Examples IX - XX contained no gross flaws. In the leach test column of Table II, a "low" rate indicates less than 1.0 wt. % of active ingredient per day; "moderate" indicates less than 2.0%/day, and "high" indicates greater than 2.0%/day. The active ingredient was copper (II) sulfate pentahydrate, the composition of the fill being:
25.6% cupric sulfate-pentahydrate
72.43% water
1.97% thickener and surfactant
Table II______________________________________Composition* (parts by wt.) Porosity LeachEx. X Y Z MO (Vol. %) VCR Rate______________________________________ 9 45 45 10 0 3.67 1.186 low10 45 40 15 0 10.96 1.264 low11 45 40 15 2 11.87 1.26 low12 45 30 20 0 12.07 1.404 high13 40 35 25 0 9.71 1.548 high14 40 35 25 0 23.11 1.548 high15 40 35 25 2 17.83 1.54 high16 50 15 35 0 24.03 1.781 high17 20 40 40 0 5.23 2.233 **18 44 40 16 0 14.40 1.315 moderate19 43 40 17 0 19.13 1.339 moderate20 42 40 18 0 15.44 1.365 moderate______________________________________ *X is the polyolefin; Y is the hydrocarbon resin; Z is the paraffin wax; MO is mineral oil. **High release rate due to capsule shell wall failure in water. Wax forme continuous phase.
The aforementioned stain test procedure is described below:
A. A small sized strainer was filled with capsules to a depth of 1/4 inch.
B. The strainer was submerged in a reservoir filled with ink (stamp pad ink -- solution type, not pigmented type).
C. The capsules were allowed to remain in submerged for one minute.
D. The strainer was removed from the ink reservoir and allowed to drain.
E. The capsules were then rinsed with tap water so as to remove all surface ink.
F. The thus rinsed capsules were placed on paper and allowed to dry.
G. Stained flaws or darkened capsules were noted.
No darkened capsules (indicating gross flaws) were noted in any of the preceding Examples. The only stains noted were pinholes, indicating large pores, in the walls of the capsules of Examples XII, XVII, XIX, and XX.
EXAMPLES XXI - XXV
The manufacture of these capsules was as in Examples IX - XX. All capsules had a polyethylene "AC 617" (X) component, a hydrocarbon resin (Y) component, and a wax (Z) component. The amounts used in each of these Examples were as follows:
______________________________________ Parts by WeightX: Polyethylene 45Y: Hydrocarbon resin 40Z: Wax 15______________________________________
The data for Examples XXI - XXV are given in Table III.
TABLE III______________________________________Hydrocarbon Porosity LeachEX. Resin Wax (vol. %) VCR Rate______________________________________21 S-100.sup.1 SW700.sup.4 12.14 1.269 low22 100SF.sup.2 SW700.sup.4 11.57 1.269 moderate23 S-85.sup.1 SW700.sup.4 36.98 1.279 low24 WT-95.sup.3 SM500.sup.5 20.71 1.243 low25 85SF.sup.2 SW700.sup.4 16.59 1.279 high______________________________________.sup.1 "Piccolytes": polyterpenes described previously.sup.2 "Piccopales": synthetic polymerized petroleum hydrocarbons, described previously.sup.3 "Wing-Tack 95": described previously.sup.4 "Shellwax" 700: described previously.sup.5 "Shellmax" 500: described previously
Examples 21, 23, and 24 showed no staining whatever in the stain test. The other Examples exhibited tiny pinholes. The capsule walls in Examples 23 and 24 appeared to form three incompatible or distinct solid phases upon cooling. The mercury porosimeter values for these two Examples probably indicate high surface roughness, hence, the low leach rates, which otherwise correlate well with the VCR values. Examples 22 and 25 indicate the high pore-forming ability of the Piccopale - containing systems. Crush strength was good for Examples 21 and 22, lower (8.5 - 11 psi) for Examples 23 - 25.
EXAMPLE XXVI
Capsules were made according to Example X, except that the fill material was the following oil-in-water type emulsion:
______________________________________ Parts by wt."Abate 4E"(Cyanamid, mosquito larvicide ofU.S. Patent 3,317,636) 3.34Water 58.13Sucrose 28.4320,000 MW polyethylene glycol 9.16Emulsifiers 0.93______________________________________ In actual field trials on field areas of at least 0.1 acre, the capsules were found to provide controlled release of the active larvicide, prolonging the usefulness of the active chemical at least by a factor of 8.
As the preceding Examples indicate, the capsules of this invention provide controlled release of a variety of dissolved or suspended substances. The solvent or other encapsulated liquid can also be controllably released by a transport and evaporation mechanism if the liquid is volatile at the temperature of use. For example, encapsulated water can be used to provide a high humidity environment. Reverse pass-through of solutes or the like is also possible, permitting water-filled capsules to be used to stabilize the concentration of a solute in a given system.
As shown by the aforementioned Arens et al. U.S. Pat. No. (3,423,489), both polar and non-polar, relatively high surface tension liquids, which boil at temperatures above 60° C., e.g. imidazole, alkylene glycols, carboxylic acids, higher alkanes, etc. can be encapsulated in molten organic materials by the biliquid column technique, and hence can be used as fill materials in this invention. | The disclosed substantially spherical capsules are particularly adapted for containing a liquid and have permeable or semi-permeable capsule walls. The capsule walls can comprise a first crystalline phase, an amorphous phase which ordinarily is intimately associated with the crystalline phase, and, preferably, a dispersed (discontinuous) second crystalline or semi-crystalline phase such as a wax. These capsules have the ability to release a solute by an effect resembling osmosis and to release a liquid by a transmission and evaporation mechanism. | 1 |
RELATED APPLICATIONS
The present application claims the priority date benefit of French Patent Application No. 11/58882 entitled “Multizone Epicardial Pacing Lead” and filed Sep. 30, 2011.
FIELD OF THE INVENTION
The present Invention relates to “active implantable medical devices” as defined by the Jun. 20, 1990 90/395/CEE directive of the European Community Council, which includes devices that continuously monitor a patient's cardiac rhythm and deliver to the heart if and as needed electrical pulses for stimulation (pacing), cardiac resynchronization, cardioversion and/or defibrillation in response to a rhythm disorder detected by the device, and more particularly to “epicardial” leads that are directly fixed on the outer wall of the heart, as contrasted with “endocardial” leads which are inserted in a cavity of the heart where they are introduced via the venous system, and “coronary” leads implanted in the heart coronary network.
BACKGROUND
The epicardial leads may be prescribed for the stimulation of the left ventricle, as an alternative to pacing leads implanted via the coronary sinus, which require a delicate approach for their implantation and are not without various drawbacks.
Nevertheless, unlike endocardial leads introduced via the venous network (see for example U.S. Pat. Publication No. 2009/0157136 A1), the implantation of an epicardial lead constitutes a very invasive operation, usually requiring general anaesthesia and the use of surgical techniques. It is indeed necessary that a chest surgeon incises the thorax so as to provide access to the pericardial sac (the pericardium being the fibro-serous envelope that surrounds the heart) and the myocardium itself, in order to fix the lead on the external wall of the latter, by suturing or by screwing.
For this reason, the implantation of an epicardial lead, though representing a known technique, is often seen as a back-up solution in case of failure of implantation of a lead through the coronary sinus. Moreover, an epicardial lead often provides poor results, especially with respect to electrical performance.
Several types of epicardial leads have been proposed, but all have serious enough drawbacks. A first type of lead uses an electrode pressed against the wall of the epicardium, wherein it is supported by suturing. These leads are very stable, but require broad access to allow the suture by the surgeon, and the possible implantation zone is very limited, as it is restricted to the vicinity of the chest incision.
A variant of this type of lead is a lead body that is divided into two distinct branches, each branch having a distal end supporting a pacing electrode to be sutured on the cardiac wall. This support is provided by an absorbable suture terminated with a needle: during the procedure, after suturing the electrode to its support on the cardiac wall, the surgeon buries the absorbable suture using the needle, which needle is subsequently removed by cutting the suture. This permanent traction effort provides excellent contact of the electrode, positively biased against the heart wall. The presence of two separate electrodes also allows application of a bipolar stimulation, over a somewhat wider surface area.
Another type of lead proposed is equipped with an anchoring helical screw for screwing in the myocardium wall. Screwing can be performed directly, but the work area is then limited in the same way as a sutured lead. It can also be performed using a special insertion tool having an articulated head on which the lead is mounted, but the area of possible implantation, although broader, is nevertheless limited by the rigidity and the large diameter of the support tube of the instrument that the surgeon must manipulate in the curved pericardial space.
Moreover, from the mechanical point of view, the screws of current leads are very generously sized, due to the mechanical stresses exerted on the screw during implantation, arising from the high amplitudes of displacements and the radial tractions that are exerted. These generously sized screws are relatively traumatic to the tissues, with possible creation of local fibrosis reactions.
One disadvantage which is common to all these leads, besides the highly invasive surgery, is their relatively poor electrical performances, particularly because of the large size of the sutured electrode (which should ensure a satisfactory contact with the heart wall) or because of the large dimensions of the screw (needed to withstand implantation constraints). But a large electrode does not provide a satisfactory current density, which is detrimental to the stimulation efficiency.
In addition, the stimulation is punctual (only one stimulation site), with two drawbacks:
A less effective stimulation compared to a multisite configuration, and The risk that the chosen site is not the most effective, or that because of cardiac remodeling, the site originally chosen over time become less effective. In this regard, given the invasive nature of the operation, it is not a realistic option to consider further surgery on the patient to try to improve the situation by seeking a possible alternative site that would be more effective than the originally chosen site.
A final drawback of existing epicardial leads, particularly for screw leads, is that it is almost impossible to extract them once they are implanted.
For all these reasons, the use of epicardial leads remains undeveloped, and these leads are generally used as a last resort when other techniques are not feasible.
The U.S. Pat. Publication No. 2007/0043412 A1 proposes a device implementing multiple electrodes (of a conventional type) located in different parts of the epicardium to form a network of electrodes. From an electrical point of view, each electrode is provided with its own connecting conductor, and the respective conductors are connected together to a common conductor connected at its other (proximal) end to the generator. The pacing pulses can thus be simultaneously spread to several electrodes at several points of the myocardium, corresponding to the points of implantation of the electrodes.
WO 2005/039690 A1 describes a different lead configuration, wherein two screw epicardial electrodes are implanted facing each of the two ventricles, each electrode being connected to the generator by its own conductor.
With these devices, since the electrodes used are of a conventional type (typically, screw electrodes), the problems mentioned above related to the nature of the electrodes remain, including: difficulty of implantation with the use of complex instruments particularly for in situ screwing after the implantation position is reached; need of a highly invasive intervention, which is traumatic for tissues with possible creation of a local fibrosis reaction of large sized screws because of mechanical constraints; poor electrical performances because of the large size of the electrode, which does not provide a satisfactory current density, to the detriment of the stimulation effectiveness.
OBJECT AND SUMMARY
It is, therefore, an object of the present invention to propose an epicardial lead having multiple stimulation points which is simple in construction (and therefore inexpensive to manufacture and with high reliability), and, above all, can also be implemented by operative techniques usually practiced by surgeons.
The present invention is directed to an epicardial pacing lead whose active part:
guarantees an excellent and sustainable electrical contact with the tissues to stimulate; and improves the stimulation efficiency by multiplying or expanding the stimulation area, allowing (unlike traditional leads) simultaneous stimulation of several regions of the epicardium.
In this latter regard, it has been found with cardiac resynchronization therapy (CRT) devices that using multiple stimulation points on the left ventricle is a factor that substantially improves the quality of CRT.
Essentially, the solution of the present invention is to distribute on the surface of the heart muscle, or therein, an array of micro-electrodes that are in turn carried by a plurality of microcables.
These microcables are very flexible and extend outwardly from, i.e., radiate from a common distributor housing or hub, mounted at the end of an epicardial lead body, ensuring the distribution of current to the various microcables, with the possibility of bipolar pacing and/or of multiplexing of the different microcables. The distributor housing preferably has its own means for attachment to the heart wall (e.g., a suture or screw), and is itself devoid of any electrodes.
Broadly, the present invention is directed to an epicardial stimulation lead including, as known in the prior art, in particular from U.S. Pat. Publication No. 2007/0043412 A1 referenced above: a lead body made of a sheath of deformable material, enclosing at least one connection conductor; a proximal end including a connector for coupling the epicardial lead to a generator of an active implantable medical device; a distal end including a means for anchoring the epicardial lead to a wall of the epicardium and an active part comprising a plurality of stimulation electrodes, directly coming in contact with, or into, the wall of the epicardium; a distributor housing, placed at or near the distal end of the lead body, and a network of electrically insulated flexible conductors radiating from the distributor housing and extending between a proximal end connected to the distributor housing and a remote and free distal end, the proximal end being electrically connected at or via the distributor housing to an appropriate connection conductor of the lead body.
Preferably, the flexible conductors are microcable elements having a diameter of at most 2 French (0.66 mm). Each microcable more preferably comprises at least one denuded area, and each of these denuded areas forms one of the stimulation electrodes, such that the stimulation electrodes formed by denuded areas on the same microcable are electrically connected together. Each microcable further comprises at least one transverse elongate member extending at an angle to the main direction of the microcable, for penetrating into the wall of the epicardium.
In one embodiment, at least one transverse elongated member is a burying loop formed by a curvature of the microcable or a free extension formed on a bypass of the microcable.
In one embodiment, a radially distal end of said at least one transverse elongate member includes one of said denuded areas, so as to allow the electrode to be buried in the epicardium tissue—below the surface—to provide an in depth stimulation of the epicardium.
In one embodiment, each microcable comprises a succession of elongated portions extending along the main direction of the microcable, separated by compliance loops extending in a direction transverse to the microcable and providing the microcable flexibility and extensibility in the longitudinal direction.
In one embodiment, denuded areas of each microcable are formed at one radially distal end of the compliance loops, so as to allow a stimulation of the epicardium surface.
In one embodiment, the compliance loops and the transverse elongate elements extend in different respective planes forming an angle between them.
In one embodiment, the length of each microcable, in the deployed state, is between 5 and 80 mm.
In one embodiment, the distributor housing bears the anchoring means to a wall of the epicardium.
In one embodiment, the total exposed surface of the denuded areas of each microcable is at most 10 mm 2 .
In one embodiment, the length in the longitudinal direction of each denuded area of each microcable is at most 10 mm.
In one embodiment, the lead body encloses a connection conductor comprising a plurality of separate connection conductors, and the lead comprises a corresponding plurality of microcables electrically isolated from each other and respectively connected to the plurality of connection conductors, so as to allow a bipolar or multipolar stimulation between denuded areas of different respective microcables.
In a preferred embodiment, the lead comprises a corresponding plurality of microcables electrically isolated from each other, and the distributor housing comprises a controlled switch means between on the one hand, a microcable selected from a number of the plurality of microcables and, on the other hand, a common connection conductor of the lead body, so as to allow selection from among the denuded areas from different respective microcables.
In one embodiment, the microcable is formed of a plurality of wires twisted together, wherein at least some of the wires incorporate a core of a radio-opaque material such as platinum-iridium or tantalum wrapped in a mechanically durable sheath of a material such as nitinol (NiTi) or stainless steel (or vice versa).
Preferably, the microcable comprises a multiwire structure coated by an insulating material, for example, parylene or a sheath of PET or PMMA, wherein the denuded areas are formed by ablation, leaving openings in the insulating layer along the microcable.
In one embodiment, the distal end of each microcable has a curved needle for stitching and burying of the microcable during implantation of the lead, this needle being subsequently separated from the microcable by cutting (e.g., an absorbable suture may be provided between the needle and the end of the microcable for this purpose).
DRAWINGS
Further features, characteristics, and advantages of the present invention will become apparent to a person of ordinary skill in the art from the following detailed description of preferred embodiments of the present invention, made with reference to the annexed drawings, in which:
FIG. 1 schematically illustrates an epicardial lead according to a first preferred embodiment of the present invention;
FIG. 2 schematically illustrates an epicardial lead according to a second embodiment of the present invention wherein each microcable has a plurality of stimulation electrodes;
FIG. 3 schematically illustrates an epicardial lead according to a third embodiment of the present invention implementing a multiplexing system between the different microcables of the lead;
FIG. 4 illustrates a perspective view of a first representative configuration for a microcable for an epicardial lead of the present invention;
FIG. 5 illustrates the microcable of FIG. 4 , seen in projection in two orthogonal planes P 1 and P 2 ;
FIG. 6 illustrates a variant of FIG. 5 , with a different positioning of the stimulation electrodes;
FIG. 7 is a schematic plan view of an epicardial lead according to the present invention, implanted with a microcable configuration such as that illustrated in FIG. 5 ;
FIG. 8 is homologous to the epicardial lead of FIG. 7 , in a cross-sectional view through the heart wall;
FIG. 9 illustrates a perspective view of a second possible configuration of a microcable for a lead of the present invention;
FIG. 10 illustrates the microcable of FIG. 9 , seen in projection in two orthogonal planes P 1 and P 2 ; and
FIG. 11 is a schematic view, in cross section, through the heart wall, of an epicardial lead according to the present invention, implanted with the microcable configuration of FIG. 9 .
DETAILED DESCRIPTION
With reference to the drawing FIGS. 1-10 , several exemplary embodiments of an epicardial lead in accordance with the present invention will now be described.
The epicardial lead 10 according to the present invention essentially comprises a lead body 12 terminated at its proximal end by a connector 14 of conventional type (IS-1 or IS-4).
At its distal end, lead body 12 has a distributor housing or hub 16 provided with anchoring means of a known type (e.g. a suture or a screw), but which is not stimulating: indeed, the present invention does not expect or require distributor housing 16 to carry a stimulation electrode. Distributor housing 16 preferably includes a perforated foil collar to strengthen the anchoring by development of fibrosis. Distributor housing 16 may, for example, have a flattened cylindrical shape, with a typical diameter of 6 mm and a height of 4 mm.
In one embodiment, a plurality of microcables 18 is connected to distributor housing 16 by their proximal ends, their other distal ends being free (optionally already provided with a needle attached for the surgeon to use, who removes it once the implantation is performed). Distributor housing 16 includes typically six to eight microcables 18 , but this number is given only as an example and is not intended to be limiting in any way. The length of each microcable 18 , in the deployed state, is typically between 5 and 80 mm.
Distributor housing 16 ensures the physical connection of each electrical microcable 18 with a corresponding internal conductor of lead body 12 , this conductor extending to connector 14 .
The term “microcable” should be understood to refer to a very small diameter cable, of at most two French (0.66 mm), preferably about 1 French (0.33 mm). Each microcable is formed of an electrically isolated metallic conductor, except for at least one denuded area 20 or “window”, forming a corresponding stimulation electrode (represented by a star in the Figures).
In the embodiment illustrated in FIG. 1 , each microcable 18 includes one denuded area 20 , 20 ′ forming an electrode (hereinafter, the terms “denuded area”, “electrode” and “window” are interchangeably used).
A first number of microcables 18 carry electrodes 20 and are connected together in distributor housing 16 to a first conductor of lead body 12 , and a second number of microcables 18 carrying electrodes 20 ′ connected together and to a second conductor of lead body 12 , the second conductor being different from the first conductor. It is thus possible to apply bipolar pacing between, on one hand, electrodes 20 (schematically shown by white stars) and electrodes 20 ′ (schematically shown by black stars).
With reference to FIG. 2 , an embodiment is shown in which each microcable 18 carries a plurality of electrodes, for example, two electrodes 20 or two electrodes 20 ′, which thus expands the stimulation area along a same microcable.
With reference to FIG. 3 , a third embodiment is illustrated in which microcables 18 respectively include electrodes 20 , 20 ′, 20 ″, 20 ′″ . . . and wherein each microcable 18 is connected to the input of a multiplexing module having a switch incorporated in distributor housing 16 . An appropriate command sent to the multiplexing module housing is used to select at will via the switch the one or the other set of electrodes 20 , 20 ′, 20 ″, 20 ″″ . . . to test the possible stimulation sites and choose the one or ones providing the best results from a physiological standpoint. The multiplexing system can be, for example, that described in EP 1938861 A1 (and its counterpart: U.S. Pat. Publication No. 2008/0177343) and EP 2082684 A1 (and its counterpart: U.S. Pat. Publication No. 2009/0192572) (both assigned to Sorin CRM S.A.S., previously known as ELA Medical), which are hereby incorporated herein by reference. Such a multiplexing module allows in particular to implement the concept of “electronic repositioning” to direct or redirect the electric field between different electrodes by selecting, among the various possible configurations, those providing the best efficiency from the electrical and hemodynamic points of view. This technology also helps to manage the behavior of hemodynamic changes (reverse remodeling), simply by reprogramming the generator via telemetry through the skin, without the need for further surgical intervention.
In a preferred embodiment, to increase the stimulation area a variant of the present invention is to provide, for example, four independent microcables 18 or groups of microcables 18 each connected to four separate conductors within lead body 12 . Connector 14 is then implemented as an appropriate connector, for example, of the IS-4 type, thus benefiting from four independent stimulation areas.
In all cases, denuded areas 20 of each microcable 18 form a succession of individual electrodes, together constituting a set of electrodes connected in series. This allows multiple points of contact with the heart wall and thus ensures a multi-zone distribution of the stimulation energy at several points in the epicardium and thus the left ventricle.
Preferably, the individual surface area of each electrode is at most 1 mm 2 , which allows disposing several electrodes on microcable 18 without exceeding a combined total area of 10 mm 2 . Due to the low cumulative surface area, the benefits of a “high current density” lead is achieved, with both more efficient physiological stimulation and reduced energy consumption. Advantageously, this is achieved maximizing the likelihood of physical, therefore electrical, contact between the electrodes and excitable tissue, due to the multiplication of these electrodes.
Regarding microcable 18 used in these various embodiments, the core of it is advantageously made of nitinol (NiTi alloy) or of MP35N-LT (35% Ni, 35% Co, 20% Cr and 10% Mo stainless steel), materials whose main advantage is their extreme endurance and fatigue resistance, with a coating of platinum-iridium. The result is native corrosion resistance at the electrodes, while ensuring fatigue resistance, which are imperatively required.
More preferably, the structure of microcable 18 is advantageously a multiwire structure in which each wire strand is preferably consisting of a core of platinum-iridium coated by a thickness of nitinol or MP35N-LT—or vice versa, so as to optimize response to the requirements of both corrosion and fatigue resistance. The wire strands can then be coated with a thin layer of parylene (for example, of C type). In this case, more or less complex windows are arranged along the microcable, for example by plasma ablation, to form electrodes 20 . To improve the electrical performance, these denuded areas can further be coated, for example, with titanium nitride. Alternatively, the wire strands can be enveloped in a polyurethane tube interrupted (i.e., containing apertures) at the locations of electrodes 20 ; or one or more layers made of tubes made of PET (polyethylene terephthalate), fluoropolymer, PMMA (methyl polymethacrylate), PEEK (polyetheretherketone), polyimide or other suitable similar material.
Such a microcable structure, without any internal lumen and with several microwires braided together, is both enduring (against cardiac movements) and resisting to stress in particular during the implantation.
Another advantage of this solution, particularly significant, is due to the highly flexible and floating (floppy) property of the microcable, which provides excellent atraumaticity. In chronic implantation, such a microcable is very non traumatic to the tissues and thus preserves the cells in the immediate vicinity of the electrodes: one can therefore expect good electrical performance including in the long term, unlike the traditional epicardial leads, which are far more traumatic.
These types of braided microcables are available, for example, from Fort Wayne Metals Inc., Fort Wayne, Ind., USA, and are used in the medical field in particular for the production of defibrillation conductors—but having a different arrangement of materials: in these known applications the structure is a multiwire structure in which each wire includes a core of silver (to improve conductivity) coated by a thickness of stainless steel; these microstructures, isolated or not, are then incorporated into a multi-lumen lead body of classic construction.
Alternatively, it is nevertheless possible to have a platinum-iridium wire in the center of a 1×7-type multiwire structure, the more fragile wire being then embraced and protected by the more durable outer wires.
Finally, the platinum-iridium material can be replaced by any radio-opaque material such as tantalum.
Various possible geometric conformations of microcables 18 (preformed at manufacturing), with reference to FIGS. 4-11 , will now be discussed.
In FIGS. 4 and 5 , a first representative configuration is illustrated, wherein microcable 18 comprises a series of alternating corrugated portions 22 , 24 with one or more transverse elongate members 22 extending in a first plane P 1 and compliance loops 24 extending in a second plane P 2 orthogonal to the plane P 1 , the intersection of these two planes P 1 and P 2 coinciding with the main direction Δ (longitudinal direction) of microcable 18 .
Transverse elongate members 22 are landfill loops designed to make a penetration in the thickness of the epicardium, with the locally denuded areas 20 forming the stimulation electrodes, which are located on top of landfill loops 22 .
Compliance loops 24 , for example, formed as two half-periods of a sinusoid or of a similar shape, can prevent the transmission of cyclic stresses, resulting from the beating of the heart, to the stimulating areas formed by the electrodes 20 on top of landfill loops 22 .
Note that the simplicity of the structure—isolated microcable with occasionally denuded areas forming the electrodes—allows without difficulty having an electrode on top of a (preshaped) ripple (corrugation) of the microcable, which would be much more difficult with conventional structures, for which it is considered that the areas of maximum curvature a priori are the most stressed ones, which leads to avoid locating the electrodes there.
Furthermore, placing denuded areas 20 at the top of the landfill loops 22 offers the possibility of employing sector electrodes. In this regard, in cross-sectional view, the denuded areas do not span around the entire periphery of microcable 18 , but rather only span over an angular sector located on the side of the outer face of the curvature, that is to say the side facing the tissues with which they come into contact. It is thus possible to keep isolated much of the angular sector, which further limits the stimulating surfaces, resulting in the direct benefits outlined above in terms of increase of the current density.
The use of a buried electrode corresponding to the configuration of FIGS. 4 , 5 and 8 allows in deep stimulation and reduces the risk of phrenic nerve stimulation, and the deep stimulation that it provides ensure better efficiency from the electrical and hemodynamic point of view.
Alternatively, it is possible to provide a different configuration, such as that illustrated in FIG. 6 , wherein the electrodes 20 are arranged at the top of the compliance loops 24 . Landfill loops 22 are then only used as anchors of the microcable to the heart wall. With this second configuration, the surface in which the compliance loops 24 extend is preferably a curved surface S 2 ( FIG. 4 ) instead of a plane P 2 , with a curvature directed towards the wall (that is to say in the direction of landfill loops 22 ). This allows forcing the mechanical contact of electrodes 20 with the muscle surface, due to the vertical spring effect of compliance loop 24 , since the curvature of surface S 2 is, in the free state, greater than that of the heart muscle.
With, in this method, a surface contact with the electrode instead of a buried electrode, the trauma suffered by the tissues is reduced, which increases the electrical performance. To reduce the risk of phrenic nerve stimulation, it is possible to sectorize the surface of stimulation electrodes 20 located at the top of compliance loops 24 , that is to say the side facing the tissues with which they come into contact. It is thus possible to keep isolated much of the angular sector, which further limits the stimulating surfaces, resulting in the direct benefits outlined above in terms of increasing the current density.
FIGS. 7 and 8 are schematic views, respectively a plan view and a cross section view through the heart wall 26 , of an epicardial lead according to the present invention with a microcable configuration such as that illustrated in FIG. 5 , in an implanted situation.
The implantation of the lead according to the invention begins with the attachment of the distribution housing 16 to the heart wall.
The next step is to successively implant the various microcables on the heart wall, with burial of loop or loops 22 to ensure the continued position of the microcable. These loops 22 , carrying (or not) the stimulation electrodes, may be buried in the muscle by a series of regularly spaced punctures.
The end of the microcable is equipped for this purpose, as explained above, with a curved needle, preferably factory fitted, to bite/bury the microcable at regular intervals, the needle being cut off after burial. The cut end of the microcable is then isolated by a deposit of biocompatible glue. To minimize the risk of creating an additional electrode at the location of the cut, it is possible to insert an absorbable suture between the needle and the end of microcable, the cut separating the needle being then performed on the absorbable suture.
It should be understood that the particular configuration of the lead of the invention is particularly well suited to an intervention by robotic microsurgical techniques, taking advantage of the remarkable capabilities of this technology to automatically operate “microsutures” controlled at a distance by the surgeon.
FIGS. 9 , 10 and 11 are counterparts of FIGS. 4 , 5 and 8 , respectively, for a variant of the microcable in which the one or more transverse elongated elements, instead of being landfill loops, are free extensions 28 substantially straight, bearing at their free end stimulation electrode 20 . These extensions 28 are connected at their other end to microcable 18 running on the surface of the heart muscle (this microcable 18 being of course provided with compliance loops 24 to prevent the transmission of stresses between the free extensions 28 ).
For implantation, each free extension 28 can be previously housed inside a puncture breakable micro-needle, to achieve the burial of the stimulating free extension 28 by insertion of the needle and subsequent removal of it (thanks to its breakability) once the landfill is made.
This microcable configuration delivers a deep stimulation of the myocardium, close to endocardial stimulation.
After surgery, the epicardial emergence of the free end is fixed to the wall by a known attachment method such as suture or deposit of adhesive point 30 of a biocompatible surgical adhesive such as BioGlue (registered trademark) available from Cryolife, Inc. (http://www.cryolife.com/products/bioglue-surgical-adhesive).
One skilled in the art will appreciate that the present invention can be practiced by embodiments other than those described herein, which are provided for purposes of explanation, and not of limitation. | A multizone epicardial pacing lead ( 10 ) having a lead body ( 12 ) with a proximal connector ( 14 ) for coupling to a generator of an active implantable medical device and, distally, an anchor to an epicardium wall and an active part comprising a plurality of stimulation electrodes, coming into contact with, or penetrating, the epicardium wall. This active part comprises a distributor housing ( 16 ) and a network of flexible microcables ( 18 ) radiating from the housing. Each microcable is formed of an electrically insulated conductor comprising at least one denuded area ( 20 ), each of these areas forming a stimulation electrode. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to a pellet stack length recording system, and more particularly to a nuclear fuel pellet stack segment length recording switch for automatically triggering a length measurement by the recording system.
2. Background Information
A nuclear fuel rod contains fissile material in the form of a plurality of generally cylindrical nuclear fuel pellets maintained in a row or stack thereof in the rod. One type of nuclear fuel rod, for example, is a zoned fuel rod which contains short lengths of "blanket" pellets at each end. Other fuel rod designs additionally have fuel pellets stacked in three or more zones of different pellet types including end zones of the blanket pellets. The different types of the fuel pellets include natural, enriched and enriched coated.
Fuel stacks for nuclear fuel rods may be collated by an automatic or a manual system. An example of an automatic system is disclosed in U.S. Pat. No. 4,842,808 issued Jun. 27, 1989 to Stuart L. Rieben et al. entitled "Nuclear Fuel Pellet Collating System" and assigned to the assignee of the present invention, which is herein incorporated by reference.
The manual collating system consists of an operator work area for handling pellets, input pellet trays, and output pellet trays. The manual collating system further consists of linear measuring equipment having a linear scale, a standard commercial weight scale, a barcode reader, and a local data collection computer. The operator work area includes an angled table about which is conveniently mounted the input pellet tray, the output pellet tray, the linear measuring equipment, and the weight scale.
The linear measuring equipment includes a support frame having an X-Y positioning device and a digital scale. The X-Y positioning device supports a measuring arm, a measuring head and a measuring probe. The operator positions the measuring probe in order to obtain measurements from the digital scale. The digital scale records the X coordinate length and transmits the length measurement to the local data collection computer.
The weight scale includes a fixture for supporting the output pellet tray during a weighing operation. The weight scale transmits the weight measurement to the local data collection computer.
The barcode reader is connected to the local dam collection computer and provides an error free identification of the input material (e.g., the pellets). The corrugated metal input pellet trays hold the pellets and include barcode identification labels. Whenever the identification labels are scanned by the barcode reader, the reader transmits the identification of the input material to the local data collection computer in order to verify the type of material prior to use at the operator work area.
The local data collection computer, such as a desk top IBM compatible personal computer, prompts the operator during the collating process, records and verifies the pellet stack segment length and weight measurements which are taken by the operator during the stack building process, and communicates the pellet and fuel rod data to an historical data collection computer.
Accurate pellet stack segment length measurements are essential for proper quality control and nuclear fuel rod operation. In the manual system, the length measurements are provided by the linear measuring equipment which includes the manually positioned measuring probe and the digital scale. Pellet stacks typically are assembled for a lot of 25 fuel rods at a time. The pellets for each lot are contained in special trays in a container or cassette. Due to the length of the cassette trays, each stack may consist of 9 or more segments. A typical 25 fuel rod lot, or one cassette, having 11 segments, requires 11 measurements to be recorded per rod, or 275 individual length measurements per cassette.
Pellets are separated on an input tray for the zone, or a segment of the zone, row by row for each of 25 rows on the tray. Each row represents a segment of a fuel stack. The pellets, separated for the zone or segment, are measured and recorded row by row, starting with the front row and moving to the rear row. The accuracy of the pellet stack segment linear measuring equipment is provided by a spring preload device which compresses the pellet stack segment, in order to eliminate gaps between pellets, and by a zero length check of the digital scale before and after a group of measurements. Whenever measurements are taken, the operator positions the measuring probe against an individual pellet stack segment, which compresses the spring preload device. Then, the operator actuates a foot switch, in order to signal the digital scale to transmit the length of the pellet stack segment to the local data collection computer.
Although the system provides the capability for accurate length measurements, there is room for improvement. During manual operation, the operator may become overly familiar with the function of the manual system and quickly move through a relatively large number of pellet stack segment length measurements. In particular, the operator's hand - foot coordination may become non-synchronized and, hence, the spring preload device may not be fully compressed before the foot switch is depressed. Accordingly, measurement errors may result. Although these errors are detected by subsequent quality control inspections, rework, such as remeasurement of the pellet stack segments, is required.
There is a need, therefore, for a manual pellet stack segment measurement system that operates independently of the hand - foot coordination of an operator.
There is a more particular need for such a manual measurement system that consistently provides accurate pellet stack segment length measurements.
SUMMARY OF THE INVENTION
These and other needs are satisfied by the invention which is directed to a pellet stack segment length recording switch for automatically triggering a length measurement by a length measurement system. The measurement system includes a digital length scale having a manually positioned measuring arm and head, a spring loaded slider block slidably attached to the measuring head and having an adjustable sensor pin, a spring having a predetermined compression force for resisting movement of a leg of the measuring head toward the slider block, a measuring probe attached to the slider block for compressing the pellet stack segment, and a high resolution fiber optic sensor for sensing a position of the sensor pin.
The measuring arm is manually positioned, in order to jointly move the measuring head, the spring and the slider block, and to position the measuring probe at an end of the pellet stack segment. Whenever the measuring probe contacts the end of the pellet stack segment, any manual compression force applied to the measuring arm moves the measuring head, the spring, the slider block and the measuring probe, and compresses the end of the pellet stack segment. Whenever a sufficient force, which is smaller than the predetermined compression force of the spring, is manually applied, the pellet stack segment is compressed and any gaps between the pellets are eliminated. As such smaller force is applied, the measuring head compresses the spring and moves toward the slider block. Then, whenever the predetermined compression force is applied, the measuring head further compresses the spring and moves closer to the slider block.
The position of the sensor pin of the slider block is adjusted, in order that whenever the predetermined compression force of the spring is applied, the fiber optic sensor detects the position of the sensor pin, with respect to the measuring head. The fiber optic sensor, in turn, triggers the digital length scale, in order to transmit the length of the pellet stack segment to a data collection computer. In this manner, any operator hand - foot coordination error is eliminated from the length measurements. Accordingly, accurate and consistent length measurements are provided by the length measurement system.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIGS. 1A-1B, respectively, are a front view (along an X-axis) and a side view (along a Y-axis) of an X-Y positioning table utilizing a measuring arm;
FIG. 1C illustrates rows of pellet stack segments on an input tray;
FIG. 1D is an expanded view of the measuring arm of FIG. 1B which has a measuring head in a lowered position;
FIG. 1E is an expanded view of the measuring arm of FIG. 1B which has a measuring head in a raised position;
FIG. 2A is a vertical cross-sectional view, taken along line 2A--2A of FIG. 1D, of the measuring head and a slider block in accordance with the invention;
FIG. 2B is a vertical cross-sectional view, taken along line 2B--2B of FIG. 1D, of the measuring head and a slider block in accordance with the invention;
FIG. 2C is an exploded isometric view of the measuring head and the slider block of FIGS. 2A-2B;
FIG. 3 is a block diagram of a manual measuring system having a local control panel and a data collection computer in accordance with the invention;
FIG. 4 is a circuit diagram of the local control panel of FIG. 3; and
FIG. 5 is a flowchart of a software routine executed by the data collection computer of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1A-1B illustrate a manual nuclear fuel pellet collating and measuring station 2 and include, respectively, a front X-axis view and a side Y-axis view of an X-Y positioning table 4 utilizing a measuring arm 6. An operator uses the station 2 to assemble various columnar pellet stack segments 8 in a variety of stack configurations. The station 2 further includes a measuring device 10. The measuring device 10 responds to X-Y positions of the measuring arm 6 and has a linear scale 114 which, in the exemplary embodiment, is capable of measuring pellet stack segments 8, which are up to 23 inches in length, with a resolution of±0.004 inch.
Referring now to FIG. 1C, a plurality of nuclear fuel pellets 12 are positioned on an input tray 14. The manual collating process generally includes handling of a plurality of pellet input and output trays, such as the exemplary pellet input tray 14 and an exemplary pellet output tray 16, pellet manipulation to assemble the pellet stack segments 8, data entry and data manipulation (e.g., stack weight, stack length, pellet tray identification and operator identification) in a data collection computer 110 (see FIG. 3), and data transactions with an historical data collection computer (RAMS) 118 (see FIG. 3).
The pellet stack segments 8 are measured on the input tray 14 and then are transferred to the output tray 16. The exemplary input tray 14 includes 25 parallel triangular grooved rows 20 for holding individual pellet stack segments 8. A comb type reference stop 22 is used to block transfer of the pellet stack segments 8 from the input tray 14 to the output tray 16 during length measurements. Later, the stop 22 is moved in order to transfer the stack segments 8 to the output tray 16.
Referring now to FIGS. 1C-2A, the measuring arm 6 includes an attached cylindrical measuring probe 24. The measuring arm 6 and the attached probe 24 are moved into an X-Y position, above the input tray 14, at an end 26 of an individual pellet stack segment 8. A measuring head 28 is attached to the measuring arm 6 by a pair of levers 38 and is moveable in a vertical Z-direction by a handle 32. The handle 32 is attached to an end 33 of a lever 34 which pivots about a hinge 36. For simplicity, operation of only one of the levers 38 is described below, it being understood that the other lever 38 operates in a similar manner. As shown in FIGS. 1D and 1E, the lever 34, in turn, is pivotally connected to the lever 38 at an end 40 thereof. The lever 38 is pivotally connected at another end 42 to the measuring head 28. FIGS. 1D and 1E show the measuring head 28 in a lowered position and a raised position, respectively.
The cylindrical probe 24 has a diameter approximately the same as a diameter of the nuclear fuel pellets 12. The probe 24 may be lowered into an individual row 20 of the input tray 14 adjacent the stop 22, or adjacent the end 26 of a segment 8. As will be explained in greater detail with FIGS. 3 and 5 below, length measurements include, first, a zero length calibration, where probe 24 of measuring arm 6 is positioned against the stop 22; second, a series of pellet stack segment length measurements at the end 26 of each segment 8; and third, a zero length measurement which verifies the first length calibration.
Referring to FIGS. 1D and 2A, an exemplary automatic pellet stack length recording switch 50 includes the cylindrical probe 24, a slider block 44, a spring 46, a generally rectangular spacer 48, a fiber optic sensor trip screw 52, two fiber optic reflectors 54,56, a sensor mount 58, two fiber optic cables 60 and a fiber optic sensor 102 (see FIG. 3). The generally inverted-U-shaped measuring head 28 has two legs 27,29 and is connected to the measuring arm 6 by a central rod 30. The rod 30 is attached to a central mounting hole 31 (see FIG. 2C) of the measuring head 28. As discussed above, the rod 30 and the attached measuring head 28 are movable in the vertical Z-direction. As shown in FIG. 2A, whenever the measuring head 28 is lowered by the handle 32 (see FIG. 1D), a washer 35 attached to an end of the rod 30 compresses a spring 37 until the washer 35 contacts a shoulder of a spacer 39 within the measuring arm 6. Otherwise, the measuring head 28 is normally raised under the influence of the spring 37.
Two central cylindrical bores 66,68 are bored through the two legs 27,29, respectively, along a longitudinal axis of the measuring head 28. The sensor mount 58 has an oblong-shag opening 72 which is open along the longitudinal axis of the central bores 66,68. A longitudinal axis of the oblong-shaped opening 72 is perpendicular to the longitudinal axis of the bores 66,68.
Referring now to FIGS. 2A-2C, the measuring head 28 has two sets of off-center cylindrical bores 82-82A,84-84A bored through the two legs 27,29, respectively, along a longitudinal axis. The slider block 44 has two off-center cylindrical bores 86,86A. Similarly, the sensor mount 58 has two off-center holes 75,75A. The holes 75,75A of the sensor mount 58 and the bores 86,86A of the slider block 44 are positioned on the longitudinal axis of the bores 82-84,82A-84A, respectively, of the measuring head 28.
The sensor mount 58 is attached by two set screws 70 to two pins 76,78. The pins 76,78 pass through the bores 82A-84A,82-84, respectively, of the measuring head 28. The two pins 76,78 slidably support the slider block 44 within a cut out 80 between the legs 27,29 of the measuring head 28. For simplicity, operation of only pin 78 is described below, it being understood that the other pin 76 operates in a comparable manner. Similarly, only one of the bores 86 of the slider block 44 and only one of the holes 75 of the sensor mount 58 are described below. The pin 78 is fixedly attached using a set screw 70A within the bore 82 of the leg 27 of the measuring head 28 and using the set screw 70 within the hole 75 near the side 62 of the sensor mount 58. The pin 78 passes through the off-center hole 59 of the spacer 48 and is fixedly attached using a set screw 70B at an end 67 of the spacer 48. Two cylindrical beatings 87 within opposite halves of the bore 86 surround the pin 78 which slidably supports the slider block 44. Two retaining rings 88, near the opposite ends of the bore 86, hold the bearings 87 in place within the bore 86. Two bushing seals 90 seal the ends of the bore 86. The off-center bores 82,84,86 and the off-center hole 75 are parallel with the central bores 66,68 of the measuring head 28. In this manner, movement of the measuring head 28, with respect to the slider block 44, is along the longitudinal axis of the central bores 66,68.
The slider block 44 also has a central cylindrical bore 92 and a counter-bore 91 which are positioned on the longitudinal axis of the central bores 66,68 of the measuring head 28. The trip screw 52, having a threaded head 51 and a shaft 53, is threadably attached by the head 51 within the bore 92. The shaft 53 of the trip screw 52 protrudes into the bore 68 of the measuring head 28. A set screw 49 is threadably attached within the bore 92 and is axially positioned next to the head 51 of the trip screw 52. As will be described more fully below, the trip screw 52 has an adjustable position within the bores 68,91,92.
The generally rectangular spacer 48 includes a central hole 55, two off-center holes 57,59 which are on opposite sides of the central hole 55, two longitudinal surfaces 61,63, and two end surfaces 65,67. The longitudinal surface 63 is adjacent the leg 29 of the measuring head 28. The central hole 55 is positioned on the longitudinal axis of the central bores 66,68. The hole 55 and the bore 68 have diameters which are larger than a diameter of the shaft 53 of the trip screw 52. The shaft 53 freely passes through the hole 55 without contacting the spacer 48. Furthermore, the shaft 53 freely passes through the bore 68 and enters the opening 72 without contacting the sensor mount 58. As described above, the spacer 48 is attached to the pins 76,78 by set screws 70B through the end surfaces 65,67, respectively.
Continuing to refer to FIGS. 2A-2C, the spring 46 is positioned around the shaft 53 of the trip screw 52 and within the counter-bore 91 of the slider block 44. The spring 46 has an end which abuts an inner surface 93 of the counter-bore 91 and another end which abuts the surface 61 of the spacer 48. The spring 46 is selected to provide a predetermined compression force to resist a movement of the measuring head 28 and the spacer 48 toward the slider block 44. The surface 61 of the spacer 48 provides an end stop for movement of the spacer 48 toward the slider block 44.
The cylindrical probe 24 is affixed to a lower grooved alignment surface 25 of the slider block 44 by two set screws 70C. As will be described in greater detail below, an operator moves the measuring arm 6, in order that the probe 24 contacts and compresses an end 26 of a pellet stack segment 8 (see FIG. 1C). In this manner, the combination of the measuring arm 6, measuring head 28, spacer 48, spring 46, slider block 44 and probe 24 are used to apply a compression force to the end 26 of the pellet stack segment 8 for each length measurement.
After a compression force is applied by the probe 24, in response to operator movement of the measuring arm 6, the measuring head 28 and the spacer 48 move left, with respect to the slider block 44 of FIG. 2A, and compress the compression spring 46. In the same manner, the sensor mount 58 also moves left with respect to the shaft 53 of the trip screw 52. Before the predetermined compression force is applied, and before the spacer 48 contacts the slider block 44, the shaft 53 enters the opening 72 of the sensor mount 58. In the event that a compression force greater than the predetermined compression force is applied, the spacer 48 contacts the slider block 44. This restricts any further motion of the measuring head 28 toward the slider block 44.
Two protective tubes 94 (see FIG. 1D) and 96 are routed along a side of the measuring arm 6 and each contain the fiber optic cable 60. Sufficient slack is provided in the cables 60 to permit a full range of vertical motion of the measuring head 28. The fiber optic cables 60 terminate in the fiber optic reflectors 54,56. The fiber optic reflectors 54,56 are secured within the sensor mount 58 using two set screws 70D. As will be discussed more fully with FIGS. 3-4, a beam of light originates in the fiber optic sensor 102 (see FIG. 3). The light beam passes through the fiber optic cable 60 within tube 94 and is reflected perpendicular to the longitudinal axis of the bores 66,68 by the reflector 54 (see FIG. 1D) within the opening 72 of the sensor mount 58. Within the opening 72, the light beam passes to the corresponding reflector 56 which reflects the light beam into the fiber optic cable 60 within tube 96. Finally, the light beam is received by the fiber optic sensor 102. Whenever the predetermined compression force is applied, the shaft 53 of the trip screw 52 enters the opening 72 and breaks the light beam. The fiber optic sensor 102 detects the broken light beam, which signifies that the measuring head 28 is properly positioned. In turn, an output 103 (see FIG. 3) of the sensor 102 triggers a length measurement. It being understood that the invention is applicable to other types of position sensors (e.g., a proximity switch, a limit switch, etc.).
The trip screw 52 is adjusted, in order that the shaft 53 of the trip screw 52 breaks the light beam whenever the predetermined compression force is applied. The set screw 49 is inserted through the bore 66 of the measuring head 28 and is threadably attached within the bore 92 of the slider block 44. The set screw 49 is adjacent the head 51 of the trip screw 52, in order to prevent any back-off of the trip screw 52 within the bore 92 of the slider block 44.
The manual measuring system 150 of FIG. 3 includes a local control panel 100 and an exemplary data collection computer, such as conventional personal computer (PC) 110. The local control panel 100 is interconnected with the fiber optic sensor 102, a foot switch 104, two manual switches 106, and the linear scale 114. The PC 110 is interconnected by standard RS-232 interfaces 110a-1 10c with a weight scale 112, the linear scale 114, and the historical computer (RAMS) 118, respectively. The PC 110 is further interconnected by an interface, such as the exemplary keyboard interface 110d with a barcode scanner 116. The two manual switches 106 are used for selecting an automatic or a manual mode of operation (AUTO/MAN) and for manually activating an output of the interface 110b of the linear scale 114 (MANUAL TRANSMIT LENGTH).
The PC 110, in order to determine a length of a stack segment, prompts the operator to conduct a series of length measurements. The first measurement is the zero length measurement at the stop 22 (see FIG. 1C). Using interface 110b, the PC 110 instructs the linear scale 114 to calibrate a "zero length" using this zero length measurement. The second measurement is one of the stack segment length measurements at the end 26 of each segment 8 (see FIG. 1C). After all of the stack segment length measurements are completed, a final zero length measurement is performed at the stop 22 in order to verify that the linear scale 114 returns a "zero length" within a predetermined tolerance.
FIG. 4 is a circuit diagram of the local control panel 100. Power for the local control panel 100 is provided by a suitable alternating current power source (VAC) 120 on power leads 121,122. The POWER ON status of the power source 120 is indicated by a lamp 123 connected across the power leads 121,122. A dual switch 124 for selecting an automatic (AUTO) or a manual (MAN) operation mode of local control panel 100 includes two individual switches 124a, 124b. Whenever switch 124a is in the automatic position, terminal 125, which is connected to power lead 121, is connected to terminal 127, and the automatic status of panel 100 is indicated by a lamp 126 through a circuit to power lead 122. A relay coil (R1) 130 is connected between power lead 122 and a contact 128 of the foot switch 104. The contact 128 is connected between the coil 130 and terminal 127. Whenever switch 124a is in the automatic position, power lead 121 and terminal 125 are connected to terminal 127, and the closure of foot switch contact 128 energizes the coil 130 through a circuit to power lead 122. On the other hand, whenever switch 124a is in the manual position, terminal 127 is disconnected from power lead 121, the lamp 126 is extinguished to signify the manual mode of panel 100, the foot switch contact 128 is disabled, and power to the coil 130 is disconnected.
Whenever switch 124b is in the automatic position, terminal 129 is connected to terminal 131, and a relay contact (TDR1) 132 is connected across terminals 136,137 for presentation to a transmit enable input of linear scale 114. Whenever terminals 136,137 are interconnected (e.g., whenever contact 132 is closed in the automatic mode of panel 100), linear scale 114 transmits an RS-232 message representative of a length measurement of stack segment 8 (see FIG. 1C). On the other hand, whenever switch 124b is in the manual position, terminal 129 is connected to terminal 133, and a manual transmit length switch 134 is connected across terminals 136,137 for presentation to the transmit enable input of linear scale 114. Accordingly, length measurements may be requested in the manual mode of operation by closing switch 134, and may be requested in the automatic mode of operation whenever contact 132 is closed.
An alternating-to-direct current power supply (VAC/DC) 138 generates a direct current (DC) voltage at terminals 139,140 from the AC voltage of power leads 121,122. In the exemplary embodiment, a 120 VAC to+24 VDC power supply is utilized. Terminals 139,140 provide DC power and ground, respectively, to fiber optic sensor 102. The output 103 of the fiber optic sensor 102 is suitable for energizing a DC relay coil (R2) 144 whenever the light beam associated with the sensor 102 is broken. Whenever the light beam is broken, output 103 is driven to the DC ground reference of terminal 140. In this manner, a circuit is formed between DC power terminal 139, a relay contact (R1) 142, coil 144, output 103 and DC ground terminal 140. In other words, in the automatic mode, whenever the light beam is broken and foot switch contact 128 is closed, then relay coil (R1) 130 is energized, contact 142 is closed and relay coil (R2) 144 is energized. A relay contact (R2) 148 is driven by coil 144 and is interconnected with a time delay relay (TDR1) 146. The exemplary time delay relay 146 has an adjustable time delay range of 0.1 through 10 seconds on deenergization. On the other hand, the relay 146 generally has no delay on energization.
In the automatic mode, whenever foot switch contact 128 is closed, coil 130 is energized and contact 142 is closed. Then, whenever the light beam is broken, coil 144 is energized, contact 148 is closed, time delay relay 146 is energized and contact 132 is closed. In this manner, terminals 136,137 are interconnected and linear scale 114 outputs a length measurement, in the automatic mode, whenever the operator depresses foot switch 104 and the light beam is broken, which signifies that the measuring head 28 (see FIG. 2A) is properly positioned. The exemplary adjustable time delay of 0.1 to 10 seconds maintains contact 132 in a closed state for the adjusted time delay. This ensures that spurious length measurements are not provided in the event of contact bounce in contacts 128,142,148, or in the event the light beam is only partially broken.
Referring now to FIGS. 1C, 3 and 5, PC 110 executes a software routine, in order to determine length measurements of individual pellet stack segments 8. At step 180, the PC 110 prompts the operator and reads various stack building requirements from operator entry. Then, at step 182, the stack building requirements are transferred to RAMS 118. Also, a data base in RAMS is accessed in order to identify the appropriate set of input trays 14. Next, at step 184, based on the stack building requirements, the PC 110 prompts the operator to begin building up to 25 stacks. At step 186, the PC 110 prompts the operator to begin to measure the stack segment lengths. Next, at step 187, the operator is prompted to perform a zero length calibration at stop 22 in order to calibrate the linear scale 114. At step 188, the operator is prompted to perform up to 25 length measurements at the end 26 of each of the pellet stack segments 8 on the input tray 14. Then, at step 189, the operator is prompted to perform a zero length measurement which verifies the first zero length calibration. A test, at step 190, determines whether the zero length measurement is within a predetermined tolerance value. If not, then the length measurements are discarded at step 192 and step 186 is repeated in order to prompt the operator to repeat the stack segment length measurements. Otherwise, if the zero length measurement is within the predetermined tolerance value, the length measurements are accepted and saved at step 194. At step 196, the PC 110 determines whether all of the stacks are completed based on a comparison of the length measurements with the stack building requirements. If the stacks have not been completely built and measured, then step 184 is repeated in order to prompt the operator to continue building the stacks. Otherwise, when the stacks are completed, a confirmation which signifies that the stack building procedure is finished is transferred to RAMS 118 at step 198 before the software routine exits.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof. | A pellet stack length recording switch, for use in a measurement system having a movable measuring head and a measuring device for measuring a length of a nuclear fuel pellet stack segment, includes a probe for contacting and applying a compression force to an end of the pellet stack segment, a compression spring having a predetermined compression force and cooperating with the measuring head and the probe, a pin mechanism attached to the probe, and a sensor for sensing a position of the pin mechanism and outputting a position signal for triggering a measurement by the measuring device of the length of the pellet stack segment when the compression force applied by the probe is at least equal to the predetermined compression force. The probe may include a slider block, for compressing the spring, and a probe member attached to the slider block. The pin mechanism may include a trip screw for tripping the sensor. The slider block may have a bore running therethrough for positioning the pin mechanism and the spring therein, and the measuring head may have a leg and a bore running therethrough for positioning a shaft of the pin mechanism therein. The sensor may be a Fiber optic sensor having a light beam which is broken by the pin mechanism. The switch may further include a foot switch cooperating with the sensor for triggering a measurement by the measuring device whenever the foot switch is closed and the light beam of the fiber optic sensor is broken. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to an apparatus and method for measuring neutron energy and more particularly, but not by way of limitation, to a neutron detector and method utilizing a lithium tantalate crystal disposed in an oil or gas well.
There are many areas in which neutrons need to be detected and their energy measured. Neutrons are used in logging oil and gas wells. Medical equipment uses neutrons which need to be sensed for providing diagnostic/therapeutical information. Nuclear reactors use and produce neutrons whose energy needs to be monitored. Neutrons are also monitored in outer space projects.
In well logging, for example, neutrons can be detected by presently known devices. These typically include a medium which undergoes nuclear reactions in response to neutrons entering the medium and striking nuclei in the medium. Lithium fluoride and gaseous helium-3 are examples of media which have been used in neutron detectors used in the oil and gas industry. Charged pairs of alpha particles (helium-4 atoms) and/or hydrogen atoms (hydrogen-1 and/or hydrogen-3) are generated in these media in response to neutrons striking the nuclei of the lithium or helium atoms. Upon passing into another medium outside the generating medium, these charged pairs are sensed and signals generated representing the energy of the impinging neutrons.
A shortcoming of the foregoing technique is that energy loss occurs when the charged pairs pass from one medium to another for detection. Lower energy resolution results. There is the need for an improved detecting technique which avoids this loss of resolution.
SUMMARY OF THE INVENTION
The present invention overcomes the above-noted and other shortcomings of the prior art by providing a novel and improved apparatus and method for measuring neutron energy. Measurement occurs without the loss caused by charged pairs passing from one medium into another medium. This enables the present invention to be used to provide neutron energy spectrum information in situations where there is currently no method known to be available (for example, when determining the neutron dose equivalent rate to personnel in a radiation field).
The present invention uses a medium whose electrical characteristic changes in response to the nuclear reactions which result from impinging neutrons whose energy is to be measured. This electrical characteristic is proportional to the neutron energy; therefore, the electrical change indicates the neutron energy.
The foregoing is accomplished in an apparatus for measuring neutron energy, comprising: means for producing nuclear reactions within itself in response to neutrons moving into the means, which means includes a single body to which the nuclear reactions are limited, which body comprises a medium wherein a nuclear reaction causes a potential difference between two sides of the body; and means, connected to the two sides of the body, for sensing the potential difference.
In a particular embodiment, the present invention includes a neutron detector, comprising a lithium tantalate crystal having opposed sides between which an electrical charge gradient is produced in response to a neutron entering the crystal and generating a nuclear reaction with a lithium atom in the crystal, the nuclear reaction including the production of an alpha particle and a hydrogen-3 atom and the release of energy Q and energy E n . The particular embodiment further comprises means, connected to the opposed sides of the lithium tantalate crystal, for producing in response to the electrical charge gradient data representative of the energy E n of the neutron causing the nuclear reaction.
The present invention also provides a method of measuring neutron energy, comprising: placing a lithium tantalate crystal in a field of neutrons to be measured so that the crystal is polarized in response to each nuclear reaction between a neutron from the field and a lithium atom in the crystal; flowing an electrical current having a magnitude responsive to the polarization of the crystal; and determining in response to the electrical current the energy of the neutron from the field reacting with the lithium atom in the crystal.
Advantages of the present invention summarized above include: 1. the potential difference or polarization which is sensed to indicate the neutron energy occurs within the nuclear reaction medium itself; therefore, there is no loss of energy resolution due to the reaction products passing into another medium; 2. the crystalline energy-to-voltage medium provides for better efficiency compared to detectors using a gaseous medium of the same volume; 3. relatively simple external circuitry can be used to sense and measure the generated potential difference; 4. real time readout can be provided; 5. the sensed potential difference and signals provided in response thereto are directly related to the neutron energy so that little data interpretation or manipulation is required; and 6. the apparatus and method have a wide range of applications in the nuclear field.
Therefore, from the foregoing, it is a general object of the present invention to provide a novel and improved apparatus and method for measuring neutron energy. Other and further objects, features and advantages of the present invention will be readily apparent to those skilled in the art when the following description of the preferred embodiments is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a nuclear reaction which occurs within the neutron sensitive medium of the preferred embodiment of the present invention.
FIG. 2 is a schematic diagram of a preferred embodiment apparatus of the present invention.
FIG. 3 is a schematic diagram of another preferred embodiment apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention utilize the lithium-6 ( 6 Li) reaction to impinging neutrons. The reaction of the preferred embodiments includes changing the polarization within a lithium tantalate crystal (LiTaO 3 ) so that a detectable electrical charge gradient proportional to the neutron energy is produced. A lithium tantalate crystal 2 and one lithium-6 reaction are schematically represented in FIG. 1. The reaction is represented as, follows:
.sup.6 Li.sub.3 +1.sub.n.sbsb.0 →.sup.4 He.sub.2 +.sup.3 H.sub.1 +Q+E.sub.n
The energy of the neutron, En, plus the energy from the nuclear fission, Q=4.78 MeV, are released in the crystal 2. This energy changes the polarization of the molecules in the crystal 2. This creates a small charge gradient 4 across the crystal 2 as illustrated in FIG. 2. The magnitude of the gradient, which is a potential difference or voltage, is proportional to the energy deposited or released within the crystal 2.
Lithium tantalate is a specific type of means for producing nuclear reactions within itself in response to neutrons moving into the means, but it is contemplated that other materials could be used if capable of producing a representative charge gradient. Lithium tantalate is particularly suitable for sensing neutron energy because it is a pyroelectric material, namely, one wherein an electric charge is generated in a crystal by a change in temperature. In the present invention the change in temperature occurs due to the energy released by the lithium-6 reaction. Although the pyroelectric nature of lithium tantalate is known (it is used in television sets to sense infrared), I am unaware of its application in sensing neutrons.
Lithium tantalate is also desirable because the reaction energy, Q, from the lithium-6 reaction is not large enough to propel the alpha particle far. The range of the alpha particle in this specific reaction is approximately 10 microns.
To allow lithium tantalate to be used in the apparatus of the present invention, the crystal is cut in a known manner to provide at least two sides between which the polarization occurs. This construction is illustrated in FIG. 2 wherein the crystal 2 has opposing sides 6, 8 between which the charge gradient 4 exists in response to the previously described nuclear reaction. The crystal 2 is limited in the preferred embodiments to a single body of the lithium tantalate medium so that nuclear reactions are limited to a single body or medium. This enhances the energy resolution as compared to prior types of neutron detectors which operate by sensing the reaction particles passing into another medium. In the present invention, the charge gradient, not the particles, is what is directly sensed.
The present invention further comprises means, connected to the opposed sides 6, 8 of the crystal 2, for producing in response to the electrical charge gradient 4 data representative of the total of the energy E n of the neutron causing the nuclear reaction. In the FIG. 2 embodiment, this means includes means for sensing the potential difference arising from the polarization. The sensing means of FIG. 2 includes a resistance 10 connected to the crystal 2 such as by electrodes 12, 14 bonded to the sides 6, 8, respectively, of the crystal 2. The electrodes 12, 14 should be perpendicular to the polarization axis as illustrated in FIG. 2. The resistance 10 should be large (such as in the k-ohms to M-ohms range) to allow a detectable current to flow through the resultant circuit. A large resistance is needed because the polarization effect includes a relatively small number of electrons.
Used in conjunction with the resistance 10 to enable sensing of the charge gradient 4 in the crystal 2 is an amplifier 16. Because of the small electron flow in the current through the resistance 10, the amplifier 16 is preferably a high gain, ultra low noise amplifier. It is contemplated that the amplifier preferably is one that can be readily custom designed and constructed by one skilled in the art for a particular implementation of the other components in a particular application. The inputs of the amplifier 16 are connected across the resistance 10 as shown in FIG. 2.
To determine the energy of the neutrons in response to the potential difference sensed by the resistance 10 and the amplifier 16, the preferred embodiment of the present invention illustrated in FIG. 2 further comprises a multichannel analyzer 18 of a type as known in the art. Examples of a suitable multichannel analyzer 18 are the Canberra Series 20 and Series 35 PLUS multichannel analyzers. The input of the multichannel analyzer 18 is connected to the output of the amplifier 16. The multichannel analyzer responds to an input signal by displaying a neutron energy spectrum in a known manner. An input signal 20 and an output spectrum 22 are illustrated in FIG. 2. The input signal 20 provides information responsive to the energy of each nuclear reaction. The multichannel analyzer 18 accumulates this energy information over a period time and then displays it as the output spectrum 22, which is a neutron energy spectrum. The energy of the neutron involved in a nuclear reaction within the crystal 2 is equal to the total detected energy minus the total of the known reaction energy Q. This follows from the equation set forth hereinabove.
Referring to FIG. 3, another preferred embodiment of the means for producing data in response to the electrical charge gradient 4 will be described. This means in the FIG. 3 embodiment includes means, connected to the sensing means (which again includes the resistance 10 and the amplifier 16), for processing the sensed potential in a well 24 (such as an oil or gas well) illustrated in FIG. 3. The means for processing of the FIG. 3 embodiment includes either or a combination of means 26 for storing data about the sensed potential and means 28 for transmitting data representative of the sensed potential.
The storing means 26 can be implemented by reference to any suitable downhole data memory recorder. An example of such a recorder is disclosed in U.S. Pat. No. 4,866,607 to Anderson et al., incorporated herein by reference.
The transmitting means 28 can also be implemented by any suitable means. For example, signal transmission can be electrically along a wireline, acoustically along a tool string or by pressure pulse through fluid in the well. These are transmission techniques known in the art.
A combination of the two can be used, such as to first store data and then transmit it to the surface of the well 24.
To support the means for producing nuclear reactions and the means for producing data in response to the nuclear reactions, the embodiment shown in FIG. 3 also includes a housing 30 adapted to be lowered into the well 24. The housing 30 is of a conventional type such as known to be used with other types of neutron detectors used in wells. The housing 30 can be moved into and out of the well 24 in any known manner, such as on a tool string 32 or a wireline 34, both of which are represented in FIG. 3. Regarding the embodiment of FIG. 2, a suitable known type of housing can also be provided.
It is believed that the method of the present invention is apparent from the foregoing description of the illustrated preferred embodiments. As a summary, however, the method of the preferred embodiments comprises placing a lithium crystal in a field of neutrons to be measured so that the crystal is polarized in response to a nuclear reaction between a neutron from the field and a lithium atom in the crystal; flowing an electrical current having a magnitude responsive to the polarization of the crystal; and determining in response to the electrical current the energy of the neutron from the field reacting with the lithium atom in the crystal. The foregoing of course encompasses multiple neutrons, lithium atoms and nuclear reactions.
Flowing an electrical current occurs by connecting the resistance 10 across the crystal 2 and generating the charge gradient 4. In the FIG. 2 embodiment, determining the neutron energy includes connecting the multichannel analyzer across the resistance 10 (via the amplifier 16). In the FIG. 3 embodiment, determining the neutron energy can be accomplished in the same manner using the stored or transmitted data. Also with regard to the FIG. 3 embodiment, placing the crystal in a field of neutrons includes lowering the crystal into the well 24.
Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While preferred embodiments of the invention have been described for the purpose of this disclosure, changes in the construction and arrangement of parts and the performance of steps can be made by those skilled in the art, which changes are encompassed within the spirit of this invention as defined by the appended claims. | An apparatus and method utilize a neutron sensitive medium in which initially existing atoms of the medium are divided into particles, reaction energy and neutron energy. The medium undergoes polarization in response to the reaction energy and the neutron energy. This produces an electrical charge gradient which is proportional to the energies and which can be sensed and analyzed to indicate just the neutron energy. | 6 |
BACKGROUND OF THE INVENTION
Adjacent slabs of concrete are commonly connected by dowel bars, the ends of which are inserted in the side edge of a freshly poured strethc of concrete. The other extending ends of the dowels become embedded in the adjacent slap of concrete when it is poured. When the concrete sets, the adjacent portions, although poured at different times, are firmly bound together assuming the bars are properly spaced apart. In one particular job, where runways at an airport were being laid, the dowels were twenty inches long, with half the length in each of the adjacent concrete slabs. The dowels were inserted in the middle of the thickness of the slab. The dowels were one and a quarter inches in diameter and spaced about 15 inches apart. The concrete has to be very stiff to prevent the dowels from sagging prior to setting of the concrete. Once the concrete has set, the dowels remain in fixed position when the adjacent lane is poured.
It is an object of the present invention to mechanize the insertion of the dowels while confining the top and side surfaces of the slab during this operation and preventing the side retaining plates from digging into the slab should the course of the slab deviate from a straight direction.
It is common practice to establish concrete pavement slabs by using slipform pavers. These are self propelled machines having spaced vertical side forms and a screed sometimes called an extrusion meter extending between the side forms. The extrusion meter is supported by the frame and screeds the concrete deposited on the road bed ahead of the advancing machine. The pressure exerted by the side forms and the extrusion meter is sufficient so that the contour of the slab is retained as the machine moves ahead and loses contact therewith. It is into such a slab that the dowels are inserted. When an adjoining slab is formcd, one side of the slipform paver is elevated and runs on the original slab which has now firmly set, while the other side of the paver travels on the prepared grade. The two slabs are firmly connected by the embedded dowel bars.
SUMMARY OF THE INVENTION
Extending across the initial slab immediately behind the slipform paver to which it is connected is a cross member of rigid construction. Depending from each end of the cross member are side plates which abut the sides of the slab. These plates are of a height at least equal to the thickness of the slab so that the lower edges contact the ground. The central portion of the plate is provided with a slot extending forward from the rear edge to about the middle of the plate. The slot is just wide enough to enable a dowel to be inserted through it. The dowel inserting mechanism consists of a pneumatic cylinder and channel mounted on the end of the cross nember so that dowels are held in a position at right angle to the face of the concrete in which they are inserted. The mounting of the cross member permits it to swing laterally should a deviation in the path of the slab occur. Thus prevents the side plates from digging into the slab. In fact, the contour of the slab causes the plates to move sideways so they are always in the proper abutting relationship. The cross member also carries a plate that rests on the surface of the slab above the side portion into which the dowels are inserted. This plate can be deformed so that the end portion can be elevated or tilted upward to confine and shape the surface of the concrete. The pressure exerted is sufficient to prevent the elevation of the concrete to rise because of the displacement of concrete by the dowels.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of the dowel bar placer viewed from one end of the cross member support; and
FIG. 2 is a view taken from behind the cross member showing only approximately half of said member.
DETAILED DESCRIPTION OF THE INVENTION
The slipform paver to which the tie bar inserter is appended has the customary spaced crawler tracks 11' on each side and the two slipforms each of which is arranged just inside one of the tracks. An extrusion meter extends over the slab to be formed with its ends supported by the crawlers. Along with the slipforms, the extrusion meter determines the slab contour as is well known.
As shown in FIG. 1, the tracks 11' are enclosed in a housing 11 which extends rearwardly on each side from the main frame 12 of the paver. Frame 12 extends all the way across the rear of the paver and has a vertical portion which extends considerably above the crawler housings.
The dowel placer is connected to the main frame by the tie rods or arms 13, 14, and 15 each of which is connected by ball joints at their extremities so as to be capable of universal movement. The rods 13 and 14 are parallel and vertically aligned, with their forward ends supported by the bracket 16 mounted at the rear of main frame 12. The rearward ends of the arms 13 and 14 are connected to the bracket plate 17 which is mounted on a cross member 18, the cross member extending for the full width of the machine. In order to adjust the length of the cross member 18, it is made in two halves with the central ends connected by the turn buckles 19 providing adjustment for the length of the cross member.
The tie rod 15 is for the purpose of supporting the cross member 18 at the proper elevation and includes the turn buckle 20 so as to adjust the length and hence the elevation of the cross member. The ends of the tie rod 15 are connected to the same brackets 16 and 17 as the tie rods 13 and 14.
The method of mounting the cross member is the same at each of its ends, as is the structure mounted on the ends of the cross member. Accordingly only one end is shown in the drawings and will be described in detail.
Depending from the front and rear sides of the cross member are brackets 23 on which a side plate 24 is bolted. Side plate 24 has a bottom edge 25 disposed slightly above ground level and a slot 26 extending from the rear edge of the plate forward to approximately the center thereof. The width of slot 26 is greater than the diameter of the dowel bar 26', which is shown inserted into the freshly laid slab of concrete. The front edge 27 of the plate 24 is curved outwardly to afford a slight clearance with the preformed slab which extends rearwardly from the paver. The top 28 of the plate 24 extends somewhat above the top of the slab. As shown in FIG. 2, plate 24 is adjustable from sloping slightly inwardly toward the top to a vertical position to conform to the top edges of the concrete slab.
The dowel inserter consists of the fixture 31 which is open at the top so that a dowel can be placed and fitted within it in alignment with the slot 26 in the plate 24. The fixture is trough shaped with its long section at right angles to the plate 24 and the side of the slab which the plate 24 abuts. The outer end of the fixture 31 is supported by a vertical plate or bracket 32 which is supported by the tie rods 33, 34 and 35. The inner ends of rods 33 and 34 are secured to brackets 23, while the middle rod 25 is secured to a plate 36 on the end of the cross member 18. Also mounted on bracket 32 is the cylinder 37 which may be pneumatic or hydraulic and which is aligned with the open end of the fixture 31 so that the piston mounted in the cylinder has a stroke that extends into the fixture and drives the dowel through the slot 26 and embeds it in the side of the concrete slab.
The stroke of the piston causes a substantial portion of the length of the dowel bar to be inserted into the slab. Upon retraction of the cylinder, a subsequent bar is placed in the fixture 31 and is in turn inserted in the slab. The interval of time between the strokes of the piston is controlled by the operator so that the dowels are spaced the proper distance apart.
Instead of manually placing the dowels in the fixture 31, they may be mechanically fed from a magazine in which they are verically stacked and dropped one at a time.
Another feature of the invention is the provision of the surface plate 39 that extends from the outer edge of the slab a short distance inwardly. As shown in FIG. 2, this plate is about as wide as the length of the side plate 24. Plate 39 is supported by a number of tie rods; the inner tie rods 40 support the inner portion so it is approximately horizontal, while the tie rods 41 are adjustable to elevate the outer portion 42 so that the outer edge of the outer portion is slightly eleveated with respect to the rest of the plate. Actually the plate 39 may be made in one piece, but with a line of weakness as at 43 so it can be bent to the desired contour.
By providing an extrusion plate 39 the outer portion of which slopes upward to the edge of the slab, the slab may be maintained with an outer top surface that is slightly elevated, the same as it is when it leaves the slipform paver. What the plate 39 does is to keep this portion of the concrete from being elevated due to the displacement of concrete by the dowels. At the same time the side edge of the slab is maintained in the proper contour by the side plate 24 as previously described.
Since similar plates 24 are provided at each end of the cross member 18 in closely abutting relation to the slab, and since the cross member is mounted on the paver by the links that permit it to move sideways, deviation in the direction of the slab from a straight path will cause the attachment to move with the slab deviation in a lateral direction. This prevents the side plates from digging into the slab, the plates being turned on a radius less than the turning radius of the paver and independent of the steering of the paver. At the same time, the side plate adjacent the pneumatic installer cooperates with the surface pan to maintain the proper edge of the slab as the dowels are inserted.
It is possible to simultaneously install dowels on each side of the pavement slab in which case similar inserting mechanism is provided at each end of the cross member. If dowels are inserted in only one edge, the surface plate 39 can be eliminated at the other end of the cross member since the original surface contour is not disturbed.
While the invention has been described in connection with the inserter of dowel bars, it will be understood that the apparatus and method may be used to insert tie bars and other embedded items serving a similar purpose. | An attachment to a slipform paver is provided which has side plates and surface plates engaging the sides and top surface respectively of a freshly formed slab of concrete, the slide plates being movable laterally to conform to deviations in the direction of the path of the concrete slab and the surface plate inclining upwardly toward the slab edge to maintain the slab contour during insertion of the dowel bars through the side plate into the side edge of the slab. | 4 |
FIELD OF THE INVENTION
This invention relates to polymer blends and, more particularly, to a blend of thermoplastic polymers which form a single phase solid solution of excellent optical clarity and good flexural properties.
BACKGROUND OF THE INVENTION
Thermoplastic polymers useful for injection molding and extrusion to form molded articles and films often are deficient in one or more properties. Efforts to modify the properties of a polymer that is otherwise suitable, for example, by blending it with another polymer usually produce an opaque or cloudy blend which is not acceptable when the molded article or film must be clear and transparent. For example, U.S. Pat. No. 4,141,927 to White et al. discloses blends of polyetherimides and of polyesters based primarily on terephthalic acid and isophthalic acid. The patent discloses blends which formed multiple phase solid state solutions in the composition range from about 25 to 90 weight percent polyester. Such compositions are understood to be opaque and cloudy. Blends of polyarylates with polyetherimide are disclosed in the U.S. Pat. No. 4,250,279 to Robeson et al., and U.S. Pat. No. 4,908,419 to Holub et al. Three components blends of polyetherimide, polyester and a third polymer are also disclosed in U.S. Pat. No. 4,687,819 to Quinn et al. and U.S. Pat. No. 4,908,418 to Holub. None of these patents suggests a polymer composition having the combination of desired flexural properties, clarity and transparency.
There is a continuing need for thermoplastic polymer compositions that have high flexural moduli, high flexural strength and high heat deflection temperatures and that can be injection molded or extruded to form articles of excellent clarity and transparency.
BRIEF SUMMARY OF THE INVENTION
The composition of the invention is a visually clear blend of thermoplastic polymers comprising (A) a polyetherimide which is described in more detail hereinafter and (B) a polyester of a dicarboxylic acid component comprising 2,6-naphthalene dicarboxylic acid and a glycol component comprising at least one aliphatic or cycloaliphatic glycol selected from the group consisting of ethylene glycol, 1,3-trimethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, neopentyl glycol, 1,4-cyclohexanedimethanol and diethylene glycol.
The invention also includes molded articles and films formed of the novel polymer blend. In addition, the invention includes a method for improving the physical properties of a polymer composition comprising a polyester of 2,6-naphthalene dicarboxylic acid that comprises melt blending or solution blending with the polyester a polyetherimide of the type described herein to form a single phase solid solution which is clear and transparent and of higher flexural modulus than the polyester.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole FIGURE of the drawings is a plot of polymer compositional ranges for certain clear and cloudy polymer blends.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term “polyester” means a polyester of a single dicarboxylic acid and a single glycol or a co-polyester of one or more dicarboxylic acids and one or more glycols. The term “dicarboxylic acid component” means the acid or mixture of acids (or their equivalent esters, anhydrides or halides) which react with a glycol or glycols to form a polyester. Similarly, the term “glycol component” means the glycol or glycols which react with such acid or acids (or their equivalent esters, anhydrides or halides) to form a polyester.
The novel polyetherimide/polyester blends of the invention comprise about 1% to 99% of a polyetherimide of the formula:
where n represents a whole number in excess of 1, for example 10 to 10,000 or more. The radical —O—R—O— is in the 3- or 4- and 3-′ or 4′-positions.
The radical —R— is a member of the class consisting of:
where m is 0 or 1 and Q is
and x is a whole number from 1 to 5, inclusive.
The radical —R′— is a divalent organic radical selected from the class consisting
(1) aromatic hydrocarbon radicals having from 6 to 20 carbon atoms and halogenated derivatives thereof;
(2) alkylene radicals and cycloalkylene radicals having from 2 to 20 carbon atoms; and
(3) radicals of the formula:
where R″ is:
and y is a whole number from 1 to 5, inclusive.
Such polyetherimides can be formed, for example, by the reaction of an aromatic bis(ether anhydride) of the formula:
with a diamino compound of the formula:
H 2 N—R′—NH 2
Included among the methods of making the polyetherimide are those disclosed in U.S. Pat. Nos. 3,847,867; 3,847,869; 3,850,885; 3,852,242; 3,855,178; 3,887,588; 4,017,511; and 4,024,110. These disclosures are incorporated herein by reference.
The novel polyester/polyetherimide blends of the invention also comprise about 99% to 1% of a polyester of 2,6-naphthalenedicarboxylic acid and of one or a mixture of two or more of the following aliphatic and cycloaliphatic glycols:
ethylene glycol
1,3-trimethylene glycol
1,4-butanediol
1,5-pentanediol
1,6-hexanediol
1,7-heptanediol
neopentyl glycol
1,4-cyclohexanedimethanol (cis and trans isomers and mixtures thereof)
diethylene glycol
In addition, the polyester or copolyester may be modified by other acids or a mixture of acids including, but not limited to:
terephthalic acid
isophthalic acid
phthalic acid
4,4′-stilbenedicarboxylic acid
oxalic acid
malonic acid
succinic acid
glutaric acid
adipic acid
pimelic acid
suberic acid
azelaic acid
sebacic acid
1,12-dodecanedioic acid
dimethylmalonic acid
cis-1,4-cyclohexanedicarboxylic acid
trans-1,4-cyclohexanedicarboxylic acid
The glycols or mixture of glycols may also be modified by other glycols or a mixture of glycols including, but not limited to:
1,8-octanediol
1,9-nonanediol
1,10-decanediol
1,12-dodecanediol
2,2,4,4-tetramethyl-1,3-cyclobutanediol
The amount of modifying acid or glycol (preferably less than 10 mole percent) which may be incorporated in the polyester while still achieving a clear, single phase blend depends on the particular acids and glycols which are used. Although it is not intended for this invention to be limited by any particular theory, the polyester and copolyester compositions which will produce single phase, clear materials can generally be determined by the method of Coleman, et al. [M. M. Coleman, C. J. Serman, D. E. Bhagwagar, P. C. Painter, Polymer, 31, 1187 (1990).] for prediction of polymer-polymer miscibility. Polyesters of 1,6-naphthalene dicarboxylic acid having solubility parameters between about 10.85 (cal·cm −3 ) 0.5 and about 15.65 (cal·cm −3 ) 0.5 as calculated by the method of Coleman et al. in general form single phase, clear blends.
Polyetherimides of the invention which are preferred are those in which:
R′ is an aromatic hydrocarbon radical having from 6 to 10 carbon atoms, or an alkylene or cycloalkylene radical having from 2 to 10 carbon atoms; or where
m, x and y are as defined above.
Polyetherimides of the invention which are even more preferred are those in which:
Polyetherimides of the invention which are even more preferred are those in which
Preferred blends of polyetherimides and polyesters of the invention are those in which the glycol component is ethylene glycol or 1,4-cyclohexanedimethanol or a mixture of ethylene glycol and 1,4-cyclohexanedimethanol.
In another aspect of the invention, a blend wherein the dicarboxylic acid component of said polyester comprises 2,6-naphthalene dicarboxylic and terephthalic acid and the glycol component of said polyester comprises ethylene glycol and 1,4-cyclohexanedimethanol is preferred.
In yet another aspect of the invention, a blend wherein said polyester has an acid component which comprises 100 to 10 mole percent 2,6-naphthalenedicarboxylic acid and 0 to 90 mole percent of terephthalic acid, isophthalic acid, or a mixture of terephthalic and isophthalic acid is preferred.
In yet another aspect of the invention, a blend wherein said polyester has an acid component which comprises 50 to 10 mole percent 2,6-naphthalenedicarboxylic acid and 50 to 90 mole percent terephthalic acid, or a mixture of terephthalic acid and isophthalic acid is preferred.
In yet another aspect of the invention, a blend wherein the dicarboxylic acid component of said polyester consists essentially of 2,6-naphthalenedicarboxylic acid and terephthalic acid and the glycol component of said polyester consists essentially of ethylene glycol and 1,4-cyclohexanedimethanol, and wherein the amount of 2,6-dinaphthalene dicarboxylic acid in said dicarboxylic acid component is at least about 32 mole percent and the amount of 1,4-cyclohexanedimethanol in said glycol component is no more than about 65 mole percent, is preferred.
A most preferred embodiment of the composition of the invention comprises (A) about 10 to 50 weight percent of a polyetherimide and (B) about 90 to 50 weight percent of the polyester. Preferred polyesters are polyesters of 2,6-naphthalenedicarboxylic acid and ethylene glycol or copolyesters of 2,6-naphthalenedicarboxylic acid and ethylene glycol modified with terephthalic and/or isophthalic acid and with butanediol and/or 1,4-cyclohexanedimethanol.
The blends of the invention can be compounded in the melt, for example, by using a single screw or twin screw extruder. They may also be prepared by solution blending. Additional colorants, lubricants, release agents, impact modifiers, and the like can also be incorporated into the formulation during melt blending or solution blending.
The examples which follow further illustrate compositions and the method of the invention and provide comparisons with other polymer blends.
This invention can be further illustrated by the following examples of preferred embodiments thereof, although it will be understood that these examples are included merely for purposes of illustration and are not intended to limit the scope of the invention unless otherwise specifically indicated. The starting materials are commercially available unless otherwise indicated.
EXAMPLES
Example 1
Polyesters and copolyester of Table 1 below were blended in equal parts by weight with a polyetherimide (PEI). The polyesters were prepared by reacting the acids, 2,6-naphthalenedicarboxylic acid (NA) or terephthalic acid (TA), or mixtures thereof, with ethylene glycol (EG) or 1,4-cyclohexanedimethanol (CG), or mixtures thereof. The polyetherimide was Ultem 1000™ polyetherimide, which is commercially available from General Electric Company. This polyetherimide is essentially the reaction product of 2,2-bis[4(3,4-dicarboxyphenoxy)phenyl] propane dianhydride:
and meta-phenylenediamine.
The 50/50 by weight polyester/polyetherimide blends were prepared in a solution of 75/25 by volume methylene chloride/hexafluoroisopropanol and precipitated by dropping into methanol, with stirring. The precipitate was isolated by decanting and dried under vacuum at ≈60° C. for three days. The blends were tested by differential scanning calorimetry in order to determine the glass transition temperature (T g ), crystallization temperature (T c ), and melting temperature (T m ). Particular note was taken as to whether each blend exhibited one or two glass transition temperatures, intermediate between the glass transition temperatures of the polyester and polyetherimide. The blends were also melt pressed into thin films at ≈280° C. The films were inspected visually for clarity.
The results of differential scanning calorimetry and film clarity observations shown in Table 1 demonstrate the particular copolyester composition ranges over which a solid single phase blend with good clarity may be obtained. All of the pressed films exhibited a light brown color similar to that of the pure polyetherimide. Based on the observations of T g s and film clarity, a map of the composition range over which a visually clear blend is obtained is illustrated in the drawings.
TABLE 1
Mole % in Acid
Mole % in Glycol
Number
Film
Sample
NA
TA
EG
CG
of Tgs
Clarity
A1
0
100
100
0
Two
Cloudy
B1
0
100
42
58
Two
Cloudy
C1
0
100
28
72
Two
Cloudy
D1
0
100
0
100
Two
Cloudy
E1
100
0
100
0
One
Clear
F1
68
32
0
100
One
nd
G1
100
0
35
65
One
Clear
H1
66
34
35
65
One
Clear
I1
66
34
68
32
One
Clear
J1
32
68
36
64
One
Clear
K1
34
66
67
33
One
Clear
L1
5
95
0
100
Two
Cloudy
M1
10
90
0
100
Two
Cloudy
N1
20
80
0
100
Two
Cloudy
O1
51
49
100
0
One
Clear
P1
16
84
100
0
One
Clear
Q1
16
84
29
71
Two
Cloudy
nd: not determined
The blends of polyetherimide with polyesters of terephthalic acid and ethylene glycol or 1,4-cyclohexanedimethanol, or mixtures thereof, formed two phase solid solutions and thus resulted in cloudy films (i.e. samples A1, B1, C1, D1), in accordance with the teachings of White et al. in U.S. Pat. No. 4,141,927. The blends with polyesters of terephthalic acid with ethylene glycol or 1,4-cyclohexanedimethanol, or mixtures thereof, which were modified by 20 mole percent or less of 2,6-naphthalenedicarboxylic acid (i.e. samples L1, M1, N1) also resulted in two phase solid solutions and cloudy films. In contrast, the blends of polyesters based on 2,6-naphthalenedicarboxylic acid with ethylene glycol and 1,4-cyclohexanedimethanol, or mixtures thereof, (i.e. samples E1, G1) surprisingly formed single phase solid solutions and clear films. The results also demonstrate that visually clear blends may still be obtained if a polyester based on 2,6-naphthalenedicarboxylic acid with ethylene glycol and 1,4-cyclohexanedimethanol, or a mixture thereof, is modified with certain amounts of terephthalic acid. This is demonstrated by samples H1, I1, J1, K1, O1 and P1. Furthermore, the results demonstrate that the amount of modifying terephthalic acid which may be used while still obtaining a visually clear blend is dependent on the particular glycol or mixture of glycols which is used. For example, the polyesters of both samples P1 and Q1 are composed of 16% 2,6-naphthalendicarboxylic acid and 84% terephthalic acid. However, sample P1 is a clear blend while sample Q1 is a cloudy blend. The difference is due to the particular glycols which are used in these samples, namely, 100 mole percent ethylene glycol in the clear blend P1 and 100 mole percent 1,4-cyclohexanedimethanol in the cloudy blend Q1.
Example 2
Blends of polyesters and the same polyetherimide described in Example 1 were compounded in the melt and injection molded. The polyesters compounded were as follows: poly(ethylene 2,6-naphthalenedicarboxylate); poly(ethylene terephthalate); poly(ethylene-cocyclohexane-1,4-dimethylene terephthalate) with 42 mole % ethylene and 58 mole % cyclohexane-1,4-dimethylene in the glycol; and poly(ethylene-co-cyclohexane-1,4-dimethylene terephthalate) with 28 mole % ethylene and 72 mole % cyclohexane-1,4-dimethylene in the glycol.
The polyester compositions along with the blend compositions and observed clarity are reported in Table 2. All of the blends exhibited a light brown color similar to that of the pure polyetherimide.
The diffuse transmittance of injection molded articles formed from several of the blends, which is a measure of the visual clarity of the articles, was determined by the procedure of ASTM D1003. The results of these measurements are included in Table 2.
TABLE 2
Polyester Composition
Mole % in
Mole % in
Weight %
% Diffuse
Acid
Glycol
PEI
Visual
Transmit-
Sample
NA
TA
EG
CG
in Blend
Clarity
tance
A2
0
100
100
0
0
Clear
B2
″
″
″
″
10
Cloudy
C2
″
″
″
″
20
Opaque
D2
″
″
″
″
30
Opaque
19
E2
0
100
42
58
0
Clear
80
F2
″
″
″
″
10
Opaque
G2
″
″
″
″
20
Opaque
13
H2
″
″
″
″
30
Cloudy
17
I2
0
100
28
72
0
Clear
81
J2
″
″
″
″
10
Opaque
K2
″
″
″
″
20
Opaque
11
L2
″
″
″
″
30
Opaque
5
M2
100
0
100
0
0
Clear
N2
″
″
″
″
10
Clear
51
O2
″
″
″
″
20
Clear
51
P2
″
″
″
″
30
Clear
46
Samples B2, C2, D2, F2, G2, H2, J2, K2, L2 were opaque or cloudy because they formed two phase solid solutions, as taught by White and Matthews in U.S. Pat. No. 4,141,927. However, samples N2, 02, and P2 (which are compositions of this invention) were surprisingly clear. In addition, the molded articles formed from these compositions exhibited a high percentage of diffuse light transmittance.
Example 3
Blends of poly(ethylene 2,6-naphthalenedicarboxylate) with the same polyetherimide described in Example 1 were prepared by first compounding on a co-rotating twin screw extruder and the injection molding into parts for mechanical testing. All of the blends exhibited excellent transparency and a light brown color similar to that of the pure polyetherimide. The blend compositions, processing conditions, and mechanical properties are given in Table 3. The diffuse transmittance of the articles formed from blends of the invention, measured according to ASTM D1003, are also included in Table 3.
TABLE 3
Sample
A3
B3
C3
D3
PEI Weight %
0
10
20
40
Compounding Temp. (° C.)
295
295
295
295
Molding Temp. (° C.)
300
305
305
305
% Diffuse Transmittance***
51
41
42
Appearance
Clear
Clear
Clear
Clear
Izod Impact Strength (ft · lb/
in)****
Notched 23° C.
0.6
0.6
0.6
Notched −40° C.
0.7
0.6
0.5
0.5
Unnotched 23° C.
20.1
21.9
17.0
26.4
Unnotched −40° C.
10.2
8.5
11.8
14.5
Flexural Strength (psi)*
14410
15600
16510
18520
Flexural Modulus (kpsi)*
347
370
377
411
Heat Deflection Temperature
(° C.)**
at 66 psi
109
115
125
141
at 264 psi
88
98
110
125
*measured according tc ASTM D790
**measured according to ASTM D648
***measured according to ASTM D1003
****measured according to ASTM D256
Some of the advantages of these blends are demonstrated by these results. The flexural strength, flexural modulus, and heat deflection temperatures increase with the addition of the polyetherimide to the polyester. In addition, the blends can be processed at a much lower temperature than that which is required when processing the pure polyetherimide, and the molded articles exhibit high diffusive transmittance. Because of these properties of the novel polymeric blends, they can be molded at reasonably low temperatures to form articles which are resistant to deformation at elevated temperatures. For example, molded articles of the novel polymeric blends can be used as containers that can withstand heat such as cooking vessels or as polymeric. parts positioned near motors in golf carts, lawnmowers and the like. In all of these uses the optical clarity and the resistance to thermal deformation are valuable properties of the novel polymer blends of the invention.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | This invention relates to a visually clear blend of thermoplastic polymers comprising a polyetherimide and a polyester of (a) an acid component comprising 2,6-naphthalene dicarboxylic acid and (b) a glycol component comprising at least one glycol selected from the group consisting of ethylene glycol, 1,3-trimethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, neopentyl glycol, 1,4-cyclohexanedimethanol and diethylene glycol. | 2 |
TECHNICAL FIELD
[0001] Embodiments described herein relate generally to a nonwoven textile product, and more particularly to a nonwoven textile product having one or more reduced density or thinned regions and one or more full density regions.
BACKGROUND
[0002] Textile products have been in use for thousands of years and come in many forms. One way to classify textile products is by whether they are woven products (such as cotton products) or non-woven products (such as felt products). Generally, both have many applications and are widely used. Generally, “woven” products, as used herein, includes knitted textile products
[0003] One example of a nonwoven textile is felt, which has been used to make goods for centuries. Felt may be formed by placing randomly aligned wool and/or synthetic fibers under pressure and adding moisture, and optionally chemicals. With sufficient time, heat and water, the fibers bond to one another to form a felt cloth. This process may be known as “wet felting.”
[0004] As another option, fibers may be formed into a felt through “needle felting.” In needle felting, a specialized notched needle is pushed repeatedly in and out of a bundle or group fibers. Notches along the shaft of the needle may grab fibers in a top layer of the bundle and push them downward into the bundle, tangling these grabbed fibers with others. The needle notches face toward the felt bundle, such that the grabbed felt is released when the needle withdraws. As the needle motion continues, more and more fibers are tangled and bonded together, again creating a felt cloth.
[0005] Although two different ways to create felt products have been described, it should be appreciated that variants and/or other methods may be employed. Regardless of the production method, however, felts share certain characteristics. For example, felts are often used as an acoustic damper due to their relatively dense natures. Likewise, felt tends to pull apart readily, due to its nonwoven nature, if the integrity of the bonds between the threads is compromised. This tendency to break apart when subjected to certain stresses and/or chemical may limit the usefulness of felt for certain applications.
SUMMARY
[0006] Embodiments described herein may take the form of a textile fabric, including: a first region defined by a first plurality of textile fibers; a second region adjacent the first area and being formed from a second plurality of textile fibers and a hot melt material adjacent the second plurality of textile fibers; wherein the first region is free of hot melt material.
[0007] Other embodiments may take the form of a method for fabricating a textile product, including the operations of: applying heat to a textile having associated hot melt fibers, thereby melting the hot melt fibers; modifying a mechanical property of a portion of the textile by introducing a solvent to the textile; and stopping an action of the solvent on the textile when the mechanical property reaches a target.
[0008] Additional embodiments and configurations will be apparent upon reading this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 depicts a magnified view of a portion of a fabric incorporating hot melt fiber.
[0010] FIG. 2 depicts a sheet of textile material.
[0011] FIG. 3A depicts a first example of the fiber textile sheet of FIG. 2 after selectively heating portions of the sheet.
[0012] FIG. 3B depicts a second example of the fiber textile sheet of FIG. 2 after selectively heating portions of the sheet.
[0013] FIG. 4 depicts the sheet of FIG. 3 after application of a solvent.
[0014] FIG. 5 is a sample method of manufacturing a textile product having thinned regions.
[0015] FIG. 6 shows a sample consumer product formed from a textile product having thinned regions.
[0016] FIG. 7 shows a second sample consumer product formed from a textile product having thinned regions.
DETAILED DESCRIPTION
[0017] Embodiments described herein may take the form of a textile product having one or more selectively thinned or weakened regions. In certain embodiments, the textile may be a woven fabric, such as a cotton, polyester or the like. In other embodiments, the textile may be a nonwoven fabric, such as a felt.
[0018] Generally, some or all strands of material forming the textile may be interspersed with, at least partially encircled by, interwoven with, or otherwise associated with a hot melt fiber. This hot melt fiber may be incorporated into the textile at specific areas or volumes or may be incorporated into the entirety of the textile. Likewise, the density of the hot melt material with respect to the fibers may vary (e.g., more or fewer hot melt fibers per area or volume of textile may be employed in certain regions), as may the thickness of the hot melt fibers, the number of hot melt fibers, the ratio of hot melt fibers to textile fibers, and so on. It should be appreciated that such variations may occur only in certain portions, segments or areas of the textile. Likewise, multiple variations may occur in multiple portions.
[0019] Generally, references to an “area” herein are intended to also encompass three-dimensional areas, e.g., volumes. Likewise, the term “region” encompasses both an area and a volume.
[0020] As described in more detail below, the hot melt fibers may be melted onto or into the textile, at least in certain areas or volumes, through the application of heat. Sufficient heat may cause the hot melt fibers to melt and flow into a protective matrix, thereby at least partially coating and/or bonding textile fibers positioned near or adjacent the protective matrix. Generally, the melting point of the hot melt fiber is lower than a melting point of the textile fabric, and often below a temperature at which the fabric may scorch or burn.
[0021] Typically, the hot melt material is chosen to be impervious to one or more solvents that may dissolve or otherwise weaken the textile fabric. Thus, when a textile product is exposed to a solvent after the protective matrix is formed by the hot melt, the matrix may prevent the solvent from affecting protected portions of the textile fabric. Meanwhile, unprotected portions of the textile fabric may be weakened, dissolved, removed, thinned, decreased in density, or the like by the solvent. By selectively applying and/or melting the hot melt fibers, certain areas or volumes may be protected from the action of the solvent while others are exposed. In this fashion, various patterns may be created in a textile for a variety of effects, many of which are discussed herein.
[0022] FIG. 1 shows a sample bundle of textile fibers 100 wrapped about with a hot melt fiber 105 . The hot melt fiber 105 is shown generally encircling the bundle of fibers 100 , although in alternative embodiments the relationship between the hot melt fiber and bundle of textile fibers may be different. For example, the hot melt fibers may overlay the textile fibers, such that the hot melt fibers and the textile fibers essentially occupy different adjacent planes of a textile object. As another alternative, the hot melt fibers 105 may be interspersed or interwoven with the textile fibers 100 throughout a textile product. Both alternatives will be discussed in more detail, below. Further, it should be appreciated that the hot melt fiber may underlay some textile fibers and still generally encircle the fibers. For example, and as shown in FIG. 1 , the hot melt fiber 105 (the dark fiber) is wrapped around a bundle of fibers 100 but passes beneath some of them, at least on some windings of the hot melt fiber 105 .
[0023] Continuing with the description of FIG. 1 , the diameter of the hot melt fiber 105 may be substantially less than the diameter of the bundle of textile fibers 100 or, in some embodiments, less than the diameter of any individual textile fiber. The relative diameters of the hot melt fiber and the textile fibers may influence the dispersion of the hot melt fibers within the textile. For example, thinner hot melt fibers may require the use of more fibers to cover or impregnate a given area or volume of textile. Likewise, thicker hot melt fibers may allow fewer fibers to be used in a given area or volume.
[0024] It should also be appreciated that the bundle of fibers 100 shown in FIG. 1 is formed from woven fibers. However, nonwoven fibers may also be use in some embodiments, with hot melt fibers 105 snaking through the nonwoven fibers, overlaying the nonwoven fibers, or encircling such fibers.
[0025] FIG. 2 illustrates a sample textile sheet 200 that may be formed into a cover for a tablet computing device (not shown) in accordance with the discussion and methods herein. The textile sheet 200 may be formed from textile fibers 100 (woven or nonwoven) and hot melt fibers 105 , as discussed above. Generally, the textile sheet 200 is patterned into a series of hot melt areas/volumes 205 and non-melt areas/volumes 210 . The hot melt areas 205 may have hot melt fibers 105 present therein, while the non-melt areas 210 may lack hot melt fibers.
[0026] For example, FIGS. 3A and 3B depict alternative examples of the textile sheet 200 with hot melt fibers 105 in the hot melt areas 205 . In the example of FIG. 3A , the hot melt fibers 105 are interspersed throughout the textile sheet 200 in each hot melt area 200 . That is, the hot melt fibers may run randomly or semi-randomly throughout the hot melt areas of the textile sheet. As can be seen in FIG. 3A , there are generally no (or very few, or only incidental) hot melt fibers in the non-melt regions 210 . In alternative embodiments, the hot melt fibers 105 may extend throughout or into the non-melt regions 210 . In such embodiments, heat may not be applied to the non-melt regions, thereby preventing the hot melt fibers from melting in that area and leaving the textile fibers exposed.
[0027] FIG. 3B illustrates an alternative textile fiber sheet 200 having hot melt fiber 105 associated therewith. In this embodiment, the hot melt fiber 105 may impregnate or wrap only a portion of the textile fibers 100 to define a hot melt area 205 , specifically those on an upper surface 300 of the textile sheet 200 . As an alternative, the hot melt fibers 105 may be deposited on an upper surface 300 of the textile sheet in specific patterns 305 or shapes to form the hot melt areas 205 and non-melt areas 210 .
[0028] The discussion now turns to FIG. 4 . FIG. 4 depicts the textile sheet 200 after application of heat and a solvent. As discussed below with respect to FIG. 6 , heat mat be applied at least to the upper surface 300 of the textile sheet 200 (or whichever surface is impregnated with, wrapped by, overlaid by, or otherwise contains the hot melt fibers 105 ). In alternative embodiments, the entirety of the textile sheet 200 may be heated.
[0029] The heat generally causes the hot melt fibers 105 to melt, wicking across the textile fibers 100 . The hot melt fibers 105 may spread across an entirety of adjacent textile fibers 100 or may partially envelop or shield the textile fibers. As one other example, the hot melt fibers may coat the textile fibers at intersections between adjacent textile fibers and taper out from such intersections along the lengths of the fibers. This may have the added effect of strengthening such intersections, and may be particularly useful in the fabric is a nonwoven material, such as felt, since the bond between adjacent nonwoven fibers may be strengthened by the hot melt. Further, it should be appreciated that the hot melt fibers, when melted onto the textile fibers, need not form a contiguous or continuous surface. The melting of the hot melt fibers 105 may form hot melt areas or volumes 405 where the textile fabric is covered or impregnated with the hot melt and unprotected areas or volumes 400 that lack any hot melt.
[0030] A solvent may be applied to the textile sheet 200 after the hot melt fibers 105 are melted. The solvent may be applied as a bath or may be forced through the textile by pressure and/or gravity. For example, the textile sheet 200 may be pressure washed with a solvent. Alternatively, the textile sheet may be dipped into a solvent or placed into a solvent bath. In many embodiments, the solvent may be forced or fed through the textile sheet 200 from the upper surface 300 (e.g., the surface associated with the now-melted hot melt fibers 105 ).
[0031] The solvent may dissolve, partially dissolve, or weaken the textile fibers 100 . However, the hot melt fibers 105 are typically impervious, or at least resistant, to the solvent. Thus, in regions where the hot melt fibers 105 have been melted, the hot melt may protect the textile fibers 100 from the action of the solvent. In this fashion, the textile sheet may be thinned in regions 400 that lack any hot melt materials, while the hot melt regions 405 are unaffected by the solvent. After the solvent has sufficiently thinned or weakened the textile fibers in the unprotected regions 400 , the textile sheet 200 may be washed or otherwise cleaned of the solvent.
[0032] Selectively thinning, weakening or perforating the textile sheet 200 in specific areas 400 (generally corresponding to the non-melt areas 210 ) to form a desired pattern may provide certain benefits. For example, the unprotected areas 400 may be altered to be acoustically transmissive or transparent, or near-transparent, even though the textile itself generally may be an acoustic muffle. Likewise, the unprotected areas 400 may be thinned or changed sufficiently by the solvent to be light-transmissive, at least partially. For example, the unprotected areas may appear translucent when backlighted or may emit a relatively diffuse light, or may be at least partially see-through when backlit. As yet another example, the textile sheet may bend more easily in the unprotected areas 400 after operation of the solvent while the hot melt areas 405 may retain their original stiffness. Thus, by selectively masking portions of the textile sheet with hot melt 105 , the textile sheet 200 may be configured to provide certain functionality that is otherwise lacking in a standard textile sheet 200 .
[0033] FIG. 5 shows one example of a cover 500 for an electronic device that may be formed from a textile sheet treated as discussed herein. Generally, the cover 500 may be a finished product corresponding to the textile sheet 200 shown in FIGS. 2 and 4 . The cover may bend at the unprotected areas 400 as they have been softened by the action of the solvent. The hot melt areas 405 may be relatively stiff when compared to the unprotected areas. Thus, the cover 500 may be configured to selectively bend and/or be reshaped.
[0034] FIG. 6 is a flowchart setting forth general operations in accordance with certain embodiments herein. In operation 600 , hot melt fibers 105 are added to a textile sheet 200 to form a particular pattern or patterns. The hot melt fibers may be added or introduced in any fashion described herein.
[0035] In operation 605 , heat is applied to the textile sheet 200 . The heat may be uniformly applied, concentrated or applied only in certain areas (like those areas incorporating hot melt fibers 105 ), applied to fewer than all sides or edges, or the like, and so on. The heat is typically sufficient to flow the hot melt fibers 105 . The maximum heat may be less than a burning or scorching temperature of the textile sheet, or the heat may be applied for a time sufficient to flow the hot melt fibers but not to damage the textile fibers. In embodiments where the hot melt fibers are generally interspersed or placed throughout the entirety of the textile fabric, heat may be selectively applied only to those regions in which the hot melt fibers are to be melted.
[0036] Next, in operation 610 , solvent is applied to the textile sheet 200 . The solvent may be poured or pushed through the textile sheet 200 in some embodiments, while in others the textile sheet may be placed or laid face-down in a solvent bath. The solvent generally weakens, things, and/or reduces the density of the textile fibers, which are vulnerable to the action of the solvent (e.g., are solvable). After the solvent thins or weakens the textile fibers 105 that are not protected by hot melt, the solvent may be removed or neutralized in operation 615 .
[0037] In operation 620 , the hot melt 105 may optionally be removed from the textile sheet. Removal of the hot melt 105 may be practical, for example, in embodiments where the hot melt coats a surface of the textile sheet 200 rather than being incorporated into the sheet. Removal may also be practical in embodiments where only a portion of the textile sheet 200 is impregnated with hot melt. This operation is optional and may not be performed in many embodiments. Likewise, hot melt may be removed in certain areas only and left in other areas of a textile sheet 200 . Further, it should be appreciated that some embodiments may perform this operation before applying solvent in order to define features within a hot melt region 405 that may be affected by the solvent. As one example, an entire surface of a textile sheet 200 may be protected by hot melt 105 and the hot melt may be specifically removed from certain regions to permit the solvent to operate on the textile fibers 105 .
[0038] In operation 625 , it may be determined if another solvent operation (e.g., a bath, a stream or the like) is to be applied to the textile sheet 200 . Multiple solvent applications may be made when different features are to be formed in the textile sheet, as one example. Such features may be of different thicknesses or strengths, as another example, and thus may be exposed to solvent for differing periods of time. As yet another option, or in addition to the foregoing, multiple different types of solvent may be employed in multiple applications of solvent to the textile.
[0039] If another solvent operation is required or desired, the method may return to operation 610 . Otherwise, operation 630 is accessed and the textile may be formed into a final configuration. The textile maybe cut or shaped, for example. In many embodiments, operation 630 may be omitted.
[0040] It should be appreciated that a variety of items may be made from a textile fabric 200 selectively treated with a hot melt material 105 . For example, a variety of covers or cases may be formed. FIG. 7 shows one example of an exterior case 700 for a tablet computing device 705 that may be formed in accordance with the present disclosure. The case 700 may define one or more acoustic outlets 710 and/or acoustic inlets 715 . These acoustic outlets/inlets may be unprotected regions 400 that were exposed to solvent, thereby thinning the textile fabric sufficiently to permit sound to pass therethrough without substantial impedance or distortion. An acoustic outlet 710 may cover a speaker of the tablet computing device 705 while an acoustic inlet 715 may cover a microphone, for example. It should be appreciated that the look of these acoustic outlets 710 and inlets 715 may be identical or substantially similar to the rest of the case 700 , including any portions 720 that were protected from the action of the solvent by hot melt 105 . Thus, although the acoustic properties of the outlets 710 and inlets 715 may be altered, the visual appearance, and optionally the feel, of these elements may match the rest of the case. The dashed lines signify that these elements, while transmissive, may not form an aperture permitting objects to pass through the textile fabric.
[0041] The case 700 may also define a light-transmissive section 725 . The light-transmissive section may emit light when backlit. For example, when a status indicator is activated, the outputted light may be visible through the light-transmissive section. In some embodiments the light may be visible even though the status indicator is not.
[0042] Through multiple solvent applications, or through the use of varying concentrations of solvents selectively applied simultaneously, one or more apertures 730 passing through the textile 700 may be formed in the textile material.
[0043] It should be appreciated that any number of items may be formed from a textile fabric that is selectively altered in the fashions described herein. For example, textile seat covers for automobiles may be so manufactured. Likewise, grilles or covers for audio elements, such as speakers, may be formed. As still another example, bands or bracelets may be fabricated in this fashion. Covers for other electronic devices, such as telephones and notebook computers, may also be created. Various other products will become apparent to those of ordinary skill in the art upon reading this disclosure in its entirety. Accordingly, the proper scope of protection is set forth in the appended claims. | Embodiments described herein may take the form of a textile fabric, including: a first region defined by a first plurality of textile fibers; a second region adjacent the first region and being formed from a second plurality of textile fibers and a hot melt material adjacent the second plurality of textile fibers; wherein the first region is free of hot melt material. Other embodiments may take the form of a method for fabricating a textile product, including the operations of: applying heat to a textile having associated hot melt fibers, thereby melting the hot melt fibers; modifying a mechanical property of a portion of the textile by introducing a solvent to the textile; and stopping an action of the solvent on the textile when the mechanical property reaches a target. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ceramic composites or composite ceramic bodies which are particularly suitable as implants, such as artificial tooth roots, artificial bones, percutaneous devices, etc. The present invention also relates to a process for the production of said ceramic composites.
2. Description of Related Art
Currently, a wide variety of ceramic materials, such as calcium phosphate hydroxyapatite, alumina, and zirconia ceramic materials have been predominantly utilized as implant materials, especially for artificial tooth roots and bones.
These ceramic materials can be produced, by drying a ceramic slurry which is produced by a wet process. After drying, the dried ceramic slurry is pulverized to make a ceramic powder which ceramic powder is then molded to any desired shape. Molding is carried out by a conventional method, such as pressure molding and casting molding. The molded products are subsequently dried and calcined or sintered. Alternatively, the ceramic materials can be produced from powdered ceramics synthesized in a dry process. The powdered ceramics, without further treatment, are molded in a conventional manner to a predetermined shape, and calcined. The ceramic materials resulting from these processes generally have a dense structure.
On the other hand, ceramic materials with a porous structure are also produced. These porous ceramic material can be produced, by adding a foaming agent to a slurry of powdered ceramics and foaming the mixture, or by mixing powdered ceramics with a thermally decomposable organic substance. After molding of the mixture into a predetermined shape, the molded products are dried and calcined.
For use as implant materials, dense ceramics are suited because they have satisfactory strengths. However, due to less permeability to humor or body fluids such as blood and the like, the dense ceramics suffer from the problem that, when implanted in a patient's body, they do not adequately bond to the surrounding tissue of the implantation site. In other words, the dense ceramics do not provide enough of an inductive effect. This inductive effect, which refers to the formation of new osseous cells around the implant, is essential for attaining a good bond of the implant material to the surrounding tissue.
Insofar as the inductive effect is concerned, porous ceramics provide satisfactory results due to the passage of, humor, such as blood, through pores of the porous ceramics. As a result of this permeation of the humor, new osseous cells are easily produced in the area surrounding the implantation site, i.e., a good inductive effect is induced at the site. However, these ceramics do not have enough strength to be used as an implant material because of the porous structure thereof.
Therefore, an improved ceramic body which shows the advantageous properties of both dense and porous ceramics, namely, high strength and a good inductive effect, respectively, has been sought in this field.
Heretofore, to obtain a ceramic body having the advantageous properties associated with both dense and porous ceramics, various attempts, including the combined use of dense ceramics and porous ceramics, have been made. A typical method for producing a combined ceramic utilizes a bonding between the dense ceramic and the porous ceramic. This bonding has been attained by using different methods. For example these methods includes use of an adhesive, formation of an interlayer between the two ceramic bodies, and coating of a ceramic material or body with another ceramic material.
The ceramic composites produced according to said bonding methods have disadvantages that must to be solved. Since the presence of an adhesive layer or interlayer which has different properties from the ceramics used is essential to the first two methods, the resulting ceramic composites tend to have reduced safety to the human body and a reduced inductive effect. Further, the coating method has a drawback that the resultant coating of the ceramic material on the ceramic body is thin and therefore uses of the ceramics composites are severly restricted to. Furthermore, all of said bonding methods have drawbacks that the bonding strength obtained is not sufficiently high, and the bonding site therefore exhibits a reduced strength.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved ceramic composite comprising of a porous ceramic body and a dense ceramic body, which can be produced in a simple manner, does not have a layer in an interfacial portion of the composite having different properties from the ceramic, and achieves a high bonding strength between said porous body and said dense body.
Another object of the present invention is to provide a process for the production of said ceramic composite, which is simple, can be carried out with high reproducibility and reliability, and without the drawbacks of the prior art processes described above.
According to the present invention, there is provided a ceramic composite which comprises of a porous ceramic body having directly fitted thereon a dense body. The fitting of the dense ceramic body to the porous body is provided by a bore portion of said porous body into which a projecting portion of said dense body having the corresponding shape is inserted, and said bore portion and said projecting portion are then firmly bonded based on difference of shrinkage between said porous body and said dense body at a sintering or calcination temperature.
According to the present invention, there is also provided a process for the production of a ceramic composite comprising bonded bodies of porous ceramic and dense ceramic, which comprises the steps of:
separately producing, by molding powders of starting ceramic material porous and dense ceramic bodies having a predetermined configuration,
inserting at least a portion of said dense ceramic body into a bore portion formed in said porous body, and
simultaneously sintering both said dense and porous bodies at an appropriate sintering or calcining temperature, while maintaining the fitted condition of said bodies, so that a difference of shrinkage between said bodies at the sintering temperature will cause enough compression of said inserted part of said dense body with said bore portion of said porous body to firmly and directly bond said dense body to said porous body.
As can be appreciated from the above description, the ceramic composites of the present invention are produced by a simple process which comprises inserting at least a portion of a dense ceramic body into a bore portion of a porous ceramic body, and simultaneously sintering the resulting fitted article of said dense and porous bodies. During sintering, because the higher shrinkage rate or percentage of shrinkage of the porous body compared to the dense body, the dense body is strongly compressed around the bore portion of said porous body whereby the intended ceramic composites consisting of the porous body having directly and firmly fitted thereon the dense body are produced. The production process of the present invention requires only a few steps, and is very simple compared with the prior art processes.
The ceramic composites of the present invention passes show excellent mechanical strengths. In particular, these ceramic composites have a very high bonding strength at the interfacial area between the dense body and the porous body so that the composites are not destroyed even if a diamond disc cutter is used for cutting purposes. This is because the composites do not have an heterogeneous interlayer bonding said dense body and said porous body to form an integral article instead, according to the present invention, the dense body and the porous body are directly bonded by a tight-fitting bond. In addition to the excellent mechanical strength described above, the ceramic composites of the present invention show other superior properties, such as heat resistance, resistance to thermal cycle, water resistance and compatibility with the human body. Thus, they can be advantageously used as implants, such as artificial tooth roots, artificial bones and percutaneous devices.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a cross-sectional view of the ceramic composite showing a preferred embodiment of the present invention,
FIG. 2a is a front view of the dense ceramic body used in the production of the ceramic composite of FIG. 1,
FIG. 2b is a front view, including a cross-sectional view of the left half portion, of the porous ceramic body used in the production of the ceramic composite of FIG. 1,
FIG. 3 is an electron microphotograph (magnification×30) of the cross-sectional surface of the ceramic composite of FIG. 1 showing the state of the bonding interface of said composite,
FIG. 4 is an electron microphotograph (magnification×2,000) of the cross-sectional surface of the ceramic composite as is FIG. 3, and
FIG. 5 is a cross-sectional view of the ceramic composite showing another preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the practice of the present invention, various ceramic materials can be used as the starting ceramics materials. Usable ceramics include calcium phosphate-series or-based ceramics, hydroxyapatite, alumina, zirconia and other types of ceramic. For use of the resulting ceramics composites as biomaterials, calcium phosphate ceramics are particularly suited since they have good in vivo compatibility.
These ceramics can be obtained in a conventional manner, such as a wet synthesis process or a dry synthesis process, from the selected raw materials. For example, when the wet synthesis process is used, the slurry-like ceramics obtained can be dried and ground to form ceramic powders. When the dry synthesis process is utilized, the obtained ceramic powders are in a dry state and can be utilized in the subsequent production of the dense and porous bodies without additional treatments.
According to the present invention, the thus obtained ceramic powders are molded into a dense ceramic body having a predetermined configuration or shape. Molding of this dense body can be performed, for example, by pressure molding methods using a mold press, a rubber press or other means, or by cast molding methods in which a mixture of the ceramic powders with water and a binder such as organic resins and the like is casted. Also, after completion of molding, the molded products may be calcined at an appropriate temperature before the subsequent insertion step, if desired.
Separately, the ceramic powders obtained in accordance with the above-described methods are molded into a porous ceramic body having a predetermined configuration or shape. For example, the porous ceramic body can be produced by foaming a slurry of the ceramic powders or by mixing the ceramic powders with a thermally decomposable organic substance. The foamed slurry or the mixture is then molded to the predetermined configuration, and calcined. Suitable foaming agents that can be added to the slurry of the ceramic powders include any substances capable of causing formation of foams or cells in said slurry, for example, hydrogen peroxide, egg albumen or the like. Suitable thermally decomposable organic substances include any organic materials capable of being decomposed and volatilized upon calcination, for example, beads of organic resins, organic fibers or the like. Using these foaming agents or organic substances, a foamed slurry of the ceramics powders or a mixture of the ceramics powders with the organic substances is prepared, molded by using a manner such as cast molding, and finally calcined. A porous body of ceramics is thus obtained.
The dense ceramic body and the porous ceramic body may each be constructed from the same ceramics, from homogeneous ceramics or from different ceramics. These bodies are preferably made from the same or homogeneous ceramics. The term "homogeneous" used herein is intended to mean that both ceramic bodies have similar natures and exhibit good compatibility when bonded with each other. When different ceramics are used, the bonding strength of the resulting ceramic composites relies upon only an effect of the tight fitting bond based on the shrinkage of the porous body during sintering. However, when the same ceramic or homogeneous ceramics are used in the production of both of the dense and porous bodies, the increased bonding strength of the ceramic composites relies upon the tight-fitting bond based on shrinkage as well as an effect of the sintering at the bonding interface. Namely, when employing the same ceramic or homogeneous ceramics, an increased bonding strength can be obtained.
According to the production process of the present invention, a bore or cavity is formed in a selected position in the porous ceramic body, and at least a part, preferably a projecting part, of the dense ceramic body is inserted into said bore of the porous ceramic body. The bore of said porous body can be produced by various techniques. For example, the bore can be formed at the same time that said porous body is as molded or, by mechanical fabrication, such as cutting, after production of the porous body. Similarly, the projecting part of said dense body, that is to be inserted into said bore of the porous body, can be produced at the same time with the molding of the dense body or at a selected stage after the molding of the dense body. The projecting part should have a shape corresponding to that of the bore of the porous body so that the projecting part is tightly fitted into said bore.
As previously described, the dense ceramic body is inserted into the bore of the porous ceramics body, and then both bodies are sintered to obtain an integral ceramic composite. In order to obtain a completely integral structure and to ensure that an outer surface of the dense body is in intimate contact with an inner surface of the bore of the porous body, the configuration of the bore and the configuration of the insertion part of the dense body must be exactly determined depending upon factors, such as shrinkage factors, of the ceramics constituting said dense and porous bodies. After insertion and before sintering, said dense body and said porous body are preferably loosely fitted, but after sintering, they are tightly fitted. Further, the configuration of the bore can be widely varied depending upon use of the resulting ceramic composites and other factors. While the configuration of the bore is not limited, it is preferably in the form of round holes, square holes, deep-bored holes, through-holes etc. Similarly, the projecting or insertion part of said dense body may have any desired configuration, such as being in the shape of a cylindrical rod, a square rod, a plate, etc. However, the configuration of the projecting or insertion portion depends on the configuration of the bore of the porous body that is used in combination with this dense body. Of course, it is also possible to determine the configuration of said bore depending upon said projecting part.
In addition, the size or dimension of the bore of the porous body and the size of the projecting part of said dense body must each be determined in a range of sizes that no crack due to inappropriate sizes is produced in said porous body and/or said dense body when both bodies are simultaneously sintered. For instance, excessive shrinkage of the bore portion due to an unacceptably increased size thereof will cause crack failures in the projecting part of the dense body, since said part is subjected to excessive compression. To avoid these crack failures, it is contemplated to select the sizes of said bore and projecting part in such manner that a gap is created between the porous body and the dense body, when said dense body is introduced into the bore of said porous body. The size of this gap may be varied widely depending on the bore size, the particular ceramics, the sintering temperature and other factors. In other words, it is necessary to suitably determine this size of gap for each case.
After the insertion of the dense body into the bore of the porous body has been completed, both bodies are simultaneously sintered at an elevated temperature. During this sintering step, the dense body and the porous body start shrinkage thereof at different rates of shrinkage, since the shrinking factor of said porous body is higher than that of said dense body. As an example, when hydroxyapatite is used as the starting ceramic material for producing the dense and porous bodies and both bodies are sintered under the same conditions, i.e., sintering temperature of 1200° C., the dense body exhibits a shrinkage factor of about 80.4%, while the porous body exhibits a shrinkage factor of about 66.2%. Also, the sintered porous body exhibits a porosity of about 35.6%.
Sintering can be carried out in any sintering device which is generally used in this field, for example, the sintering device can be an electric oven or a furnace. The sintering temperature applied is preferably a temperature slightly higher than the temperature which is generally applied when the selected ceramics are sintered. For example, for calcium phosphate ceramics, the sintering temperature is preferably about 1,000° C., and more preferably about 1200° C. For zirconia ceramics, the sintering temperature is preferably about 1600° C.
The present invention will be further described with reference to typical working examples of the present invention. It should be noted that these examples do not restrict the scope of the present invention.
EXAMPLE 1
A slurry of hydroxyapatite was prepared by dropping a phosphoric acid into a slurry of calcium hydroxide. This slurry of hydroxyapatite was then granulated on a spray dryer, and calcined at 700° C. Powders of hydroxyapatite were obtained.
To produce a dense body of hydroxyapatite, the powders of hydroxyapatite prepared in the previous step were subjected to a monoaxial pressure molding process, and the molded product was hydrostatically press-molded under a hydrostatic pressure of 2,000 kg/cm 2 . The molded product was then machined in a NC (numerical controlled) cutting device to obtain a dense body of hydroxyapatite which is shown in FIG. 2a. As illustrated, the dense body of hydroxyapatite 11 comprises a tapered head portion 12 having attached to an end portion thereof a post 13.
Separately, the same powders of hydroxyapatite prepared in the previous step were mixed with an aqueous solution of hydrogen peroxide to prepare a foamed slurry of hydroxyapatite. Thereafter, the foamed slurry was dried and calcined to obtain a porous body of hydroxyapatite. The porous body was then machined in a NC cutting device. The resultant porous body of hydroxyapatite is shown in FIG. 2b. As appreciated from this drawing, the porous body of hydroxyapatite 21, as a whole, is in the form of a hollow cylinder with a closed bottom portion. A bore or cavity 22 is positioned in a central portion of the porous body 21.
Next, the post 13 of the dense body 11 was inserted into the bore 22 of the porous body 21, and both bodies 11 and 21 were simultaneously sintered at 1200° C., while maintaining the bodies in a combined condition. A hydroxyapatite composite consisting of the dense hydroxyapatite body and the porous hydroxyapatite body was thus obtained (see FIG. 1).
In this example, experiments were repeated by varying a diameter "a" of the post 13 of the dense body 11, while retaining an inner diameter "b" of the bore 22 of the porous body 21 at 6 mm. The results indicated that sintering was made at an interface of the bodies 11 and 21 when the diameter "a" applied is within the range of 5.0 and 5.9 mm, and that no crack was produced in the porous body 21 when the diameter "a" was 5.0 to 5.6 mm was applied.
The thus obtained hydroxyapatite composite is photographically shown in FIG. 3, i.e. electron micro-photograph (magnification×30) of the bonding interface (cross-sectional surface) of the composite. Also, a more magnificated photograph of the bonding interface of the same composite is shown in FIG. 4 in which magnification is×2,000. These photographs clearly demonstrate that satisfactory sintering was attained at an interfacial portion between the dense body 11 and the porous body 21.
The hydroxyapatite composites of this example are intended to be used as an artificial tooth root. These composites will provide a noticeable increased adhesion to natural bones compared with the prior art artificial root consisting essentially of a dense hydroxyapatite, when they are embedded in said bones, since the composites of the present invention have a base portion covered with porous body 21. Further, it is expected that porous body 21, when utilized as an implant, will become is more strengthened than the inner portion, i.e., dense body 11, because the porous body is changed to a more dense state under the influence of the natural bones.
EXAMPLE 2
A dense body of alumina was produced in the procedure similar to that of Example 1 except that the hydroxyapatite powders were replaced with alumina powders. The pressure-molded product was machined in a NC cutting device to obtain a dense body of alumina which is shown in FIG. 5. As illustrated, the dense body of alumina 31 comprises a head portion 32 having attached to a lower end portion thereof a pin 33.
Separately, a porous body of hydroxyapatite was produced in the procedure similar to that of Example 1. In this example, however, the porous body was NC-machined to a shape shown in FIG. 5. The resultant porous body of hydroxyapatite 41, as appreciated from FIG. 5, has a through-hole 42 in a central portion thereof.
Thereafter, the pin 33 of the dense body 31 was introduced into the through-hole 42 of the porous body 41 and maintained in such combined condition. In the combined condition, the bodies 31 and 41 were sintered at 1400° C. A composite of dense alumina-porous hydroxyapatite, as illustrated in FIG. 5 was obtained.
It was observed that in this alumina-hydroxyapatite composite, the pin 33 of the dense body 31 is tightly compressed with the ring-shaped porous body 41 as a result of shrinkage of the porous body 41.
The alumina-hydroxyapatite composite of this example is intended to be used as a percutaneous element. The percutaneous device is introduced in or under the skin or cutis to periodically conduct a dialysis for renopathy and to periodically determine a concentration of glucose for diabetes, for example, and therefore is not in contact with bones. The reason why this composite is suited to the production of the percutaneous device is that the composite possesses the following two requirements in the field of the percutaneous elements: (1) The elements should be made from dense materials such as apatite or alumina in view of their compatibility with the skin, and (2). The elements should be made from porous materials in view of the need for fixedly maintaining the element during use. The ceramic composites of the present invention can well satisfy these requirements. | Ceramic composite comprising a porous ceramic body having directly fitted thereon a dense ceramic body, the composite is produced by a process which comprises the steps of: separately producing the porous ceramic body and the dense ceramic body, inserting a projecting portion of the dense body into a bore portion of the porous body, and simultaneously sintering both the dense and porous bodies at a sintering temperature. The ceramic composite has excellent properties such as heat resistance, resistance to thermal cycle, water resistance and in vivo compatibility, and therefore is particularly useful as an implant material such as an artificial tooth root, an artificial bone and a percutaneous device. | 8 |
The present invention relates to a method for stiffening and controlled printing, adhesively coating and joining of textile fabric, by applying a suitable flowable agent by screen printing. The thus treated fabric is dried and subsequently undergoes further treatment.
BACKGROUND AND PRIOR ART
Methods are already known by means of which textile fabrics are stiffened by applying a stiffening agent. According to the method known from Swiss Pat. No. 208 340 (to which British Pat. No. 510,203 corresponds), articles made from flexible fabrics are stiffened by applying a liquid, colourless stiffening agent to the semi-finished or finished articles. Following evaporation of a solvent in the liquid, this stiffening agent must exert no adhesive action on adjacent layers of fabric. The stiffening agent is applied in such a way that a graded stiffness or flexibility is obtained or, alternatively, said stiffness or flexibility varies according to the intended use. This varying degree of stiffness is obtained by covering individual areas of the articles when applying the stiffening agent, by using solutions with different concentrations, or by applying different quantities of stiffening agent, for example by means of spraying nozzles using a different pressure or by partly covering the fabric with wire netting with varying thickness during spraying.
In the method known from British Pat. No. 911 517, a plastic material which can set or be cured under the action of heat is applied to the article in the form of an aqueous dispersion, emulsion or melt. By means of an engraved roller or a hollow screen, the stiffening agent is applied in varying quantities, so that a different degree of stiffening is obtained in individual portions of the article.
The use of known printing processes, e.g. relief, intaglio or screen printing for applying the stiffening agent to the textile fabric is proposed by the method of German Disclosure Document (Offenlegungsschrift) DE-OS No. 25 35 593.
All the printing processes for applying the stiffening agent which are proposed in conjunction with the known methods have disadvantages. Quite apart from the fact that in the known printing processes the time required for applying the stiffening agent is relatively long, it is only possible to a limited extent to adapt the metering to the particular textile fabric to be treated. In addition, the known printing processes are not suitable for processing a stiffening agent which must be drop-forming, and not viscous, in order to flow in a satisfactory manner into the fibres. As a result, the known methods are time-consuming.
THE INVENTION
It is an object to obviate the disadvantages of the known methods, to reduce the printing time for applying the stiffening agent to the textile fabric and to permit the application of any desired stiffening agent metered in a simple manner and in varying thicknesses to different points of the fabric. In in addition, the screen printing form, or stencil, should only be slightly larger than the fabric piece, and mechanical stresses on the screen printing form substantially eliminated.
According to the present invention, textile fabric is placed under a screen printing form, the stiffening agent is distributed over the complete side of the screen printing form which is remote from the textile fabric and its level is kept spaced above the screen printing form. During screen printing the thickness of the stiffening agent applied to the textile fabric is controlled by the pressure acting on the screen printing form.
The invention also relates to an apparatus for performing the method according to the invention in which the textile fabric is placed on a gradually moved substrate over which is guided a container for receiving the stiffening agent vertically towards and away from the substrate. Its base is formed by the screen printing form and its remaining walls are constructed in gas tight manner, a pressure source being connected to the container which permits the adjustment of the pressure in the container.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in detail hereinafter relative to a preferred embodiment and with reference to the drawings which show:
FIG. 1 A side view, partly in section, of a diagrammatically represented apparatus for stiffening a textile fabric. FIG. 2 A plan view of the apparatus according to FIG. 1.
FIG. 3 A vertical section through the screen printing form of the apparatus of FIG. 1 and the printing substrate on an enlarged scale.
FIG. 4 A plan view of the printing substrate of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
The invention is based on the consideration that use of a screen printing form, or stencil, although apparently suitable for applying a stiffening agent to a textile fabric, is too restricted in its presently known form, particularly with respect to the choice of stiffening agent. Thus, although the present invention uses a screen printing form for applying the stiffening agent to the textile fabric, printing takes place in a modified manner, as will be described in greater detail hereinafter.
The apparatus for stiffening textile fabric, which is shown in FIG. 1, substantially comprises a printing part 1 in which a stiffening agent is applied to a textile fabric, and a drying and after-treatment part 2. The latter is not related to the invention, so that its construction will only briefly be described. Part 2 could also be realized in some other way, without having any influence on the invention.
The essential components of printing part 1 and drying and after-treatment part 2 are covered by a housing 3 and mounted on a machine frame 4. A supply drum 5 having the shape of a six-sided prism is pivotably mounted on machine frame 4. However, it is also possible to use drums with a different number of sides or in the form of a cylinder. The supply drum 5 can also be replaced by some other conveying mechanism, e.g. a conveyor belt.
The sides 6 of supply drum 5 serve to in each case receive one of the portions to be treated, e.g. inserts for stiffening and shaping items of clothing. In FIG. 1, one side 6 of supply drum 5 with a fabric piece fixed thereto is located directly below a pressure tank or vessel 8 which is guided in vertical manner on a support 9. Pressure tank 8 is constructed in gas tight manner and has on its base a screen printing form 10 which is stretched over a frame 11 fixed to tank 8, e.g. by adhesion.
Screen printing form 10 can be made from a fabric of silk, plastic, bronze or stainless steel or can be in the form of a completely perforated screen. The fabric or screen forming the form 10 is patterned in known manner as a function of the stiffening to be carried out, e.g. by photogravure, and then forms the base of the pressure tank. As a result of the patterning, the application of the stiffening agent takes place at specific points and with a specific metering action.
The stiffening agent, which is relatively viscous, is filed to a particular level into the inner space or chamber 12 defined by pressure tank 8 and is kept at a substantially constant level by a regulating mechanism, e.g. by a float (not further described). Above pressure tank 8 is arranged a storage tank 15 which is connected to pressure tank 8 via a line 16 and a metering device, not shown. Storage tank 15 serves to supply stiffening agent to pressure tank 8 so as to maintain a constant level in the latter. Pressure tank 8 is also connected via a line 20 to a diagrammatically represented pressure source 18. The pressure in the chamber 12 is regulated by means of a diagrammatically represented pressure control system 22.
To enable the pressure tank 8 or the screen printing form 10 arranged on the bottom thereof to be centered precisely with the fabric piece held on the side 6 of supply spool 5, the pressure tank is adjustably mounted in a frame 24 guided on support 9. The adjustability of pressure tank 8 can be achieved for example by means of a cross-table construction such as is used for machine tools.
FIGS. 3 and 4 show that a printing substrate 26 is fixed to side 6 of supply spool 5. To this end, adjustable stops 28 are provided in each side and serve for centering both the printing substrate and the fabric piece. The stops 28 are under the action of a not-shown spring and are displaceable in a gap 30 in side 6. Thus, printing substrate 26 also covers gap 30 in the area of the fabric 7 to be treated. In turn, the fabric 7 is held on the printing substrate 26 by a holding-down device 32, so that after application of the stiffening agent the fabric does not stick to the screen printing form 10.
The drying and after-treatment part 2 comprises a drying mechanism 34, e.g. a drying chamber, to which hot air is supplied by means of a blower 36. The fabric 7, to which stiffening agent has been applied, is fed from supply spool 5 to a conveying mechanism 38 which moves it through the drying chamber 34. After leaving the drying chamber 34, the fabric 7 passes into a condensing section 40, where it is heated to a higher temperature to obtain the desired chemical reaction. The condensing section 40 can also have a conveying mechanism 42 by means of which fabric 7 is passed through the condensing section 40. In place of a linear condensing section 40, it is also possible to use a condensing drum. After leaving condensing section 40, fabric 7 passes into a stacking mechanism 44, from which it is conveyed away for further processing.
Operation:
Supply drum 5 places the fabric 7 applied to sides 6 below pressure tank 8, the latter being lowered until the screen printing form 10 is just above or directly at the level of fabric 7. By correspondingly regulating the pressure in the inner space 12 of pressure tank 8, the screen printing form is lowered onto the fabric 7. If the application of the stiffening agent is to be interrupted, the pressure is again changed, e.g. by setting a vacuum so that the screen printing form 10 is raised into the position shown in FIG. 3. After raising the pressure tank 8, the further operation of supply spool 5 is effected, so that the following fabric is brought below pressure tank 8. The application of the stiffening agent now takes place in precisely the same way as described hereinbefore. The holding-down devices 32 on the bottom of supply spool 5 are opened and the fabric is transferred to the conveying mechanism 38, drying and condensing then taking place in the manner described hereinbefore.
It is essential that the stiffening agent is applied by regulating the pressure in the inner space 12 of pressure tank 8. This eliminates substantially all the restrictions existing with the known printing processes. It is possible to use a relatively viscous stiffening agent and despite this the quantity thereof to be applied can be very accurately metered. Numerous possibilities exist for controlling the application of stiffening agent, such as modifying the passage of the screen printing form, the flow behaviour of the stiffening agent, the magnitude and duration of the pressure and/or vacuum, etc. It would also be possible to apply the stiffening agent by pressure regulation on the back of a porous printing substrate.
In order to permit rapid changing of the screen printing form 10, the stiffening agent can be sucked out of pressure tank 8 by means of a pump, not shown, and can be returned again after applying a new pattern.
When using the apparatus according to the invention, there are no restrictions regarding the use of different stiffening agents. The desired metering can be obtained without difficulty by choosing the most suitable pressure conditions during application of the stiffening agent.
The term textile fabric is understood to mean layers or parts of layers or punched out parts of knitted, woven or non-woven fabrics.
The products suitable for stiffening and dimensional stabilisation are those which under suitable conditions can form a chemical bond with the fabric material used, with other products applied to the fabric, or with one another, while being able to maintain the fabric dimensions stable during the reaction. For this purpose it is possible to use the conventional products of the textile industry, e.g. urea-formaldehyde precondensates; melamine compounds; carbamides; acetals; compounds of the ethylene urea, dihydroxydiethylene urea and dihydroxydimethyl diethylene urea types and all homologs thereof; and, similar substances either alone or in combination with other mentioned products and/or in combination with a suitable catalyst. It is possible to use as the catalyst organic or inorganic acids or metal salts of an organic or inorganic acid, such as e.g. alkali metal or earth, alkaline halide, or an ammonium salt. It is also possible to use other products, such as e.g. monomers which can be reacted with the fabric material or with themselves, accompanied by a condensation or polycondensation, addition or polyaddition, or polymerisation, or other chemical reactions taking place with or without the splitting off of a further reaction product, examples being styrene, ethylene, proplylene and the like.
The described process can be applied not only to the stiffening treatment of textile fabric, but can also in fact be combined with other treatments. It can be used advantageously for producing inserts, required e.g. in the manufacture of shirts and other items of clothing. These inserts are either stiffened uniformly over their entire surface or are stiffened to a differing degree, for which purpose the above-described process is also suitable. Following stiffening, said inserts are generally connected in suitable manner with an upper material, for which purpose direct adhesion of the insert to the upper material by means of thermoplastic adhesives with which e.g. one side of the substrate is coated has proved advantageously suitable. Obviously, coating can also take place on the upper material. Independently of the point of application, coating takes place at discrete points or over larger areas. The actual adhesion is accompanied by pressure and heat application, for which purpose generally special bonding presses are used.
The described stiffening process can be extended in such a way that lightly attached or loosely applied fabrics, e.g. an upper material and inserts, are stiffened together with the above-mentioned stiffening process. The stiffening agent must be dried and condensed in a condensing section. The condensing section can easily be constructed in such a way that adhesion of the fabric takes place simultaneously with the condensing of the stiffening agent. Advantageously the condensing section is constructed as a heating drum over which the fabric is guided and simultaneously pressed.
In the case of fine upper materials, it is impossible to prevent the color of the materials used for the inserts showing through. Therefore, it has proved necessary to maintain large stocks of materials with very varied colors, so that an insert or lining of the correct color is available. This disadvantage can be obviated in a very simple manner through admixing of suitable dye components with the stiffening agent. Thus, a dye treatment takes place simultaneously with the stiffening treatment in the case of the stiffening method according to the invention.
If, in the case of inserts, only certain areas are to be stiffened, by suitable choice of dye components it is possible to dye only the stiffened areas. It is also possible to add to the stiffening agent dye components which do not adhere to the latter and instead flow out of the same, thereby dyeing the whole area of the insert. However, dyeing can also be performed in a separate working step. The above-indicated process can also be used for dyeing purposes alone. The stiffening agent is replaced by the dye which is applied to the screen printing form in the pressure tank. After dyeing of the whole area of the insert, still without a stiffening agent, the substrate can be stiffened. The whole area or only parts thereof can be stiffened, as desired. As the process is based on a pressure action of the screen printing form, making the use of a doctor blade unnecessary, the form can be sub-divided into different areas. On the side remote from the printing substrate it is possible to apply different colors, so that the inserts are printed simultaneously in multicolored form. If printing takes place simultaneously with the stiffening treatment, different degrees of stiffness can be obtained in the different area portions. Thus, inserts can be produced in this way whose area portions are on the one hand only printed with color and on the other are stiffened with dye-containing stiffening agents. The different treatment of the area portions takes place in one and the same working operation.
As has already been stated, the above-described stiffening process can be extended so as to coat in punctiform manner textile fabrics with thermoplastic adhesives, such as are e.g. conventional with directly adherable inserts. All that is necessary in a corresponding screen printing form. The adhesive is applied to the side of the screen printing form remote from the fabric in the pressure tank. Coating takes place in exactly the same way as in the stiffening process by controlling the pressure action.
Coating with the above-indicated adhesives can take place before or after the dyeing or stiffening treatment, or the simultaneous dyeing and stiffening can take place in a separate operation or continuously at an additional printing station. Coating can thereby take place on one or both sides and over all or part of the total area. It is also possible without difficulty to coat all of one side and only certain areas of the other side. Due to the fact that the thermoplastic discrete point application of the coating with the described process can be distributed in any desired manner over the fabric, a varying stiffness distribution over the fabric is obtained.
As a result of the above-described extension of the stiffening process, the production of stiffened inserts and their use in conjunction with upper materials is further simplified. A considerable time-saving and reduction of stocks are possible. | A stiffening agent is applied in liquid form to the fabric by screen printing. Thereafter the fabric is dried and further treated. The agent is contained above the screen in a sealed container. Means are provided for varying the pressure in the container to thereby vary the flow of the agent through the screen. The container can be compartmentized to provide different flow rates at different locations of the screen. Also, instead of a stiffening agent, there can be printed a dye in a like manner. The dye and stiffening agent can also be printed together in a mixture. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Swiss Patent Appln. No. 01099/06, filed Jul. 10, 2006, which is incorporated herein by reference as if fully set forth.
BACKGROUND
[0002] The invention is directed to a method and a device for displaying sewing processes.
[0003] Modern sewing machines and embroidering machines generally comprise a monitor. This may be used for displaying information and (in case of touch screens) for operating or controlling the sewing machine. In particular, it is known to display small images and/or icons of embroidery patterns to be selected on touch-sensitive screens.
[0004] From U.S. Pat. No. 5,983,871 a sewing machine with a connectable control device is known. It comprises a personal computer as a control device, having a monitor and input devices for a menu controlled adjustment of various parameters, among other things, for example embroidery patterns may be selected, and for controlling the sewing machine. When the control device does not recognize a connected sewing machine the simulation mode is activated. Here, pseudo signals are created, which are equivalent to the signals created by a sewing machine during the sewing process.
[0005] In prior art, the complete stitching and embroidery patterns are each displayed on the monitor. In particular for more complex patterns the individual stitching sites and the sequence of the needle stitches in the sewing material and/or the development process of stitching and embroidery patterns displayed on the monitor are hardly discernible or not at all. Furthermore, such conventional representations do not reflect the actual conditions, because neither color nor structure of the sewing material, nor the colors of the needle thread and the bottom thread are considered.
SUMMARY
[0006] The object of the present invention is to provide a method and a device for a representation close to reality and/or equivalent to reality and/or to create a simulation of sewing and embroidery processes.
[0007] This object is attained in a method and a device for showing sewing processes according to the invention.
[0008] Using the method according to the invention and the device according to the invention, the development process of stitching patterns and embroidery patterns are shown in a manner close-to-reality and/or equivalent to reality on a preferably high-resolution monitor (for example on a section of the sewing machine monitor or on the monitor of a simulator and/or a computer running a simulation software). The color and, if applicable, also the structure of the section of the monitor showing the sewing material may be selected, depending on the embodiment of the invention, from a number of stored image samples (e.g., bitmap-samples), or directly be detected at the respective sewing material via a camera or a color sensor. Similarly, the colors and the thickness of the needle thread and the bottom thread may also be predetermined. In an advantageous embodiment of the invention the visualization of the sewing or knitting process may optionally occur during the actual operation of the sewing and/or embroidery machine or when the simulation mode is activated. In the simulation mode the stitch formation in the sewing material is prevented, for example by decoupling the needle rod from the primary drive, or by the primary drive of the sewing machine remaining switched off. For a rather realistic display of a sewing or embroidery image and its development it is therefore not necessary to sew a sample pattern onto the actual original material. For visualizing a sewing or embroidering process, for example the control values of the motors and/or the steppers can be detected, which are used to create the respective stitching or embroidering pattern, thus for example the control values of the stepper for longitudinal and lateral transport as well as for the width of the stitch and/or the motion of the needle rod.
[0009] When the sewing material is moved via transporters additionally the slip-features of the sewing material can be considered in the form of slip-factors for forward, reverse, right, and left motion. When displaying the “virtual” sewing image on the monitor, these slip-factors compensate the difference between the drive motions of the transporter and the motion of the actual material. Such slip-factors and, perhaps additional factors, can for example be entered into the sewing machine control in an initialization routine.
[0010] When using embroidery frames for moving the sewing material no slip-correction factors are necessary.
[0011] In addition to the visualization of the creation of stitch and embroidery patterns, for example the creation of button holes as well as the insertion of buttons or stitching images created by special needles can also be simulated in the sewing material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the following, the invention is explained in greater detail using the drawing figures. Shown are:
[0013] FIG. 1 is a partial view of a sewing machine with a monitor,
[0014] FIG. 2 is a representation of the sewing machine of FIG. 1 on the monitor of a simulator,
[0015] FIG. 3 a is a first partial image for showing a sewing process,
[0016] FIG. 3 b is a second partial image for showing the sewing process, and
[0017] FIG. 3 c is a third partial image for showing the sewing process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] FIG. 1 shows a partial view of a sewing machine 1 with a machine monitor, called monitor 3 for short. The monitor 3 comprises a touch-sensitive monitor (also called “touch screen” or “sensor monitor”). The sewing machine 1 comprises fixed operating elements 6 a , e.g., in the form of actual buttons, rotary knobs, and regulators. On the monitor 3 , which serves as a user interface, e.g., depending on the respective configuration of the sewing machine 1 , information and selection options may be displayed. In the example in FIG. 1 , a selection menu for different sewing stitches is shown on monitor 3 . Here, the individual stitching patterns may be selected via variable and/or virtual operating elements 5 b , which are displayed on the monitor, for example in the form of buttons or operating fields with a small, mostly simplified image or icon of the respective stitch type. The virtual buttons for selecting the stitch type additionally comprises a number for a definite identification of the respective stitching pattern.
[0019] Depending on the respective configuration of the sewing machine 1 , only a part of all available stitching patterns can be used, for example the sewing needle 7 inserted in the needle holder, the pressure foot 9 connected to the material pressure rod, and the stitching plate 11 used. Therefore, it may be provided that each stitching pattern, which cannot be used in the respective configuration, cannot be activated in said configuration and/or is marked as a non-usable stitch type, for example, by displaying it in a different color.
[0020] On one part of the monitor 3 , a selection window 13 may be shown for an enlarged display of the respectively selected stitch patterns. In a sufficient resolution of the monitor 3 the individual stitching sites 8 and/or points of the sewing needle 7 can also be shown in the display window 13 .
[0021] The information regarding the individual stitching patterns, i.e. for example the absolute or mutually relevant position of individual stitch positions as well as their sequence are stored in a memory (not shown) accessible in a sewing machine control. In an advantageous embodiment of the sewing machine 1 information regarding the characterization of the sewing material 2 to be processed ( FIGS. 3 a , 3 b , and 3 c ) and/or the needle thread and/or the bottom thread may also be saved in a suitable digitized form. Such information is, for example, color and/or structure of the sewing material 2 , color of the bottom thread, slip features of the sewing material 2 and/or correction values for the transportation of the sewing material 2 via a transporter. In such correction values or factors the slippage of the sewing material 2 is compensated in each sewing direction such that the actual stitch positions 8 of the sewing needle 7 into the sewing material 2 is equivalent to the predetermined target values.
[0022] The visualization software also comprises a configuration menu, which serves to determine the parameters that influence the stitch pattern.
[0023] In order to determine the color and structure of the sewing material 2 , a camera (not shown) may be provided, which e.g., is provided at the sewing machine head or can be effectively connected to the sewing machine 1 via an appropriate interface. The detection and storage of an image of the sewing material surface can occur, for example by operating a button temporarily displayed on the touch-screen 3 .
[0024] Alternatively a limited number of colors and structures can also be stored in the sewing machine memory and/or in a memory allocated to the sewing machine 1 , e.g., in form of a bitmap, with then each color and patterns being selected most closely resembling the actual sewing material. The features of the virtual sewing material 2 are therefore approximated, adjusted, or assimilated to the features of the real sewing material 2 .
[0025] The detection of the sewing material color or the color of the needle and the bottom thread can alternatively also occur via a color sensor.
[0026] If necessary, additional features of the sewing material 2 , such as elasticity and structure and/or features of sewing machine elements, such as e.g., the type of sewing needle used can also be determined in the configuration menu by selecting it from a number of predetermined, saved parameters. Instead of a manual configuration devices for an automatic detection of one or more such parameters may also be provided. A sewing needle 7 and/or other sewing machine elements can be provided with a code, for example with a color code or barcode or another touchlessly detectable code, which for example can be stored on a RFID-marker. Alternatively, codes that can be mechanically scanned may be provided. When such codes are automatically detected, the sewing machine control and/or the software for visualizing the sewing processes can recall the allocated stored information and automatically configure the respective elements.
[0027] The sewing machine 1 comprises a real or a virtual operating element 6 a , 5 b for switching between the normal sewing mode, in which the stitching pattern is sewn onto the sewing material 2 under the sewing needle 7 , and a simulation mode.
[0028] In the simulation mode, for example the primary motor of the sewing machine 1 is switched off or the needle rod is decoupled from the needle rod drive such that when operating the foot control or an appropriate other operating element 6 a , 5 b no real stitch formation occurs in the sewing material 2 . In this operating mode the stitch formation process is displayed on the monitor 3 . Here, the sewing needle 7 , its stitch sites 8 into the sewing material 2 , and the previously formed seam 10 between the stitching sites 8 are visible. In the FIGS. 3 a , 3 b , and 3 c , each section of the sewing material 2 shown for illustrating the sewing process during the production of a stitch pattern with a simple sewing needle 7 is displayed on the monitor 3 temporarily offset. Alternatively, the overall stitching or embroidery pattern shall be displayed with reduced intensity as a background on the monitor 3 and/or in a display window 13 of the monitor 3 . Then, during the simulation of the sewing process the actual position of the sewing needle 7 and the already formed part of the seam 10 are shown emphasized.
[0029] When using special needles, such as triple needles or sword needles, these needles and the corresponding stitch patterns and seams are shown close to reality on the monitor 3 similar to the sewing process using a sewing needle 7 .
[0030] The speed of this virtual sewing process is preferably adjustable or changeable via the foot control or the operating element 6 a , 5 b provided therefor. In particular, in the simulation the stopping and the change or direction of the virtual sewing process may be provided. This way the creation process of a stitch pattern and its effect on the sewing material 2 can be better understood and evaluated. In a particular advantageous embodiment of the invention, additional parameters, such as thread tension and material type can be predetermined and considered. In the memory of the sewing machine 1 various features, such as thickness or slippage factors can be stored for different types of materials. When the knot formation between the bottom thread and the needle thread occur based on such factors above the sewing material 2 , this can be considered in the simulation of the sewing process, in which the knots and the sections of the bottom thread visible from above are shown as well.
[0031] The visualization software can optimally be embodied for showing additional processes, such as e.g., the production of button holes. After the completion of the frame of the button hole, then the production of the cutting gap is virtually shown on the monitor 3 . Subsequently then, for example by menu control, an appropriate button is selected from a number of stored buttons and virtually guided through the button hole (not shown). Preferably only the buttons fitting to the size of the respective button hole can be selected. Images of buttons can stored as bitmap similar to the sewing material 2 . Such images can e.g., be transferred via internet or via data carriers to the memory accessible from the sewing machine control.
[0032] In the normal sewing mode, different from the simulation mode, the stitch formation device is activated so that the sewing pattern can be sewn onto the real sewing material 2 . Optionally here the seam formation process may or may not be visualized similar to the simulation mode on the monitor 3 .
[0033] Instead of a transporter, an embroidery frame (not shown) can also be used for displacing the sewing material 2 in the sewing level. Due to the fact that the sewing material 2 is stretched in the embroidery frame, in this case no slippage related stitching errors can occur. Using an embroidery frame not only small stitching patterns but also larger stitching patterns can be created. Alternatively, other transportation devices can be used for a displacement and/or positioning of the sewing material in reference to the stitch formation device, for example roller drives, as used in the larger quilting devices. The visualization explained using the stitch patterns respectively applies for the embroidery patterns as well. In the present document the term “sewing machine 1 ” also includes other stitch forming machines, in particular embroidery machines or sewing machines 1 with an embroidery frame.
[0034] Sewing and embroidery processes can alternatively also be simulated on a simulator and/or a computer and visually displayed on a simulator monitor 3 a , as shown in FIG. 2 . On the simulator monitor 3 a essentially the sewing machine 1 of FIG. 1 is shown, in which additional display windows 13 may be displayed with information, status displays, and virtual operating elements 5 b . In particular, a simulation window 13 a is shown between the upper arm and the lower arm, in which the creation process of the stitch or embroidery pattern is shown close to reality. The finished stitching or embroidery pattern is here shown not as an interference. The sewing material 2 is shown as a background with the respective bitmap pattern in the simulation window 13 a . The sewing needles 7 are visible as well as the already sewn section of the seam 10 (essentially the needle thread) with the respective stitching sites 8 in the sewing material 2 .
LIST OF REFERENCE CHARACTERS
[0000]
1 sewing machine
2 sewing material
3 monitor
3 a simulation monitor
5 a fixed operating elements
5 b virtual operating elements
7 sewing needle
8 stitching sites
9 pressure foot
10 seam
11 stitching plate
13 display window
13 a simulation window | A method and the device for displaying sewing processes to allow simulation of the formation of stitch patterns and embroidery patterns in sewing machines ( 1 ) and embroidery machines or in sewing simulators close to reality is provided. In the representation on the monitor ( 3 ) features, such as colors and the structure of the sewing material ( 2 ), are considered. By activating a simulation mode, the drive for the stitch formation unit can be disabled. | 3 |
TECHNICAL FIELD
The present invention relates to a process for mounting of an optical fiber on a substrate and for optical coupling of this fiber.
BACKGROUND OF THE INVENTION
In the field of telecommunications, the current trend is towards the replacement of certain coaxial electrical links between electronic equipments by optical links obtained by means of optical fibers placed in an appropriate sheath and interconnecting one or more sources emitting light and one or more photosensors.
The current trend is also towards the utilization of monomode fibers, which exhibit a diameter of approximately ten microns.
In order to effect the mounting of a fiber on a substrate and its optical coupling with an optoelectronic component or photosensor, whether or not via waveguide, various solutions are currently known.
A first solution consists in applying the end portion of the optical fiber onto the front face of the substrate and in retaining it by means of an auxiliary plate which exhibits a V-shaped groove in which this end portion extends.
In a known variant, the end face of the optical fiber is, prior to its mounting, beveled, this beveled end face deflecting the optical wave towards an optoelectronic component. In another known variant, the end face of the optical fiber is coupled axially to a waveguide formed on the substrate.
Another known solution consists in fixing the end of the optical fiber perpendicularly to the substrate, directly on an optoelectronic component or facing such a component through the substrate.
The principal disadvantages of the known solutions reside in the bulkiness of the devices obtained, in the difficulty of disposing in the desired position the optical fiber which exhibits a specified configuration prior to its mounting and in the addition of auxiliary parts for the fixing of the optical fiber.
SUMMARY OF THE INVENTION
The object of the present invention is in particular to remedy at least in part the disadvantages of the known techniques of mounting and of optical coupling of optical fibers on a substrate.
The process according to the invention relates to the mounting of an optical fiber on a substrate and to the optical coupling between this fiber and an optical or optoelectronic element or component such as a receiving or emitting waveguide or optical fiber formed or carried in the front face on the substrate.
According to one object of the invention, the process consists in inserting the end of an optical fiber into a through orifice formed in the substrate, engaging it by the rear face of the substrate, in sealing the end of the optical fiber in said orifice, and in forming on the path of the optical wave a deflecting facet such that the optical wave originating from the optical fiber is deflected by this facet towards said element or component, or vice versa.
According to a preferred embodiment of the invention, the end of the optical fiber is disposed perpendicularly to the substrate and the axes of the optical paths of the optical wave are, upstream and downstream of said deflecting facet, perpendicular to the substrate and parallel to the front face of the latter.
According to a further object of the invention, the process consists in inserting the end of an optical fiber into a through orifice formed in the substrate, engaging it by the rear face of the substrate, in sealing the end of the optical fiber in said orifice, and in depositing on the front face of the substrate a layer of material which covers said orifice and which is intended to form a waveguide and in forming in said layer a deflecting facet such that the optical wave originating from the optical fiber is deflected by this facet towards the waveguide, or vice versa.
According to the invention, the process may advantageously consists in inserting the end of the optical fiber as far as a position such that its end face is disposed in the plane of the front face of the substrate.
According to a further subject of the invention, the process consists in depositing on the front face of the substrate a layer of material, which layer is intended to form an optical guide, in forming an orifice passing through the substrate and at least in part the waveguide, in inserting the end of an optical fiber into said through orifice engaging it in the rear face of the substrate, in sealing the end of the optical fiber in said orifice, and in forming on the path of the optical wave a deflecting facet such that the optical wave originating from the optical fiber is deflected by this facet towards the waveguide, or vice versa.
According to the invention, the process may advantageously consist in inserting the end of the optical fiber as far as a position such that its end face is disposed in the front plane of said layer, said facet being formed at the end of the optical fiber.
According to the invention, the operation of sealing the end of the optical fiber is preferably obtained by introduction of a sealing material filling at least the portion of said orifice situated in the vicinity of the front face of the substrate.
According to the invention, the process preferably consists, before inserting the end of the optical fiber, in cementing an adhesive film at the front face of the substrate, covering said orifice, and, after sealing the end of the optical fiber, in removing the aforementioned film.
According to the invention, the aforementioned orifice is preferably cylindrical.
In a preferred form of the invention, the fiber is preferably disposed perpendicularly to the substrate.
According to the invention, the annular space separating the wall of the optical fiber and the wall of the aforementioned orifice is preferably within the range between 10 and 50 microns.
According to the invention, the process may advantageously consist in covering the deflecting facet with a layer of a reflective material.
According to the invention, the process may likewise consist in forming another deflecting facet at another location of the waveguide, facing an optoelectronic component inserted and sealed in the substrate, this other facet being such that the optical wave originating from the waveguide is deflected by this other facet towards this optoelectronic component, or vice versa.
In one embodiment, the operation of forming the aforementioned deflecting facet may be obtained by etching.
According to a variant, the aforementioned etching operation is effected through a layer of a photosensitive material, which layer is deposited on the aforementioned layer, in which material there is previously formed a profile matched to the profile of the deflecting facet to be formed.
The operation of formation of said deflecting facet or of said profile may advantageously be performed through an adapted photolithographic mask or directly by irradiation.
The subject of the invention is also a substrate equipped with at least one optical fiber and exhibiting on the front face at least one optical or optoelectronic element or component such as a waveguide.
According to the invention, the optical fiber exhibits an end inserted into a through orifice of the substrate by a rear face of the latter and sealed in this orifice by a sealing material, this end of the optical fiber extends perpendicularly to the substrate and a deflecting facet such that the optical wave originating from the optical fiber is deflected by this facet towards the waveguide, or vice versa, is provided in the waveguide and/or the sealing material and/or is formed by the end face of the optical fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood on studying various processes for mounting of optical fibers on substrates and for optical coupling of such fibers, which processes are illustrated diagrammatically, in views which are greatly enlarged, by the drawing, in which:
FIGS. 1 to 3 rate the steps of a process according to the invention;
FIG. 4 illustrates a variant of the process according to the invention;
FIG. 5 illustrates another variant of the process according to the invention;
FIGS. 6 and 7 illustrate the steps of another process according to the invention; and
FIGS. 8 and 9 illustrate variants of substrates obtained with the processes of the invention.
DETAILED DESCRIPTION
With reference to FIGS. 1 to 3, a description will first of all be given of a first process for mounting of an optical fiber 1 on a substrate 2 in the form of a wafer and for optical coupling of the latter with an optoelectronic component 3 inserted into the substrate 2 in such a manner that its front face 4 extends in the same plane as the front face 5 of the substrate.
First of all, as shown by FIG. 1, a through orifice 6 is formed in the substrate 2, which extends perpendicularly to the front face 4 of the substrate 2. In the example, this orifice 6 is cylindrical and may be obtained by piercing by means of a laser beam. In another variant, this orifice might be obtained by etching by microlithographic definition or KOH etching and might exhibit a conical shape according to an angle of for example 54° its smallest diameter being situated on the side of the front face 5 of the substrate.
Then, an adhesive film 7 is cemented against the front face 5 of the substrate 2 and then this substrate 2 is placed and retained on the plane upper face of a support 8 in a position such that the film 7 extends between the substrate 2 and this support 8.
Then, after having removed the sheath 9 surrounding the end portion of the optical fiber 1, its end is introduced into the cylindrical orifice 6 until its end face is in contact with the film 7.
Then, a sealing material 2a is introduced into the annular space separating the end of the optical fiber 1 and the wall of the orifice 6, the optical fiber 1 exhibiting a diameter within the range between 5 and 100 microns and this space preferably exhibiting a thickness within the range between 10 and 50 microns. This sealing material is preferably constituted by a thermally crosslinkable or photo-crosslinkable fluid adhesive, for example of the epoxide, polyimide or acrylic type, which is at the same time thermostable and optically transparent at the wavelength of the optical wave conveyed by the optical fiber 1.
This sealing material is moreover preferably constituted by an epoxide resin without a solvent, which is fluid and photo-crosslinkable by an ultraviolet radiation in accordance with a mode of ionic polymerization also permitting the hardening of the unexposed zones.
Then, the substrate 2 equipped with the optical fiber 1 is separated from the support 8, and the adhesive film 7 is removed by peeling. The optical fiber 1 is at this point mounted on the substrate 2 and inserted into the latter by its rear face opposite to its front face 5.
As shown by FIG. 2, the substrate 2 is then placed such that its front face 5 is turned upwards.
There is deposited on this front face 5 a layer 10 of a material intended to form an optical waveguide, which is optically transparent at the wavelength of the optical wave conveyed by the optical fiber 1, for example of a dielectric material such as silica or a thermostable transparent polymer.
The material utilized to form the layer 10 may advantageously be identical to that utilized as sealing material to fix the end of the optical fiber 1 in the orifice 6 of the substrate 3.
Then, there is deposited on the layer 10 a thick layer 11 of photosensitive resin, of the photosensitive polyimide or novolac type. Then, with the aid of a photolithographic mask 12 described in particular in French Patent No. 85 17 487 which includes micron patterns 13 and 14 which are disposed facing the optical fiber 1 and the sensitive zone of the optoelectronic component 3, the irradiation of the photosensitive layer 11 through the patterns 13 and 14 of the mask 12 is undertaken in order to form, by virtue of obtaining a luminous intensity decreasing along these patterns, inclined facets 15 and 16 in the photosensitive layer 11.
Then, after having removed the mask 12, the etching of the layer 10 through the layer 11 is undertaken, for example by plasma etching.
As shown by FIG. 3, there is first obtained a waveguide 17 formed in the layer 10, the edges of which may advantageously be formed at the same time. This waveguide 17 exhibits, at its ends, inclined facets 18 and 19 situated respectively facing the end of the optical fiber 1 and the sensitive zone of the optoelectronic component 3. These facets 18 and 19 are such that the optical wave, originating from the optical fiber 1 along a geometric axis perpendicular to the front face 5 of the substrate 2, is deflected by the deflecting facet 18 into the waveguide 17 along a geometric axis parallel to the front face 5 of the substrate 2, and is then deflected by the other deflecting facet 19 to strike the sensitive part of the optoelectronic component 3 perpendicularly to the front face 5 of the substrate 2, or vice versa. In the example, the facets 18 and 19 are formed at 45° in relation to the front face 5 of the substrate 2.
Referring now to FIG. 4, it is seen that instead of utilizing the special mask 12 for the formation of the facets 15 and 16 in the photosensitive layer 11, it is possible to utilize, in a variant, an emitter 20 of a particle beam, for example of an electron beam, to form the facets 15 and 16 by irradiation of the photosensitive layer 11, dosing this irradiation in a decreasing manner.
In another variant, the emitter 20 may be utilized to erode the layer 10 directly in order to form the deflecting facets 18 and 19 in this layer directly, at the ends of the waveguide 17.
Referring now to FIG. 5, it is seen that a substrate 21 has been shown, which is equipped, as previously, with an optical fiber 22 and with an inserted optoelectronic component 23, which are connected by a waveguide 24 formed in the front face 25 of the substrate 21.
This substrate 21 thus equipped may be formed by following the steps of the process described previously with reference to FIGS. 1 to 4, but differs therefrom by the fact that in the course of the insertion of the end of the optical fiber 22, the end face 26 of the latter is not in the plane of the front face 25 of the substrate 21, but is slightly set back and the sealing material 27 entirely fills the front portion of the orifice 28 in which the optical fiber 22 is inserted, and thus extends between the front face 26 of this optical fiber 22 and the waveguide 24.
Referring now to FIGS. 6 and 7, a description will now be given of a process for mounting of an optical fiber 29 on a substrate 30 and for optical coupling of the fiber to an optoelectronic component 31 inserted into this substrate 30 in such a manner that, as previously, its front face 32 extends in the plane of the front face 33 of the substrate 30.
As shown by FIG. 6, this other process differs from the previously described processes only in that the layer 34, which is intended to constitute a waveguide, is deposited on the front face 33 of the substrate 30 prior to the insertion of the optical fiber 29.
In fact, since the optoelectronic component 31 is inserted into the substrate 30, the layer 34 is deposited on the front face 33 of the substrate 30.
A cylindrical orifice 35 passing through the substrate 30 and the layer 34 is formed perpendicularly to this front face 33.
An adhesive film 36 is cemented on the layer 34, and the substrate 30 is placed and retained on a support 37, the film 36 being in contact with this support 37.
The end of the fiber 29 is inserted into the orifice 35, and, as previously, it is fixed by introducing a sealing material 38 into the annular space separating the optical fiber 29 and the wall of the orifice 35. The substrate 30 thus equipped is separated from the support 37, and the adhesive film 34 is removed by peeling.
The formation of deflecting facets 39 and 40 is then undertaken, in order to convey the optical wave from the optical fiber 29 towards the optoelectronic component 31, or vice versa, as shown by FIG. 7.
The formation of these facets may be effected in accordance with the steps of the previously described processes. However, on this occasion the facet 39 is formed at the end of .the optical fiber 29 if the latter was engaged as far as the frontal plane of the layer 34, or in the sealing material 38 if the end face of the optical fiber 29 has been inserted short of the front face 33 of the substrate 30.
Moreover, the deflecting facets 39 and 40 may be covered with layers 39a and 40a of a reflective material.
Referring now to FIGS. 8 and 9, a description will now be given of various variants of a substrate equipped with optically coupled optical fibers and utilized in accordance with any one of the previously described processes.
With reference to FIG. 8, it is seen that the substrate 41 carries an optoelectronic component 42 which projects beyond the front face 43 of this substrate, an optical fiber 44 inserted by the rear face of the substrate 41 and a waveguide 45 formed on the front face 43 of the substrate 41. This waveguide 45 exhibits an inclined deflecting face 46 facing the optical fiber 44 and guides the optical waves towards the sensitive lateral face 47 of the optoelectronic component 42. However, in this example, the waveguide 45 is interrupted before this face 47. It might also be interrupted at another location.
Referring now to FIG. 9, it is seen that a substrate 48 is equipped with two optical fibers 49 and 50 which are inserted by the rear face of this substrate 48 and, on its front face, with a waveguide 51 which exhibits two deflecting facets 52 and 53 which are formed facing the optical fibers 49 and 50 in such a manner as to couple the latter optically.
The present invention is not limited to the examples described hereinabove. Many other modified embodiments are possible without departing from the scope defined by the appended claims. | A process for mounting of an optical fiber (1) on a substrate (2) and for optical coupling between this fiber and an optical or optoelectronic element (17) or component such as a waveguide, a receiver or an emitter formed or carried on the front face (5) by the substrate, consisting in inserting the end of an optical fiber (1) into a through orifice (6) formed in the substrate (2) engaging it by the rear face of the substrate, in sealing the end of the optical fiber in said orifice, and in forming on the path of the optical wave a deflecting facet (18) such that the optical wave originating from the optical fiber is deflected by this facet towards said element or component (17), or vice versa. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a control apparatus for an internal combustion engine with a three-way catalyst for purification of exhaust gas installed on an exhaust system, and more particularly, it relates to a new technique to detect the degradation of the three-way catalyst in a reliable manner.
[0003] 2. Description of the Related Art
[0004] In general, in internal combustion engines, a three-way catalyst is used to purify harmful components of an exhaust gas. The three-way catalyst has an oxygen occlusion capability to keep the atmosphere inside the three-way catalyst at a stoichiometric air fuel ratio by occluding oxygen in the exhaust gas when the air fuel ratio of the exhaust gas is leaner than the stoichiometric air fuel ratio, while releasing the oxygen occluded therein when the air fuel ratio of the exhaust gas is richer than the stoichiometric air fuel ratio.
[0005] In addition, the three-way catalyst also has a capability to oxidize HC and CO among three harmful components contained in the exhaust gas and to reduce NOx, thereby purifying these respective components into harmless gases. Further, since the purification ability of the three-way catalyst becomes maximum in the vicinity of the stoichiometric air fuel ratio, the exhaust gas is excellently purified by combining the oxygen occlusion ability and the purification ability of the three-way catalyst with each other.
[0006] However, when the exhaust gas becomes leaner than the stoichiometric air fuel ratio to cause the amount of oxygen occluded in the three-way catalyst to exceed the oxygen occlusion capacity thereof, the atmosphere in the three-way catalyst becomes no longer kept at the stoichiometric air fuel ratio, so the NOx purification rate of the catalyst is deteriorated to a remarkable extent.
[0007] In addition, when the exhaust gas becomes richer than the stoichiometric air fuel ratio so the amount of oxygen occluded in the three-way catalyst becomes lacking or insufficient, the atmosphere in the three-way catalyst can not be kept at the stoichiometric air fuel ratio, thus deteriorating the purification rate of HC and CO. Here, it is known that as the three-way catalyst is deteriorated, the oxygen occlusion capacity thereof decreases, thus worsening the purification performance thereof.
[0008] Accordingly, there has been proposed a control apparatus for an internal combustion engine in which a pair of air fuel ratio sensors are arranged at an upstream side and at a downstream side, respectively, of a three-way catalyst so as to directly measure an oxygen occlusion capacity thereof to detect the degradation of the three-way catalyst (see, for instance, a first patent document: Japanese patent No. 2812023). In this case, in changes of the air fuel ratios at the upstream and downstream sides of the three-way catalyst and in a change of the concentration of harmful components in the exhaust gas at the downstream side of the three-way catalyst, the air fuel ratio at the upstream side of the three-way catalyst is switched from a predetermined air fuel ratio, which is preset to a lean side, into a first prescribed air fuel ratio, which is preset to a rich side, across the stoichiometric air fuel ratio.
[0009] At this time, even if the air fuel ratio at the upstream side of the three-way catalyst changes into the rich side, the oxygen adsorbed and held in the three-way catalyst is released. As a result, the air fuel ratio at the downstream side of the three-way catalyst is first maintained at the stoichiometric air fuel ratio only for a first predetermined period of time, and thereafter reaches a first air fuel ratio which is at the rich side. Subsequently, the air fuel ratio at the upstream side of the three-way catalyst is switched from the predetermined air fuel ratio, which is preset at the rich side, into a second prescribed air fuel ratio, which is preset at the lean side, across the stoichiometric air fuel ratio.
[0010] At this time, oxygen is adsorbed and held in the three-way catalyst, contrary to the above case. As a result, the air fuel ratio at the downstream side of the three-way catalyst is first maintained at the stoichiometric air fuel ratio only for a second predetermined period of time, and thereafter reaches the second air fuel ratio at the lean side. Hereinafter, an absolute amount of the oxygen adsorbed and held by the three-way catalyst is calculated from a difference between the switched air fuel ratio and the stoichiometric air fuel ratio, and from the amount of the exhaust gas that has passed through the three-way catalyst for the first or second predetermined period of time, so that the degradation level of the three-way catalyst is detected from the absolute amount of adsorbed oxygen thus calculated (see FIG. 6 of the above-mentioned first patent document).
[0011] In the known control apparatus for an internal combustion engine as referred to above, after the amount of oxygen occluded in the three-way catalyst has been decreased to zero (or saturated) without fail, the air fuel ratio at the upstream side of the three-way catalyst is switched, and then the absolute amount of the oxygen adsorbed and held by the three-way catalyst is calculated. Accordingly, the purification rate of the three-way catalyst in a period of time in which the amount of the oxygen occluded in the three-way catalyst is being decreased to zero or saturated is reduced, thus posing a problem that the exhaust gas is deteriorated.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention is intended to solve the problem as referred to above, and has for its object to obtain a control apparatus for an internal combustion engine which is capable of detecting the degradation of a three-way catalyst with high accuracy without causing deterioration in an exhaust gas by controlling the amount of change (i.e., the amount of occlusion or release) of the oxygen in the three-way catalyst to such an amount slightly more than the oxygen occlusion capacity of a degraded three-way catalyst specified by the relevant laws.
[0013] A control apparatus for an internal combustion engine according to the present invention includes: a three-way catalyst disposed in an exhaust system of the internal combustion engine; a first air fuel ratio detection part disposed in the exhaust system at a location upstream of the three-way catalyst for detecting a first air fuel ratio of an exhaust gas; a second air fuel ratio detection part disposed in the exhaust system at a location downstream of the three-way catalyst for detecting a second air fuel ratio of the exhaust gas; a target oxygen change amount calculation part that calculates a target oxygen change amount of the three-way catalyst; an oxygen change amount calculation part that calculates an oxygen change amount of the three-way catalyst from an amount of exhaust gas passing through the three-way catalyst and the first air fuel ratio; and an air fuel ratio operation part that inversely operates the first air fuel ratio in accordance with the oxygen change amount. The air fuel ratio operation part controls, in an inverting manner, the first air fuel ratio to a rich side and a lean side across a stoichiometric air fuel ratio with a prescribed air fuel ratio width each time the oxygen change amount in the three-way catalyst reaches the target oxygen change amount.
[0014] According to the present invention, by controlling the amount of change of the oxygen in the three-way catalyst to an amount slightly more than the oxygen occlusion capacity of the deteriorated three-way catalyst, the variation of the oxygen in the three-way catalyst, if in its normal state, does not exceed the oxygen occlusion capacity of the three-way catalyst. As a result, the oxygen concentration at the downstream side of the three-way catalyst does not vary, thus making it possible to avoid the deterioration of the exhaust gas at the downstream side of the three-way catalyst. On the other hand, if the three-way catalyst is in a deteriorated state, the variation of the oxygen in the three-way catalyst exceeds the oxygen occlusion capacity of the three-way catalyst. Consequently, the oxygen concentration at the downstream side of the three-way catalyst is inversely varied to a rich side and a lean side across the stoichiometric air fuel ratio, thus making it possible to detect the degradation of the three-way catalyst with high accuracy.
[0015] The above and other objects, features and advantages of the present invention will become more readily apparent to those skilled in the art from the following detailed description of a preferred embodiment of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a configuration view showing a control apparatus for an internal combustion engine according to one embodiment of the present invention together with its peripheral equipment.
[0017] FIG. 2 is a flow chart illustrating an oxygen change amount control routine for a three-way catalyst for purification of an exhaust gas according to this embodiment of the present invention.
[0018] FIG. 3 is a flow chart illustrating a degradation detection routine for the three-way catalyst according to this embodiment of the present invention.
[0019] FIG. 4 is a timing chart illustrating the operation of a three-way catalyst degradation detection device when the three-way catalyst is in a normal state, according to this embodiment of the present invention.
[0020] FIG. 5 is a timing chart illustrating the operation of the three-way catalyst degradation detection device when the three-way catalyst is in a degraded state, according to this embodiment of the present invention.
[0021] FIG. 6 is a view illustrating a relation between the oxygen occlusion capacity of the three-way catalyst and the amount of exhaust gas emission during travelling in a US FTP mode when the three-way catalyst is degraded.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Now, a preferred embodiment of the present invention will be described below in detail while referring to the accompanying drawings.
Embodiment 1
[0023] FIG. 1 is a block diagram that shows an entire arrangement of a control apparatus for an internal combustion engine according to one embodiment of the present invention together with its peripheral equipment.
[0024] In FIG. 1 , an internal combustion engine 101 includes, as an air intake system, an intake pipe 105 having an air cleaner 102 , a throttle valve 103 and a surge tank 104 install thereon.
[0025] The intake pipe 105 further includes an air flow sensor 106 for detecting the amount of intake air Qa, an injector 107 for injecting fuel into the intake pipe 105 , a throttle sensor 117 for detecting the throttle opening θ of a throttle valve 103 , and an idle switch 118 for detecting when the internal convention engine 101 is idling. The idle switch 118 generates an idle signal DL that becomes on at an idling opening (i.e., the throttle opening θ is in a fully closed state).
[0026] In addition, the internal combustion engine 101 further includes, as an exhaust system, an exhaust pipe 108 . A three-way catalyst 109 is arranged in the exhaust pipe 108 for purifying harmful components in the exhaust gas, and a linear air fuel (A/F) ratio sensor 110 and a λ oxygen sensor 111 are arranged at an upstream side and at a downstream side, respectively, of the three-way catalyst 109 .
[0027] An internal combustion engine control unit 112 (hereinafter referred to as an “ECU ”), being constituted by a microcomputer, includes a central processing unit 113 (hereinafter referred to as a “CPU ”), a read-only memory 114 (hereinafter referred to as a “ROM ”), a random-access memory 115 (hereinafter referred to as a “RAM ”), an input and output interface 116 (hereinafter referred to as an “I/O interface ”), and a drive circuit 122 .
[0028] The internal combustion engine 101 further includes a water temperature sensor 119 for detecting the temperature of cooling water WT, a crank angle sensor 120 four generating a crank angle signal CA corresponding to a crank angle position (i.e., the rotational angle or position of a crankshaft), and a cam angle sensor 121 for generating a cam angle signal corresponding to a cam angle position (i.e., the rotational angle or position of a camshaft).
[0029] The water temperature sensor 119 , the crank angle sensor 120 , and the cam angle sensor 121 together constitute various kinds of sensors for detecting the operating conditions of the internal combustion engine 101 , together with other sensors (e.g., the air flow sensor 103 , the linear air-fuel ratio sensor 110 , the λ oxygen sensor 111 , the throttle sensor 117 , the idle switch 118 , and so on). The respective detection signals from these sensors are input to the ECU 112 as engine operating condition information.
[0030] In the internal combustion engine 101 as shown in FIG. 1 , the intake air cleaned by the air cleaner 102 is sucked into the respective engine cylinders through the surge tank 104 and the intake pipe 105 while being controlled by the throttle valve 103 into an amount corresponding to a load on the internal combustion engine 101 . At this time, the amount of intake air Qa sucked into the internal combustion engine 101 is detected by the air flow sensor 106 , and fuel supplied to the respective cylinders of the internal combustion engine 101 is injected into the intake pipe 105 through the injector 107 .
[0031] A mixture (i.e., air and fuel) sucked into the respective cylinders of the internal combustion engine 101 is burned therein in combustion stroke and turned into an exhaust gas, which is then exhausted into the ambient atmosphere through the three-way catalyst 109 arranged on the exhaust pipe 108 while the harmful components in the exhaust gas are purified by the three-way catalyst 109 .
[0032] At this time, the linear A/F sensor 110 arranged at the upstream side of the three-way catalyst 109 detects the air fuel ratio A/F of the mixture by linearly detecting an oxygen concentration in the exhaust gas at the upstream side of the three-way catalyst 109 . The λ oxygen sensor 111 arranged at the downstream side of the three-way catalyst 109 detects an oxygen concentration λ O2 in the exhaust gas at the downstream side of the three-way catalyst 109 . The detection signals of the respective sensors 110 , 111 contribute to the detection processing of the states of the exhaust gas upstream and downstream of the three-way catalyst 109 according to the ECU 112 .
[0033] In the ECU 112 , various pieces of operating condition information (e.g., the amount of intake air Qa, the throttle opening θ, the idle signal DL, the cooling water temperature WT, the air fuel ratio A/F, the oxygen concentration λ O2, the crank angle signal CA, the cam angle signal from the cam angle sensor 121 , etc.) are taken into the CPU 113 through the I/O interface 116 .
[0034] The ECU 112 constitutes an air fuel ratio feedback control system which generates a drive signal for the injector 107 based on the air fuel ratio A/F and the oxygen concentration λ O2 from the respective sensors 110 , 111 arranged before and after (upstream and downstream of) the three-way catalyst 109 , so that a required amount of fuel can be injected by the injector 107 .
[0035] In the air fuel ratio feedback control system in the ECU 112 , the CPU 113 drives the injector 107 through the drive circuit 122 in such a manner that the internal combustion engine 101 can be operated in a predetermined air fuel ratio on the basis of a control program and various maps stored in the ROM 114 . The actual air fuel ratio (A/F) is controlled to a target air fuel ratio A/Fo according to this air fuel ratio feedback control.
[0036] Here, note that the ECU 112 also functions as a degradation detection device for the three-way catalyst 109 so as to control the internal combustion engine 101 at an optimal manner, as will be described later. In addition, the drive circuit 122 in the ECU 112 drives not only the injector 107 but also various kinds of actuators such as, for instance, an ISC valve (not shown), associated with the internal combustion engine 101 .
[0037] That is, the ECU 112 performs, in addition to the air fuel ratio control, various kinds of control such as ignition timing control, idling speed control, etc., and at the same time detects, as a self-diagnosis function, failure of various kinds of components from which deterioration in the exhaust gas results.
[0038] The CPU 113 and the drive circuit 122 , which serve to drive the injector 107 in a controlled manner, together constitute an air fuel ratio operation part which controls, in an inverting manner, the air fuel ratio A/F to a rich side and a lean side across the stoichiometric air fuel ratio with a prescribed width of the air fuel ratio each time the amount of change of the oxygen in the three-way catalyst 109 reaches a target oxygen change amount.
[0039] Moreover, the ROM 114 stores therein not only a routine for controlling the amount of change of the oxygen in the three-way catalyst 109 , but also control programs such as a degradation detection routine for the three-way catalyst 109 , etc., along with necessary maps for these control processes.
[0040] Hereinafter, the control apparatus for an internal combustion engine according to the this embodiment of the present invention shown in FIG. 1 will be described in detail while referring to flow charts of FIGS. 2, 3 , timing charts of FIGS. 4, 5 and an explanatory view of FIG. 6 . Here, the description will be made along the contents of processing according to a control routine for controlling the amount of change of the oxygen in the three-way catalyst 109 as well as a degradation detection routine for detecting the degradation of the three-way catalyst 109 , these routines featuring the present invention.
[0041] FIG. 2 is a flow chart that illustrates an air fuel ratio control routine, which is the control routine for controlling the amount of change of the oxygen in the three-way catalyst 109 for purification of an exhaust gas, according to the this embodiment of the present invention.
[0042] In FIG. 2 , first of all, it is determined whether a degradation determination execution condition for the three-way catalyst 109 holds (step 201 ). When it is determined that the degradation determination execution condition does not hold (that is, NO), the processing routine of FIG. 2 is immediately terminated and a return is performed.
[0043] On the other hand, when it is determined in step 201 that the degradation determination execution condition holds (that is, YES), it is subsequently determined whether the value of a degradation determination execution counter CN 1 is greater than “0” (step 202 ). When it is determined as CN 1 =0 (that is, NO), a predetermined number of degradation determination executions have been completed, so the processing routine of FIG. 2 is terminated at once and a return is carried out.
[0044] At this time, it is assumed that only when the degradation determination execution condition holds for the first time (step 201 ), the degradation determination execution counter CN 1 and an oxygen occlusion amount initialization counter CN 2 are set to initial values, respectively. In addition, it can be determined that the degradation determination execution condition holds, for example, when the following conditions are satisfied: that is, the internal combustion engine 101 is after warmed up; the amount of intake air Qa is in a predetermined range; and the number of revolutions per minute and the load of the engine are in predetermined ranges, respectively.
[0045] The degradation determination execution counter CN 1 is a subtraction counter which is decremented by “1” each time a lean flag FL (to be described later) is switched. Accordingly, if the initial value of the degradation determination execution counter CN 1 is set to “5”, for example, the target air fuel ratio A/Fo, after first enriched, is controlled to be made lean and rich in an alternate manner. Such enriching and leaning are carried out a total of five times.
[0046] On the other hand, when it is determined as CN 1 >0 in step 202 (that is, YES), it is subsequently determined whether the value of the oxygen occlusion amount initialization counter CN 2 is greater than “0” (step 203 ).
[0047] The oxygen occlusion amount initialization counter CN 2 is a subtraction counter which is decremented by “1” each time the processing of enriching the target air fuel ratio A/Fo is carried out during the initialization of the amount of oxygen occlusion (to be described later). In this case, by making the target air fuel ratio A/Fo richer than the stoichiometric air fuel ratio over a predetermined period of time, it is possible to suppress deterioration in the amount of NOx emission resulting from the oxygen occlusion capacity of the three-way catalyst 109 being saturated by the amount of oxygen in the three-way catalyst 109 in the lean processing of the target air fuel ratio A/Fo executed when the value of the oxygen occlusion amount initialization counter CN 2 is “0”.
[0048] When it is determined as CN 2 >0 in step 203 (that is, YES), the amount of change of the oxygen QOX in the three-way catalyst 109 is set to “0” (step 204 ), and the target air fuel ratio A/Fo is enriched by a predetermined amount from the stoichiometric air fuel ratio based on a map that is set in accordance with the number of revolutions per minute and the load of the internal combustion engine 101 (step 205 ).
[0049] Also, the oxygen occlusion amount initialization counter CN 2 is decremented by “1” (step 206 ), and the lean flag FL is set to “1 (hold) ” in preparation for the post termination of the initialization of the amount of change of the oxygen QOX in the three-way catalyst 109 , after which the processing routine of FIG. 2 is ended. If the lean flag FL is set to “1(hold) ” after the termination of the initialization of the oxygen occlusion amount, the target air fuel ratio A/Fo is made lean, whereas if the lean flag FL is cleared to “0 (not hold) ”, it functions as a determination flag to enrich the target air fuel ratio A/Fo.
[0050] On the other hand, if it is determined as CN 2 =0 (that is, NO) in step 203 , the target oxygen change amount QOXo is obtained by arithmetic calculations (step 208 ). Here, note that the target oxygen change amount QOXo is set to a value that is equal to the oxygen occlusion capacity of the three-way catalyst 109 , at which the catalyst 109 should be detected as degraded according to the relevant laws, added by a predetermined amount of margin (e.g., about 20%).
[0051] FIG. 6 is an explanatory view that illustrates a relation between the oxygen occlusion capacity [g] at the time when the three-way catalyst 109 is degraded and the amount of exhaust gas emission at the time of travelling in a US FTP (Federal Test Procedure: Exhaust Gas Measuring Procedure) mode, wherein an alternate long and short dash line indicates NMHC (Non-Methane Hydro Carbon: HCs other than methane), and a broken line indicates an amount of NOx emission. In FIG. 6 , a regulation value (with respect to a self-diagnosis function for emission failure) according to the United States OBD (On Board Diagnosis)-2 is defined in such a manner that a failure should be detected when the amount of exhaust gas emission at the time of travelling in the US FTP mode exceeds a predetermined times of an emission regulation value.
[0052] Here, the oxygen occlusion capacity of the three-way catalyst 109 , at which the degradation of the catalyst 109 should be detected, is set so as to satisfy the United States OBD-2 regulation value. Here, it is assumed that characteristic data of FIG. 6 is stored in the ROM 114 in the ECU 112 . Thus, when the target oxygen change amount QOXo is calculated in step 208 , the amount of change of the oxygen QOX in the three-way catalyst 109 is subsequently calculated by the following expression (1) (step 209 ).
QOX=QOX (last value)+| A/F−A/Fb|÷A/Fb×Qa×ΔT×α (1)
where ΔT is a calculation period or cycle of the oxygen change amount QOX; α is an oxygen amount conversion factor; and A/Fb is a basic target air fuel ratio. The basic target air fuel ratio A/Fb is a target air fuel ratio which is set when the air fuel ratio of the mixture is not made rich or lean, and which is a stoichiometric air fuel ratio corresponding to a driving operation point of the internal combustion engine 101 . Further, it is assumed that the amount of intake air Qa is substantially equal to the amount of gas that has passed the three-way catalyst 109 .
[0053] After the oxygen change amount QOX is calculated according to expression (1) above in step 209 , it is subsequently determined whether the oxygen change amount QOX is smaller than the target oxygen change amount QOXo (step 210 ). When it is determined as QOX≧QOXo in step 210 (that is, NO), the oxygen change amount QOX reaches the target oxygen change amount QOXo. Accordingly, the oxygen change amount QOX is set to “0” (step 212 ), the lean flag FL is inverted (e.g., from “1 (hold) ” to “0 (not hold)”) (step 213 ), and the control flow proceeds to step 211 .
[0054] On the other hand, when it is determined as QOX<QOXo in step 210 (that is, YES), it is subsequently determined whether the lean flag FL is set as “1 (hold) ” (step 211 ). When it is determined as FL=1 in step 211 (that is, YES), the target air fuel ratio A/Fo is increased or made leaner by a predetermined amount (e.g., 0.4) than the basic target air fuel ratio A/Fb (step 214 ), and the processing routine of FIG. 2 is terminated.
[0055] On the other hand, when it is determined as FL=0 in step 211 (that is, NO), the target air fuel ratio A/Fo is decreased or made richer by a predetermined amount (e.g., 0.4) than the basic target air fuel ratio A/Fb (step 215 ), and the processing routine of FIG. 2 is terminated.
[0056] FIG. 3 is a flow chart that illustrates a routine for detecting the degradation of the three-way catalyst 109 according to the this embodiment of the present invention. In FIG. 3 , first of all, it is determined whether the degradation determination execution condition holds (step 301 ), and when it is determined that the degradation determination execution condition does not hold (that is, NO), the processing routine of FIG. 3 is immediately terminated and a return is performed.
[0057] On the other hand, when it is determined in step 301 that the degradation determination execution condition holds (that is, YES), it is subsequently determined whether the value of the degradation determination execution counter CN 1 is greater than “0” (step 302 ), and when determined as CN 1 =0 (that is, NO), the control flow advances to step 312 (to be described later).
[0058] When it is determined as CN 1 >0 in step 302 (that is, YES), it is subsequently determined whether the value of the oxygen occlusion amount initialization counter CN 2 is greater than “0” (step 303 ), and when determined as CN 2 >0 (that is, NO), the processing routine of FIG. 3 is terminated at once, whereas when determined as CN 2 =0 in step 303 (that is, YES), it is subsequently determined whether the lean flag FL is the same as the last value (step 304 ), and when determined that the current FL is not equal to the last FL (that is, NO), the control flow advances to step 310 (to be described later).
[0059] On the other hand, when it is determined in step 304 that the current FL is equal to the last FL (that is, YES), it is subsequently determined whether a λ O2 inversion flag Fλ downstream of the three-way catalyst 109 is equal to “0 (not hold)” (step 305 ), and when determined that the degradation determination execution condition does not hold (that is, NO), the processing routine of FIG. 3 is immediately terminated.
[0060] When it is determined as Fλ=0 in step 305 (that is, YES), inversion determination processing for the oxygen concentration λ O2 detected by the λ oxygen sensor 111 is carried out (step 306 ). Specifically, it is determined whether the output value of the λ oxygen sensor 111 downstream of the three-way catalyst 109 is lower than a lean inversion threshold value during the lean processing of the target air fuel ratio A/Fo, or it is determined whether the output value of the λ oxygen sensor 111 downstream of the three-way catalyst 109 exceeds a rich inversion threshold value during the rich processing of the target air fuel ratio A/Fo.
[0061] Here, note that when the value of the oxygen occlusion amount initialization counter CN 2 is greater than zero (i.e., CN 2 >0), the λ O2 inversion flag F λ downstream of the three-way catalyst 109 is set to “0 (not hold)”, and in case of CN 2 =0, the λ O2 inversion flag F λ downstream of the three-way catalyst 109 is set to “1 (hold)” if it becomes less than the lean inversion threshold value when inverted (i.e., at the time of the lean processing of the target air fuel ratio A/Fo), or if it becomes greater than the rich inversion threshold value at the time of the rich processing of the target air fuel ratio A/Fo. In addition, the lean inversion threshold value is set to 0.3 [V] for instance, and the rich inversion threshold value is set to 0.7 [V ], for instance.
[0062] Then, by detecting the timing at which the inversion determination holds in step 306 , it is determined whether the inversion determination of the oxygen concentration λ O2 holds (step 307 ), and when determined that the inversion determination of the oxygen concentration λ O2 does not hold (that is, NO), the processing routine of FIG. 3 is immediately terminated.
[0063] On the other hand, when it is determined in step 307 that the inversion determination of the oxygen concentration λ O2 holds (that is, YES), it is further determined whether the λ O2 inversion flag Fλ downstream of the three-way catalyst 109 is set to “1 (hold)” (step 308 ), and a degradation determination hold counter CN 3 is incremented (i.e., added by “1”)(step 309 ), after which the processing routine of FIG. 3 is terminated.
[0064] Here, note that each time the output value of the λ oxygen sensor 111 downstream of the three-way catalyst 109 is inverted, the degradation determination hold counter CN 3 is incremented by “1”, and when the degradation determination execution counter CN 1 (e.g., initial value=5) becomes “0”, a final degradation determination (to be described later) holds if the value of the degradation determination hold counter CN 3 becomes equal to or greater than “4”.
[0065] On the other hand, when in step 304 the lean flag FL is inverted and hence it is determined that the current FL is not equal to the last FL (that is, NO), the λ O2 inversion flag Fλ downstream of the three-way catalyst 109 is set to “0 (not hold)” (step 310 ), and the degradation determination execution counter CN 1 is subtracted or decremented (step 311 ), after which the processing routine of FIG. 3 is terminated.
[0066] Further, when it is determined in the above step 302 that the degradation determination execution counter CN 1 is equal to zero (CN 1 =0) (that is, NO), final degradation determination processing is carried out in which it is determined whether the degradation determination hold counter CN 3 exceeds a final degradation determination threshold value (preset in the ROM 114 ) (step 312 ).
[0067] Subsequently, in step 313 , it is determined whether the degradation determination execution condition holds in step 312 , and when the degradation determination hold counter CN 3 is less than 4 (i.e., CN 3 <4) and hence it is determined that the degradation determination execution condition does not hold (that is, NO), the processing routine of FIG. 3 is immediately terminated. On the other hand, when in step 313 the degradation determination hold counter CN 3 is equal to or greater than 4 (i.e., CN 3 ≧4) and hence it is determined that the final degradation determination holds (that is, YES), a MIL (Malfunction Indicator Light) lamp is lit so as to inform the driver of the fact that the three-way catalyst 109 is in its deteriorated state (step 314 ), and the processing routine of FIG. 3 is terminated.
[0068] FIG. 4 and FIG. 5 are timing charts that illustrate the operation of the degradation detection device for detecting the degradation of the three-way catalyst 109 according to the this embodiment of the present invention, wherein FIG. 4 shows an operation when it should be detected that the three-way catalyst 109 has been deteriorated, and FIG. 5 shows an operation when the three-way catalyst 109 is normal.
[0069] In FIG. 4 and FIG. 5 , there are illustrated the time-related changes in the respective values of the target air fuel ratio A/Fo (≠A/F at the upstream side of the three-way catalyst 109 ), the oxygen change amount QOX, the oxygen concentration λ O2, the downstream λ O2 inversion flag F λ, the degradation determination execution counter CN 1 , the oxygen occlusion amount initialization counter CN 2 , the degradation determination hold counter CN 3 , and the lean flag FL.
[0070] Hereinafter, reference will be made to the specific contents of processing of the oxygen change amount control routine and the degradation detection routine for the three-way catalyst 109 as stated above along respective steps 401 through 439 while referring to FIG. 4 .
[0071] In FIG. 4 , when the degradation determination execution condition holds by a first time point a, initial values are set in the degradation determination execution counter CN 1 and the oxygen occlusion amount initialization counter CN 2 , respectively (steps 401 , 402 ), and in step 404 , the target air fuel ratio A/Fo is enriched until the value of the oxygen occlusion amount initialization counter CN 2 becomes “0” (steps 403 through 408 ).
[0072] In the enriching period by the first time point a, the oxygen change amount QOX is set to “0” (step 405 ), and the lean flag FL is set to “1” (step 406 ), and the λ O2 inversion flag Fλ downstream of the three-way catalyst 109 is fixed to “0” (step 407 ).
[0073] Subsequently, when the oxygen occlusion amount initialization counter CN 2 becomes “0” within a period from time point a to time point b (step 408 ), the target oxygen change amount QOXo is calculated (step 409 ), and the oxygen change amount QOX is also calculated (step 410 ). Hereinafter, the target air fuel ratio A/Fo is made leaner until the oxygen change amount QOX reaches the target oxygen change amount QOXo (step 411 ).
[0074] When the output value λ O2 (oxygen concentration) of the λ oxygen sensor 111 downstream of the three-way catalyst 109 falls below the lean inversion threshold value within the above-mentioned period from time point a to time point b (step 412 ), the λ O2 inversion flag Fλ downstream of the three-way catalyst 109 is set to “1” (step 413 ), and the degradation determination hold counter CN 3 is incremented (step 414 ).
[0075] Hereinafter, when the oxygen change amount QOX reaches the target oxygen change amount QOXo at time point b as shown in FIG. 5 , the oxygen change amount QOX is set to “0” (step 415 ), and the lean flag FL is set “0” (step 416 ), and the target air fuel ratio A/Fo is made richer. At the same time, the λ O2 inversion flag F λ downstream of the three-way catalyst 109 is set to “0” (step 418 ), and the degradation determination execution counter CN 1 is decremented (step 419 ).
[0076] Subsequently, the target oxygen change amount QOXo and the oxygen change amount QOX are calculated within a period from time point b to time point c, similar to the period from time point a to time point b (steps 420 , 421 ). Thereafter, the target air fuel ratio A/Fo is made richer until the oxygen change amount QOX reaches the target oxygen change amount QOXo (step 417 ).
[0077] When the output value λ O2 (oxygen concentration) of the λ oxygen sensor 111 downstream of the three-way catalyst 109 exceeds the rich inversion threshold value within the period from time point b to time point c (step 422 ), the λ O2 inversion flag F λ is set to “1” (step 423 ), and the degradation determination hold counter CN 3 is incremented (step 424 ).
[0078] Hereinafter, when the oxygen change amount QOX reaches the target oxygen change amount QOXo at time point c as shown in FIG. 5 , the oxygen change amount QOX is set to “0” (step 425 ), and the lean flag FL is set to “1” (step 426 ), and the target air fuel ratio A/Fo is made leaner (step 427 ). At the same time, the λ O2 inversion flag F λ downstream of the three-way catalyst 109 is set to “0” (step 428 ), and the degradation determination execution counter CN 1 is decremented (step 429 ).
[0079] Subsequently, the target air fuel ratio A/Fo is repeatedly made leaner and richer in an alternate manner (steps 427 , 431 , 432 , 433 ) until the value of the degradation determination execution counter CN 1 becomes “0” (step 430 ) within a period from time point c to time point d, similar to the period from time point a to time point c, and the degradation determination hold counter CN 3 is incremented each time the λ O2 inversion flag F λ is set to “1” (steps 434 , 435 , 436 ).
[0080] Hereinafter, when the degradation determination execution counter CN 1 reaches “0” at time point d (step 430 ), as shown in FIG. 5 , the final degradation determination is executed (step 437 ). At this time, when the final degradation determination holds, the MIL lamp is lit (step 438 ), and the degradation detection routine for the three-way catalyst 109 is completed.
[0081] In addition, the target air fuel ratio A/Fo is set to the basic target air fuel ratio A/Fb, and the oxygen change amount control routine for the three-way catalyst 109 is completed (step 439 ). In FIG. 4 , the operation at the time of the degradation detection of the three-way catalyst 109 is illustrated, and the oxygen concentration λ O2 downstream of the three-way catalyst 109 alternately indicates an oxygen occlusion excess state and an oxygen release shortage state for the oxygen change amount QOX.
[0082] On the other hand, the respective operation sequences or steps 401 through 439 in FIG. 5 (at the time of normal operation) are similar to those in the case of FIG. 4 (at the time of degradation detection), but since the three-way catalyst 109 is normal, the output value λ O2 (oxygen concentration) of the λ oxygen sensor 111 downstream of the three-way catalyst 109 is not inverted within the period until time point d, so the degradation determination hold counter CN 3 is not incremented. Also, the oxygen concentration λ O2 downstream of the three-way catalyst 109 continuously indicates a normal value, so at time point d, the final degradation determination becomes “not hold ”, and the MIL lamp is accordingly not lit.
[0083] As described above, the control apparatus for an internal combustion engine according to the this embodiment of the present invention comprises, as shown in FIG. 1 , the three-way catalyst 109 that is arranged in the exhaust system of the internal combustion engine 101 , air fuel ratio detection parts 110 , 111 that are arranged at the upstream side and at the downstream side, respectively, of the three-way catalyst 109 for detecting an air fuel ratio in an exhaust gas, and the ECU 112 that includes a target oxygen change amount calculation part, an oxygen change amount calculation part and an air fuel ratio operation part.
[0084] In the ECU 112 , the target oxygen change amount calculation part calculates a target oxygen change amount, and the oxygen change amount calculation part calculates the amount of change of the oxygen in the three-way catalyst 109 based on the amount of gas having passed through the three-way catalyst 109 (the amount of intake air Qa) and the air fuel ratio A/F upstream of the three-way catalyst 109 .
[0085] In addition, the air fuel ratio operation part controls, in an inverting manner, the air fuel ratio A/F at the upstream side of the three-way catalyst 109 to a rich side and a lean side across the stoichiometric air fuel ratio with a prescribed width of the air fuel ratio each time the amount of change of the oxygen in the three-way catalyst 109 reaches the target oxygen change amount. Moreover, the air fuel ratio operation part controls the air fuel ratio at the upstream side of the three-way catalyst 109 to a prescribed air fuel ratio, which is at a side richer than the stoichiometric air fuel ratio, over a predetermined period of time prior to the start of the operation of the air fuel ratio upstream of the three-way catalyst 109 based on the target oxygen change amount.
[0086] By controlling the amount of change of the oxygen in the three-way catalyst 109 to an amount slightly more than the oxygen occlusion capacity of the deteriorated three-way catalyst 109 , the variation of the oxygen in the three-way catalyst 109 , if in its normal state, does not exceed the oxygen occlusion capacity of the three-way catalyst 109 . As a result, the oxygen concentration λ O2 at the downstream side of the three-way catalyst 109 does not vary, thus making it possible to avoid deterioration of the exhaust gas at the downstream side of the three-way catalyst 109 . On the other hand, if the three-way catalyst 109 is in a deteriorated state, the variation of the oxygen in the three-way catalyst exceeds the oxygen occlusion capacity of the three-way catalyst 109 . Consequently, the oxygen concentration λ O2 at the downstream side of the three-way catalyst 109 is inversely varied to a rich side and a lean side across the stoichiometric air fuel ratio, thus making it possible to detect the degradation of the three-way catalyst 109 with high accuracy.
[0087] Further, by making the air fuel ratio at the upstream side of the three-way catalyst 109 richer than the stoichiometric air fuel ratio over a predetermined period of time prior to the start of the operation of the air fuel ratio upstream of the three-way catalyst 109 based on the target oxygen change amount, it is possible to control the amount of change of the oxygen in the three-way catalyst 109 within a range in which the amount of oxygen occluded in the three-way catalyst 109 does not saturate the oxygen occlusion capacity thereof, thus making it possible to prevent deterioration in the amount of NOx emission.
[0088] Although in the this embodiment of the present invention, the relatively inexpensive λ oxygen sensor 111 is arranged at the downstream side of the three-way catalyst 109 , the present invention is not limited to this, but for example, a linear A/F sensor may be arranged in place of the λ oxygen sensor 111 so as to improve the control accuracy for the air fuel ratio. In addition, although inversion of the output value λ O2 (oxygen concentration) of the λ oxygen sensor 111 at the downstream side of the three-way catalyst 109 is used as a degradation determination reference for the three-way catalyst 109 , the present invention is not limited to this, but for example, an inversion frequency ratio between the respective output values of the sensors arranged at the upstream side and at the downstream side, respectively, of the three-way catalyst 109 may instead be used.
[0089] While the invention has been described in terms of a preferred embodiment, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims. | A control apparatus for an internal combustion engine can detect degradation of a three-way catalyst with high accuracy without causing deterioration in an exhaust. A pair of first and second air fuel ratio detectors are disposed in an exhaust system at locations upstream and downstream of the three-way catalyst for detecting a first and a second air fuel ratio of an exhaust gas. A target oxygen change amount calculator calculates a target oxygen change amount of the three-way catalyst, and an oxygen change amount calculator calculates an oxygen change amount of the three-way catalyst from an amount of exhaust gas passing through the three-way catalyst and the first air fuel ratio. An air fuel ratio operator inversely controls the air fuel ratio to a rich side and a lean side with a prescribed air fuel ratio width each time the oxygen change amount reaches a target oxygen change amount. | 8 |
BACKGROUND OF THE INVENTION
This invention concerns a method of plating aluminum workpieces in the presence of ultrasonic agitation and more specifically has reference to a method wherein an aluminum workpiece is disposed in a body of molten metal maintained at an elevated temperature while the molten metal is subjected to sonic or ultrasonic energy. Exemplary of such a method is the placing of an aluminum workpiece into an ultrasonic apparatus comprising a pool of molten tin which is maintained at an elevated temperature and which is subjected to ultrasonic energy produced by electroacoustic or magnetostrictive transducers either coupled to the outside surface of the tank supporting the pool or by means of sonically activated horns contacting the pool.
As is known in the prior art, tinning of aluminum using tin or lead-tin alloys can be done most effectively by means of an ultrasonically activated bath. The ultrasonic energy displaces the tenacious oxide layer normally adhering to the aluminum surface and causes a clean oxide-free surface to which the tin adheres.
The above described process has received renewed attention in connection with the desire of producing parts, especially electrical conductors, made of aluminum rather than copper. Aluminum is not only less expensive, but is also more plentiful than copper ore.
Heretofore tinned electrical grade aluminum parts, such as buss bar or electrical wire, coated with pure tin or an alloy of lead-tin, have been afflicted with certain shortcomings which have caused the industry to reject the use of such tinned aluminum parts. In particular, when the coating was applied in the presence of ultrasonic activation, the coating failed to provide a strong metallurgical interface bond between the tin and the aluminum. The lack of such bond permitted continued oxidation of the aluminum surface resulting in the occurrence of cracks and even the flaking off of the tin coating.
One prior solution was to use a zinc aluminum (95/5) solder coating on the aluminum part. The solder coating, while forming a metallurgical bond with the aluminum part, also increased the electrical resistance of the finished product. As a result, the zinc-aluminum coated aluminum part has not been successful in many applications, for example as an electrical buss bar termination.
Another application comprises the coating of aluminum horns (also known as resonators, tools, mechanical amplitude transformers etc.) as used for transmitting sonic or ultrasonic vibrations from an electroacoustic transducer to a workpiece. In the past, such horns have been made from titanium. The price of this latter metal recently has tripled and, therefore, it has become more economical to utilize aluminum for those applications where the lower yield strength of aluminum as compared with titanium can be tolerated. However, aluminum exhibits a relatively soft surface and it is necessary to provide a harder finish, usually chrome plating, in order to reduce wear. In view of the fact that chrome cannot successfully be deposited, electrically or chemically, upon aluminum, an intermediate metal coating must be provided. Tin performs such a function. Unless there is an extremely tenacious bond between the aluminum and the tin, the high frequency cyclic expansions and contractions to which a horn is subjected cause a disruption of the bond between the tin and the aluminum and as a result, the chrome layer peels and flakes off. The rather expensive horn must then be replaced.
SUMMARY OF THE INVENTION
The present invention overcomes the heretofore encountered problems by making use of the phase diagrams of binary alloy systems. The temperature of the sonically activated plating bath is selected to provide a liquid alloy interface between the workpiece and the pool of molten metal. In the specific application where the plating bath comprises commercially pure tin and the aluminum is electrical grade aluminum, the pool is maintained at a temperature of at least 300°C. The result when the workpiece disposed in the bath reaches a temperature of 300°C is an interface alloy of approximately 98% Sn by weight and 2% Al. As the temperature increases, the percentage of aluminum in the resultant alloy increases. The creation of an alloy at the interface provides truly a metallurgical bond between the tin coating and the aluminum workpiece as contrasted with the adhesive bond provided heretofore.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a phase diagram of a typical binary alloy system, in the present case aluminum-tin.
DESCRIPTION OF THE INVENTION
The FIGURE depicts a phase diagram of binary alloy systems, in the present example aluminum-tin. The vertical axis indicates degrees of temperature, the horizontal axis identifies weight percentage of tin. The curve is the demarcation line between the solid and liquid phase. The area above the curve denotes a liquid state.
Hence, when an aluminum workpiece, substantially pure grade, is immersed in a pool of pure tin at 300°C, there will be produced an alloy of approximately 98% Sn by weight and 2% Al. Similarly, at 600°C the ratio will be 50/50.
In order to provide a tenacious bond between the surface metal and the material of the workpiece, it is desirable that at the transition area (interface) there be an alloy encompassing both metals. This is essentially a metallurgical bond as contrasted with an adhesive bond. In the case of an aluminum workpiece and a tin surface coating, a two to ten percent interface aluminum content has been found adequate.
Coating of an aluminum workpiece with tin, in accordance with the present invention, comprises the steps of providing a pool of substantially pure molten tin which is maintained at a temperature of not less than 300°C and immersing the workpiece in the pool of tin and awaiting the surface of the workpiece to attain a temperature of at least 300°C. Alternatively, the workpiece may be preheated prior to contact with the molten metal. While the workpiece is immersed in the pool high frequency vibrations in the sonic or ultrasonic frequency range (1 to 100 kHz) are applied to the pool for causing the molten metal to be agitated and scrub the aluminum workpiece surface free from oxide to achieve an oxide free metallurgical interface alloy, and withdrawing the workpiece from the tin pool.
Additional decorative or hard metallic surface layers, such as hard chrome, can then be applied to the outer tin coating as is well-known in the art. The high frequency vibrations can be applied to the molten metal pool simultaneously with the immersion of the workpiece in the molten metal bath, or after the workpiece has been brought into contact with the plating bath. The failure of providing high frequency vibrations when using the aluminum and tin combination causes the absence of a proper bond due to the prevailing oxide layer.
The fluxless coating of aluminum with solder using high frequency vibrations in the sonic or ultrasonic frequency range has been disclosed, for instance, by Barwich, U.S. Pat. No. 2,397,400, dated Mar. 26, 1946.
Tests conducted for evaluation purposes on electrical grade aluminum parts which have been plated in accordance with the teachings of the present invention with reflow oil have shown that an improved metallurgical bond is manifest at the interface of the two metals. Workpieces having a first layer of tin, plated in accordance with this test method, are placed in a second pool of molten tin having a layer of oil floating thereon for plating a second layer of tin upon the workpiece. The reflow oil floating on the molten tin strips away any tin which has not formed a sound metallurgical bond with the aluminum workpiece. Tests conducted on parts plated with tin/aluminum alloys using commercially pure tin which is applied at a temperature below the phase curve exhibited a significant amount of peeling, stripping and cracking of the coating when contacted with the reflow oil. In comparison, the aluminum parts coated with ultrasonically agitated tin at temperatures of 300°C or higher failed to exhibit peeling or stripping when subjected to the same test conditions.
In another application, aluminum wire of 0.375 inches (9.5 mm) diameter was coated with tin in accordance with the process described above. The cross-section of the wire was then reduced by consecutive drawing processes to a final diameter of 0.135 inches (3.5 mm). No flaking or peeling of the tin coating was discernible.
It will be observed that the present invention provides a significant improvement over the plating methods known heretofore. | This invention discloses the plating of a metallic workpiece, particularly aluminum with a layer of tin. The plating is accomplished in the presence of sonic or ultrasonic vibrations at a temperature determined by the phase diagram for a binary alloy to provide for the presence of an alloy interface encompassing both metals. This contrasts with the heretofore achieved adhesive bond. | 2 |
BACKGROUND OF THE INVENTION
[0001] DE 101 24 506 A1 relates to a starter for a motor vehicle. The starter comprises a pole housing which contains the starter motor, an engagement relay which is arranged parallel to said pole housing and contains a solenoid switch, an engagement lever, which is rotatably mounted with a transition region between the pole housing and the engagement relay, for coupling the starter motor to the internal combustion engine. A seal to prevent the ingress of contaminants and moisture into the engagement relay is also provided. The seal is formed by a rubber diaphragm, which is connected to the housing walls, within the transition region between the pole housing and the engagement relay.
[0002] DE 195 49 179 A1 relates to an engagement relay for a starter apparatus. The engagement relay comprises a contact bridge which bridges at least two contact pins in the switched-on state and which is fitted to a moving switching spindle. The contact bridge has in each case at least two defined contact areas which are associated with one contact pin and which are provided on spring arms which are flexible in their longitudinal extent and transverse to their longitudinal extent.
[0003] Whereas approximately 40 000 starting processes are completed over the service life of a vehicle in conventional electrical starting apparatuses for internal combustion engines, up to half a million and more switching processes are carried out in starters which are employed in internal combustion engines with a start/stop functionality. This means that the electrical starting apparatus has to be correspondingly designed.
[0004] The electrical starting apparatus accordingly has to be designed for such a high number of switching cycles and complete these without problems. It has been found that relatively high demands are made of the acoustics of the electrical starting apparatus in passenger cars which are equipped with a start/stop functionality. Noises which are produced by metal elements being struck in the components of a starter, in particular an electrical starting apparatus, are found to cause discomfort and to be disturbing.
SUMMARY OF THE INVENTION
[0005] In order to reduce the noise level when operating an electrical starting apparatus, the invention proposes pneumatically providing pneumatic damping between components which move relative to one another, in particular a linearly moving relay armature and an armature return. When power is supplied to the magnet coils of the relay of an electrical starting apparatus, the relay armature which is displaceably guided in the relay housing moves toward an armature return which is arranged in a stationary manner in the relay. Both the end faces of the relay armature which moves relative to the armature return and those of the armature return have a mutually complementary geometric contour and form a hollow space which is filled with a fluid, in particular air.
[0006] By virtue of providing suitable sealing measures, for example providing a V-shaped sealing lip or a sealing ring which is fitted to the casing surface of the relay armature which moves relative to the relay housing, the volume of fluid which remains in the hollow space between the relay armature and the armature return is sealed off to prevent losses, that is to say leakage, and therefore the volume of fluid can be used as a fluid cushion for damping the stopping movement of the end face of the relay armature against the corresponding end face of the armature return, it being possible for this to be used to drastically reduce the momentum of the moving relay armature and accordingly to reduce its energy. Examples of a fluid are air or another gas and also a liquid. The volume of fluid remaining in the hollow space between the end face of the relay armature and the correspondingly designed end face of the armature return forms a fluid cushion which damps the stopping movement of the end face of the relay armature as it moves into the relay housing and accordingly damps the striking movement, which is produced when contact is made between the end face of the relay armature and the end face of the armature return, by virtue of a reduction in energy.
[0007] The denser the volume of fluid within the hollow space between the end face of the relay armature and the end face of the armature return can be kept, the greater the damping effect that can be achieved with the solution proposed according to the invention on account of the low leakage losses. Instead of the V seal between the circumference of the relay armature and the relay housing, it is also possible to form a precise transition fit, for example a H7/g6 fit, in order to keep the leakage losses, that is to say the flow of fluid out of the hollow space between the end faces of the relay armature and the armature return, as low as possible.
[0008] In a further variant embodiment for the pneumatic damping of a relay as proposed according to the invention, in particular for operating or for initializing an electrical starting apparatus, the relay armature can contain a longitudinal bore. Said longitudinal bore is connected both to the hollow space between the end face of the relay armature and to the surrounding area. Furthermore, a longitudinal bore, which issues into the hollow space between the end face of the relay armature and the end face of the armature return at one end and into a relief space in the relay housing at the other end, likewise extends through the thickness of the armature return. A valve, for example a non-return valve, can be incorporated in this channel which connects the hollow space to the relief space. If the valve is in the form of a non-return valve, for example, it is oriented in such a way that it closes when the volume of fluid within the hollow space between the end faces of the relay armature and armature return is compressed, and thereby prevents a volume of fluid from flowing out of this hollow space. In one possible variant embodiment of the solution proposed according to the invention, when a valve is provided in the armature return, a main channel, which can be closed by a valve element, and an auxiliary channel, which issues next to the closing element and is always open, for example, issue at the valve seat of said valve. The flow cross sections of the main channel and the auxiliary channel preferably have a size such that the flow cross section of the main channel is larger than the flow cross section of the auxiliary channel. If the volume of fluid in the hollow space between the end face of the relay armature and the end face of the armature return is compressed, the closing element is pushed into the seat and closes the main channel. In accordance with the design of the flow cross section of the auxiliary channel which stays open, the volume of fluid flows out of the hollow space between the end face of the relay armature and the end face of the armature return in a throttled manner, and therefore a volume of fluid which damps the stopping movement of the end face of the relay armature against the end face of the armature return is maintained in the hollow space, this being only partially relieved of pressure into the relief space by means of the auxiliary channel which serves as an outflow channel when the volume of fluid is compressed.
[0009] In a further variant embodiment of the solution proposed according to the invention for the pneumatic damping of the relay armature and armature return, by way of example, a guide bush which surrounds a switching pin can be provided with a number of openings, for example transverse bores. These transverse bores allow, depending on the degree of opening of said transverse bores, the volume of fluid to flow out via the openings, depending on the degree of opening of said openings, in the event of a relative displacement with respect to the armature return which is arranged in the relay in a stationary manner. The guide bush serves, depending on the operating path of the switching pin, as a slide, with the volume of fluid flowing out of the hollow space between the relay armature and the armature return of the relay being defined by the degree of opening or degree of overlap of the openings which are formed in the wall filling bush. The volume which flows out of the hollow space between the relay armature and the armature return via the openings in the wall of the guide bush flows into the relief space in the relay.
[0010] In a further variant embodiment of the solution proposed according to the invention, when a specific travel movement, that is to say a specific distance ΔS between the end face of the relay armature and the end face of the armature return which is arranged in the relay in a stationary manner, is achieved, a valve can be operated by the end face of the relay armature itself. To this end, a peg-like valve element is provided in the armature return, said valve element being prestressed by means of a spring and being in the closed state as the end face of the relay armature approaches. If the end face of the approaching relay armature strikes an end of the peg-like valve when the distance Δs is reached, said valve is opened as the relay armature gets closer, and therefore fluid flows out of the hollow space, which is defined by the distance Δs, between the end face of the relay armature and the end face of the armature return, which is accommodated in the relay in a stationary manner, only when the distance Δs is reached, and a counterpressure is built up and maintained in order to reach the distance Δs, said counterpressure counteracting the stopping movement of the end face of the relay armature against the end face of the armature return of the relay in a damping manner.
[0011] A channel in which the peg-like valve element in the armature return is accommodated can preferably be formed in such a way that said channel is connected to a slot by means of which a volume of fluid flows out of the remaining hollow space, which is defined in accordance with the distance Δs, between the end face of the relay armature and the end face of the armature return when the peg-like valve element is operated by the end surface of the relay armature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will be described in greater detail below with reference to the drawing, in which:
[0013] FIG. 1 shows a longitudinal section through a starting apparatus,
[0014] FIG. 2 shows a schematic illustration of the relay having a relay armature and an armature return,
[0015] FIG. 3 shows a variant embodiment of a valve in the form of a non-return valve,
[0016] FIG. 4 shows a guide bush, which acts as slide, in the armature return, accommodated on a switching pin which is not illustrated in FIG. 4 ,
[0017] FIG. 5 shows a V lip formed in a circumferential slot in the relay armature,
[0018] FIG. 6 shows a valve which is operated when a distance Δs is reached between the end face of the relay armature and the end face of the armature return which is arranged in the relay armature in a stationary manner, and
[0019] FIG. 6.1 shows a section through a channel having a slot in the armature return of the relay.
DETAILED DESCRIPTION
[0020] FIG. 1 shows a starting apparatus 10 . This starting apparatus 10 has, for example, a starter motor 13 and a relay 16 . The starter motor 13 and the relay 16 are attached to a common drive end plate 19 . The starter motor 13 has the functional task of driving a starter pinion 22 which is generally in the form of a spur gear. The starter pinion 22 meshes with a ring gear 25 of an internal combustion engine, which is not illustrated in FIG. 1 .
[0021] The starter motor 13 has, as a housing, a pole tube 28 which has pole shoes 31 on its inner circumference, with a field winding 34 being wound around each of said pole shoes. The pole shoes 31 in turn surround an armature 37 , which has an armature stack 43 comprising laminations 40 and an armature winding 49 arranged in slots 46 . The armature stack 43 is pressed onto a drive shaft 44 . Furthermore, a commutator 52 is fitted at that end of the drive shaft 44 which is remote from the starter pinion 22 , said commutator comprising, inter alia, individual commutator laminations 55 . The commutator laminations 55 are electrically connected to the armature winding 49 , in a known manner, in such a way that, when power is supplied to the commutator laminations 55 by carbon brushes 58 , a rotary movement of the armature 37 is produced in the pole tube 28 . A power supply line 61 which is arranged between the meshing relay 16 and the starter motor 13 supplies power to both the carbon brushes 58 and the field winding 34 in the switched-on state. The drive shaft 44 is supported on the commutator side by a shaft journal 64 and a sliding bearing 67 which in turn is held fixed in position by a commutator bearing cap 70 . The commutator cap 70 is in turn fixed in the drive end plate 19 by means of tension rods 73 , which are arranged distributed over the circumference of the pole tube 28 (screws, for example two, three or four pieces). In the process, the pole tube 28 is supported on the drive end plate 19 , and the commutator bearing cap 70 is supported on the pole tube 28 .
[0022] In the drive direction, the armature 37 is adjoined by a sun gear 80 , which is part of a planetary gear mechanism 83 . The sun gear 80 is surrounded by a plurality of planet gears 86 , usually three planet gears 86 , which are supported by means of roller bearings 89 on axle journals 92 . The planet gears 86 roll in a hollow wheel 95 , which is mounted externally in the pole tube 28 . In the direction toward the output drive side, the planet gears 86 are adjoined by a planet carrier 98 , in which the axle journals 92 are accommodated. The planet carrier 98 is in turn mounted in an intermediate bearing 101 and a sliding bearing 104 which is arranged therein. The intermediate bearing 101 is configured in the form of a pot in such a way that both the planet carrier 98 and the planet gears 86 are accommodated in said intermediate bearing. Furthermore, the hollow wheel 95 is arranged in the pot-shaped intermediate bearing 101 and is ultimately closed by a cover 107 with respect to the armature 37 . The intermediate bearing 101 is also supported by way of its outer circumference on the inner face of the pole tube 28 . The armature 37 has a further shaft journal 110 on that end of the drive shaft 44 which is remote from the commutator 52 , said shaft journal likewise being accommodated in a sliding bearing 113 . The sliding bearing 113 is in turn accommodated in a central bore in the planet carrier 98 . The planet carrier 98 is integrally connected to the output drive shaft 116 . This output drive shaft 116 is supported by its end 119 which is remote from the intermediate bearing 101 in a further bearing 122 , the A bearing, which is formed in the drive end plate 19 . The output drive shaft 116 is divided into various sections: a section with a straight gearing 125 (inner gearing) which is part of a shaft-hub connection 128 thus follows the section which is arranged in the sliding bearing 104 of the intermediate bearing 101 . This shaft-hub connection 128 makes it possible in this case for a driver 131 to perform an axially linear sliding movement. This driver 131 is a sleeve-like protrusion, which is integral with a pot-shaped outer ring 132 of the freewheel 137 . This freewheel 137 (ratchet) furthermore comprises the inner ring 140 , which is arranged radially within the outer ring 132 . Clamping bodies 138 are arranged between the inner ring 140 and the outer ring 132 . The clamping bodies 138 , in interaction with the inner and the outer ring, prevent a relative movement between the outer ring and the inner ring in a second direction. The freewheel 137 allows a relative movement between the inner ring 140 and the outer ring 132 in only one direction. In this exemplary embodiment, the inner ring 140 is integrally formed with the starter pinion 22 and the helical gearing 143 (outer helical gearing) thereof.
[0023] The relay 16 has a pin 150 , which constitutes an electrical contact and is connected to the positive terminal of an electrical starter battery (not illustrated in FIG. 1 ). This pin 150 is passed through a relay cover 153 . This relay cover 153 closes off a relay housing 156 , which is fastened to the drive end plate 19 by means of a plurality of fastening elements 159 (screws). A pull-in winding 162 and a holding winding 165 are furthermore arranged in the relay 16 . The pull-in winding 162 and the holding winding 165 both each induce an electromagnetic field in the switched-on state, said electromagnetic field flowing through both the relay housing 156 (composed of electromagnetically conductive material), a linearly moving armature 168 and an armature return 171 . The armature 168 has a push rod 174 , which is moved in the direction of a switching pin 177 during linear pull-in of the armature 168 . With this movement of the push rod 174 toward the switching pin 177 , said switching pin is moved out of its rest position in the direction toward two contacts 180 and 181 , so that a contact bridge 184 , which is fitted at the end of the switching pin 177 , electrically connects the two contacts 180 and 181 to one another. As a result, electrical power is passed from the pin 150 , beyond the contact bridge 184 , to the power supply line 61 and therefore to the carbon brushes 58 . Power is supplied to the starter motor 13 in the process.
[0024] However, the relay 16 and the armature 168 furthermore also have the task of moving, with a pull element 187 , a lever which is arranged in the drive end plate 19 such that it can rotate. The lever 190 , usually in the form of a forked lever, engages with two “prongs” (not shown here) on its outer circumference around two disks 193 and 194 in order to move a driver ring 197 , which is trapped between said disks, toward the freewheel 137 counter to the resistance of the spring 200 and thereby to mesh the starter pinion 22 with the ring gear 25 of the internal combustion engine.
[0025] FIG. 2 shows a schematic section through the relay for operating the starting apparatus according to FIG. 1 on an enlarged scale.
[0026] The illustration according to FIG. 2 shows a relay for operating an electrical starting apparatus on an enlarged scale.
[0027] FIG. 2 shows that the relay 16 has a linearly moving armature, that is to say a relay armature 168 , the end face 206 of said armature corresponding to the end face of the armature return 171 which is accommodated in the relay housing 156 . A hollow space 236 , which is filled with a fluid, for example air, is formed between the end face 206 and that end face of the armature return 171 which is situated opposite said end face 206 . A channel 204 which issues at a mouth 208 in the end face 206 of the relay armature 168 passes through the relay armature.
[0028] A channel 210 likewise passes through the armature return 171 , a valve, which is illustrated on an enlarged scale in FIG. 3 , for example in the form of a non-return valve 212 , being accommodated in said channel.
[0029] Both the channel 204 in the relay armature 168 and the channel 210 in the armature return 171 have a diameter of only a few mm. The channel 204 in the relay armature 168 extends from the mouth 208 , runs through the relay armature 168 , and issues in the external area surrounding the relay 16 .
[0030] The channel 210 , which passes through the armature return 171 , connects the hollow space 236 to a relief space 253 on that side of the armature return 171 which is averted from the relay armature 168 and is accommodated in the relay housing 156 of the relay 16 in a stationary manner. Reference symbol 153 denotes a relay cover of the relay 16 .
[0031] FIG. 3 shows a valve which is in the form of a non-return valve 212 and is arranged in the channel 210 of the armature return 171 . A spring-loaded, in this case spherical, closing element 214 is provided in the valve 212 which is in the form of a non-return valve, said closing element being pushed by the spring into a seat 216 which is formed in the armature return 171 . Both a main channel 218 , which has a first diameter D 1 , compare reference symbol 220 , and an auxiliary channel 220 , which has a smaller, second diameter D 2 , compare item 224 , extend from the seat 216 of the valve 212 . While the main channel 218 is closed when the closing element 214 is in its seat 216 , this is not the case for the auxiliary channel 220 which is still permeable but has a second, smaller diameter D 2 , compare item 224 , than the first diameter D 1 , compare item 222 of the main channel 218 , in the closed state of the closing element 214 .
[0032] In the variant embodiment of a pneumatic damping arrangement illustrated in FIGS. 2 and 3 , the volume of fluid which is contained in the hollow space 236 is compressed as the end surface 206 approaches in the event of a linear movement of the relay armature 168 in the direction of the end face of the armature return 171 . As a result, the energy of the relay armature 168 which is moving toward the armature return 171 is reduced. On account of the build-up of pressure, the non-return valve 212 closes the seat 216 and therefore the main channel 218 , while a flow of fluid through the auxiliary channel 200 , which is not closed by the closing element 214 and issues into the relief space 253 , can be reduced. This results in a gradual reduction in pressure in the hollow space 236 , with the pressure level, however, being kept at a level such that the end surface 206 of the relay armature which is moving toward the armature return 171 does not come to a hard stop and the development of noise due to hard contact between the metals of the end surface 206 at that end surface of the relay armature 171 which corresponds to said end surface 206 is precluded.
[0033] The illustration according to FIG. 4 shows that hydraulic damping can also be achieved by a guide bush, which is accommodated on the switching pin 177 , in this variant embodiment.
[0034] In this variant embodiment, compare the illustration according to FIG. 1 , the guide bush 202 , which is accommodated on the switching pin 177 , is provided with a number of openings 230 and 232 which can be in the form of, for example, transverse bores which run through the wall of the guide bush 202 .
[0035] In the illustration according to FIG. 4 , the guide bush 202 having openings, which are in the form of transverse bores 230 and 232 , is placed in a first position 226 which is indicated by solid lines. If, as shown in the illustration according to FIG. 2 , the relay armature 168 moves by way of its end face 206 into the hollow space 236 in the relay housing 156 of the relay 16 , the volume of fluid present in said hollow space will be compressed. The switching pin 177 , which is not illustrated in FIG. 2 but is illustrated in FIG. 1 , moves into the armature return 171 , so that the guide bush 202 which is accommodated on said switching pin is moved from the first position 226 , which is illustrated in FIG. 4 and indicated by solid lines, to its second position 228 , which is indicated by dashed lines. During this movement into the relief space 253 , the openings 230 in the wall of the guide bush 202 are fully or partially exposed, so that a connection is created between the hollow space 236 and the relief space 256 within the relay housing 156 . Depending on the design of the cross sections and the number of openings in the wall of the guide bush 202 , compressed fluid flows out of the hollow space 236 and into the relief space 253 . The contact between the end face 206 of the relay armature 168 and the end face of the armature return 171 is pneumatically damped by virtue of this gradual reduction in pressure in the hollow space 236 and by virtue of compressed fluid flowing out of the hollow space 236 and into the relief space 253 in a controlled manner.
[0036] The illustration according to FIG. 5 shows a further variant embodiment of a pneumatic damping arrangement of a relay.
[0037] In this variant embodiment, the armature 168 , which is only indicated in FIG. 5 , is provided with a circumferential slot 238 or a recess over its circumference. In the illustration according to FIG. 5 , the circumferential slot 238 is approximately square and has a V lip 240 arranged in it.
[0038] The V lip 240 has a limb which engages against the wall of the relay housing 156 . If the relay armature 168 moves in the second movement direction 244 , the upper limb of the V lip 240 will engage against the wall of the relay housing 156 , so that damping in respect of the relay armature 168 is provided in a manner dependent on the movement direction. If, in contrast, the relay armature 168 is moved in the first movement direction 242 , the volume of fluid enclosed in the hollow space 236 will be relieved of pressure.
[0039] The variant embodiments of a pneumatic damping arrangement according to FIGS. 2 , 3 4 and 5 can be used to provide direction-dependent pneumatic damping if the relay armature 168 moves, by way of its end face 206 , into the hollow space 236 , the volume of fluid which is contained in said hollow space is compressed, and a gradual reduction in pressure is initiated in the hollow space 236 or, compare the illustration according to FIG. 5 , the hollow space 236 is sealed off from pressure loss, so that the development of noise when the end face 206 of the relay armature 168 stops against that end face of the armature return 171 which is accommodated in the relay housing 156 in a stationary manner is significantly damped.
[0040] The illustrations according to FIGS. 6 and 6 . 1 show a further variant embodiment of the pneumatic damping arrangement proposed according to the invention.
[0041] If the end face 206 of the armature 168 has reached a distance Δs from the end face of the armature return 171 , a valve element 246 is operated. The valve element 246 , which is in the form of a peg in this case and which is accommodated in a channel 254 such that it can move, is operated by a valve stop 250 stopping against the end of the peg-like valve element 246 . A head 252 of the valve element 246 is moved into the relief space 253 against the action of the spring force of the valve spring 248 , so that a slot 256 is exposed, volumes of fluid flowing out of the hollow space 236 which is defined by the distance Δs and into the relief space 253 via said slot.
[0042] The valve which is illustrated in the illustration according to FIG. 6 responds only when a well-defined distance Δs between the end face 206 of the relay armature 168 and the end face of the armature return 171 , which is designed to have a geometry which corresponds to said end face of the relay armature, is reached.
[0043] For the sake of completeness, it should be mentioned that reference symbol 150 denotes the pin by means of which power is supplied to the relay 16 .
[0044] The illustration according to FIG. 6 shows that the slot 256 in the armature return 171 runs, for example, above the actual channel 254 in the material of the armature return 171 . The slot 256 can also be formed at the 3 o'clock, 6 o'clock or 9 o'clock position or any other desired defined position in respect of the illustration according to FIG. 6.1 .
[0045] The valve element 246 which is illustrated in the illustration according to FIG. 6 opens only when a well-defined distance Δs between the components relay armature 168 and the armature return 171 , which is arranged in the relay housing 156 in a stationary manner, is reached. | The invention relates to a relay ( 16 ), especially for electrical starting devices for internal combustion engines. The relay ( 16 ) comprises a relay armature ( 168 ) and an armature return element ( 171 ). A fluid, enclosed in a hollow space ( 236 , Δs), between the relay armature ( 168 ) and the armature return element ( 171 ) pneumatically damps the collision between the relay armature ( 168 ) and the armature return element ( 171 ). | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 13/741,690, filed 15 Jan. 2013 (issuing as U.S. Pat. No. 8,657,532 on 25 Feb. 2014), which is a continuation of U.S. patent application Ser. No. 12/861,589, filed 23 Aug. 2010 (issued as U.S. Pat. No. 8,353,643 on 15 Jan. 2013), which is a continuation in part of U.S. patent application Ser. No. 11/749,587, filed 16 May 2007 (issued as U.S. Pat. No. 7,780,375 on 24 Aug. 2010), which claimed priority of U.S. Provisional Patent Application Ser. No. 60/824,005, filed 30 Aug. 2006, each of which is hereby incorporated herein by reference, and priority to each of which is hereby claimed.
[0002] U.S. patent application Ser. No. 12/861,589, filed 23 Aug. 2010, also claimed priority of U.S. Provisional Patent Application Ser. No. 61/356,813, filed 21 Jun. 2010, each of which is hereby incorporated herein by reference and priority to each of which is hereby claimed.
[0003] U.S. patent application Ser. No. 12/813,290, filed 10 Jun. 2010 (issued as U.S. Pat. No. 8,002,500 on 23 Aug. 2011), is hereby incorporated herein by reference.
[0004] International Patent Application No. PCT/US2010/046358, filed 23 Aug. 2010 (published as No. WO2011/162780 on 29 Dec. 2011), is hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0005] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0006] Not applicable
BACKGROUND OF THE INVENTION
[0007] 1. Field of the Invention
[0008] The present invention relates to marine platforms such as oil and gas well drilling platforms. More particularly, the present invention relates to an improved method and apparatus for elevating the deck area of a fixed marine platform to better protect equipment that is located on the deck area from the effects of a storm (e.g., hurricane, tsunami, typhoon) that generates heightened wave action.
[0009] 2. General Background of the Invention
[0010] There are many fixed platforms located in oil and gas well drilling areas of oceans and seas of the world. Such marine platforms typically employ an undersea support structure that is commonly referred to as a jacket. These jackets can be many hundreds of feet tall, being sized to extend between the seabed and the water surface area. Jackets are typically constructed of a truss-like network of typically cylindrically shaped pipe, conduit or tubing that is welded together. The jackets can be secured to the seabed using pilings that are driven into the seabed. The jacket is then secured to the piling. The part of the offshore marine platform that extends above the jacket and above the water surface is typically manufactured on shore and placed upon the jacket using known lifting equipment such as a derrick barge. This upper portion is the working part of the platform that is inhabited by workers.
[0011] Marine platforms can be used to perform any number of functions that are associated typically with the oil and gas well drilling and production industry. Such platforms can be used to drill for oil and gas. Such platforms can also be used to produce wells that have been drilled. These fixed platforms typically provide a deck area that can be crowded with extensive equipment that is used for the drilling and/or production of oil and gas.
[0012] When storms strike over a body of water, offshore marine platforms are put at risk. While the jacket and platform are typically designed to resist hurricane force wind and wave action, equipment located on the deck of the marine platform can easily be damaged if hurricane generated wave action reaches the deck area.
[0013] An additional consequence of wave action reaching the platform deck is catastrophic platform collapse, which happened in several instances during recent storms (e.g., hurricane Katrina in the United States Gulf of Mexico).
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention solves these prior art problems and shortcomings by providing a method and apparatus for elevating the deck area of an existing marine platform so that equipment that occupies the deck can be further distanced from the water surface. The method of the present invention provides more clearance, more freeboard and more protection to deck area equipment during severe storms such as hurricanes.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0016] FIG. 1 is a schematic, elevation view of a fixed marine platform;
[0017] FIG. 2 is a perspective view illustrating a method step of the present invention;
[0018] FIG. 3 is a perspective view illustrating a method step of the present invention;
[0019] FIG. 4 is a perspective view illustrating a method step of the present invention, placement of the upper and lower bushing sleeves;
[0020] FIG. 5 is a partial perspective view of a preferred embodiment of the apparatus of the present invention illustrating placement of the upper and lower bushing sleeves;
[0021] FIG. 6 is a partial perspective view of a preferred embodiment of the apparatus of the present invention illustrating a method step of the present invention;
[0022] FIG. 7 is a partial perspective view of a preferred embodiment of the apparatus of the present invention illustrating one of the extension sleeve guides;
[0023] FIG. 8 is a sectional view taken along lines 8 - 8 of FIG. 7 ;
[0024] FIG. 9 is a partial elevation view of a preferred embodiment of the apparatus of the present invention illustrating placement of the extension sleeve guides;
[0025] FIG. 10 is a partial elevation view of a preferred embodiment of the apparatus of the present invention showing positions of the leg cuts;
[0026] FIG. 11 is a partial perspective exploded view of a preferred embodiment of the apparatus of the present invention;
[0027] FIG. 12 is a partial perspective view of a preferred embodiment of the apparatus of the present invention illustrating the method of the present invention, placement of the upper ring;
[0028] FIG. 13 is a partial elevation view of a preferred embodiment of the apparatus of the present invention illustrating placement of the upper ring;
[0029] FIG. 14 is a partial perspective exploded view of a preferred embodiment of the apparatus of the present invention illustrating placement of the hydraulic pistons;
[0030] FIG. 15 is a partial perspective view of a preferred embodiment of the apparatus of the present invention illustrating placement of the hydraulic pistons;
[0031] FIG. 16 is a fragmentary elevation view illustrating the method of the present invention, namely the step of completing the leg cuts;
[0032] FIG. 17 is a fragmentary perspective of a preferred embodiment of the apparatus of the present invention illustrating extension of the leg with the hydraulics pistons;
[0033] FIG. 18 is a partial perspective view of a method and apparatus of the present invention, showing a method step of closing the sleeve openings;
[0034] FIG. 19 is an elevation view of a preferred embodiment of the apparatus of the present invention illustrating the marine platform after its deck area has been elevated using the method and apparatus of the present invention;
[0035] FIG. 20 is a partial elevation view of an alternate embodiment and method of the present invention illustrating an existing deck elevation prior to being elevated using an alternate embodiment of the apparatus of the present invention;
[0036] FIG. 21 is an elevation view illustrating an alternate method and apparatus of the present invention and showing an initial deck lift;
[0037] FIG. 22 is a partial perspective view of an alternate method and apparatus of the present invention;
[0038] FIG. 23 is a partial perspective view of an alternate embodiment of the apparatus of the present invention;
[0039] FIG. 24 is a fragmentary elevation view of an alternate embodiment of the apparatus of the present invention and alternate method;
[0040] FIG. 25 is a fragmentary perspective view of an alternate embodiment of the apparatus and method of the present invention;
[0041] FIG. 26 is a fragmentary perspective view of an alternate embodiment of the apparatus and method of the present invention;
[0042] FIG. 27 is a fragmentary perspective view of an alternate embodiment of the apparatus and method of the present invention showing the locking pin; and
[0043] FIG. 28 is a partial perspective view of an alternate embodiment of the apparatus of the present invention illustrating a sleeve and a half-pipe pin trough that is used to support the pins prior to insertion;
[0044] FIG. 29 is a partial elevation view of an alternate embodiment of the apparatus of the present invention showing an alternate method of the present invention;
[0045] FIG. 30 is a partial elevation view of an alternate embodiment of the apparatus of the present invention showing an alternate method of the present invention;
[0046] FIG. 31 is a partial elevation view of an alternate embodiment of the apparatus of the present invention showing an alternate method of the present invention;
[0047] FIG. 32 is a partial elevation view of an alternate embodiment of the apparatus of the present invention showing an alternate method of the present invention;
[0048] FIG. 33 is a partial elevation view of an alternate embodiment of the apparatus of the present invention showing an alternate method of the present invention;
[0049] FIG. 34 is a perspective view of an alternate embodiment of the apparatus of the present invention and illustrating an alternate method of the present invention;
[0050] FIG. 35 is an exploded elevation view illustrating an alternate embodiment of the apparatus of the present invention and an alternate method of the present invention;
[0051] FIG. 36 is a fragmentary view of an alternate embodiment of the apparatus of the present invention;
[0052] FIG. 37 is a fragmentary view of an alternate embodiment of the apparatus of the present invention;
[0053] FIG. 38 is a partial sectional elevational view of an alternate embodiment of the apparatus of the present invention;
[0054] FIG. 39 is a partial sectional elevational view of an alternate embodiment of the apparatus of the present invention; and
[0055] FIG. 40 is a partial sectional elevational view of an alternate embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0056] The present invention provides a marine platform deck elevating system 10 that is shown generally in FIGS. 14-15 and 17 and in method steps that are illustrated in FIGS. 2-18 .
[0057] In FIG. 1 , a fixed marine platform 11 is shown having a deck 16 that is positioned at an elevation 18 that is elevated above the water surface 12 a distance H 1 that is indicated by the numeral 19 in FIG. 1 . The numeral 19 and the dimension line H 1 represent the existing clearance above water. It is necessary to protect equipment that is contained on the deck 16 from storm generated wave action. Storms such as hurricanes can generate a storm surge and wave action that puts equipment and/or personnel located on deck 16 at peril. If a deck is not located at a safe elevation, it must be elevated. FIG. 1 illustrates a typical fixed platform 11 having a plurality of legs 14 that support the deck 16 . Diagonal braces 17 can extend between legs 14 and deck 16 as shown in FIG. 1 . The platform 11 can include other structures such as, for example, horizontal beams or members and/or additional vertical or diagonal members.
[0058] Legs 14 can be of a constant diameter or can include tapered sections 13 , wherein the diameter of the upper leg section 15 A is less than the diameter of the lower leg section 15 B. Leg 14 can thus include a number of different leg sections such as a lower, larger diameter leg section 15 B, a tapered leg section 13 , and an upper, smaller diameter leg section 15 A that is positioned above the tapered section 13 . The method and apparatus of the present invention can be used to elevate the deck 16 to a new elevation (see FIG. 19 ) that is higher than the previous, existing deck elevation 18 of FIG. 1 . The method and apparatus of the present invention thus provides a new clearance 21 above water surface 12 (also shown by the arrow H 2 in FIG. 19 ).
[0059] FIGS. 2 and 3 illustrate an initial method step of the present invention, namely the placement of lower bushing sleeve 24 . The lower bushing sleeve 24 can be comprised of a pair of half sleeve sections 22 , 23 as shown in FIGS. 2-3 . The sections 22 , 23 can be joined with welds 26 as shown in FIGS. 3-4 . Arrows 25 in FIG. 2 schematically illustrate the placement of sleeve sections 22 , 23 upon leg 14 at a position below tapered section 13 as shown.
[0060] In FIGS. 4-6 , upper bushing sleeve 29 can also be comprised of a pair of sleeve half sections. The sleeve sections 27 , 28 each provide an opening 35 or 36 that is receptive of a pin 50 as will be explained more fully hereinafter. Weld ring sections 30 , 31 can be used to attach the sleeve sections 27 , 28 to tapered section 13 . As with the lower bushing sleeve 24 , one or more welds 37 can be used to join the sleeve sections 27 , 28 to each other. Arrows 33 in FIG. 4 illustrate the placement of sleeve sections 27 , 28 upon tapered section 13 . Arrows 34 in FIG. 4 illustrate the attachment of weld ring 32 to the assembly of sleeve sections 27 , 28 and to tapered section 13 .
[0061] In FIGS. 6-9 and 11 , a plurality of extension sleeve guides 38 are shown. These extension sleeve guides 38 are attached to the platform 11 leg 14 at a position that is above upper bushing sleeve 29 . The extension sleeve guides 38 can extend from tapered section 13 to smaller diameter leg section 15 A as shown in FIGS. 6 and 9 . Arrows 39 illustrate placement of extension sleeve guides 38 to leg 14 . Each extension sleeve 38 can be comprised of flanges 40 and webs 41 . The web 41 actually contacts the leg 14 and can be shaped to conform to the shapes of tapered section 13 and smaller diameter leg section 15 A as shown in FIGS. 7 and 9 (see DIM “A”, FIG. 7 ).
[0062] In FIGS. 10-15 , an extension sleeve 44 can be comprised of a pair of extension sleeve sections 45 , 46 . Each extension sleeve section 45 , 46 has slots 47 , 48 that can be used to complete a cut through the leg 14 after the sleeve sections 45 , 46 have been attached to leg 14 and guides 38 .
[0063] Before attachment of the sleeve sections 45 , 46 , four cuts are made through leg 14 as shown in FIG. 10 . The cuts 42 , 43 do not extend 360 degrees around the leg 14 , but rather extend only a partial distance as shown in FIG. 10 . Though partial cuts 42 , 43 are made, enough of the leg 14 remains to structurally support the platform 11 and its deck 16 considering the use of sleeve 44 and the method of the present invention disclosed herein.
[0064] After the sleeve sections 45 , 46 have been installed, a cut can be made to encircle the leg 14 thus severing it in two parts. In order to complete the cut, slots are provided in the sleeve sections 45 , 46 . In FIG. 11 , the sleeve section 45 has slot 47 . In FIG. 11 , the sleeve section 46 has slot 48 .
[0065] After installing the upper bushing sleeve 29 , circular cut openings 49 are made through the leg 14 at the openings 35 , 36 in the sleeve sections 27 , 28 . These cut openings 49 enable pin 50 to be placed through the openings 67 , 68 in sleeve sections 45 , 46 respectively as well as through the openings 49 in upper bushing sleeve 29 . Pin 50 prevents uplift from damaging the platform 11 should a storm produce excess wave action before the method of the present invention can be completed.
[0066] Each of the sleeve sections 45 , 46 provides lugs to which hydraulic pistons can be attached. Sleeve section 45 provides a plurality of lugs 51 . Sleeve section 46 provides a plurality of lugs 52 . Each of the lugs provides an opening for enabling a pinned connection to be made between the lugs 51 , 52 and the hydraulic pistons 64 . Lugs 51 provide openings 53 . Lugs 52 provide openings 54 . In a preferred method and apparatus, four pairs of lugs 51 , 52 are thus provided to the extension sleeve 44 . Each pair of lugs 51 , 52 can be spaced circumferentially about sleeve 44 , about 90 degrees apart.
[0067] A ring 55 is positioned above extension sleeve 44 as shown in FIGS. 12-15 and 17 - 19 . Ring 55 is used to form a connection between the leg 14 and the hydraulic piston 64 . Ring 55 can be formed of a pair of ring sections 56 , 57 that are attached to the smaller diameter leg section 15 A as shown in FIGS. 12 and 13 . Each of the ring sections 56 , 57 provides a plurality of lugs 58 , 59 . The ring section 56 has lugs 58 . The ring section 57 has lugs 59 . Each lug 58 , 59 has a lug opening 60 that enables a pinned connection to be made between a lug 58 or 59 and a piston 64 . Each ring section 56 , 57 can be formed of arcuate generally horizontal plate sections and vertical plate sections. Each of the ring sections 56 , 57 thus provide an upper arcuate plate section 61 and a lower arcuate plate section 62 . Vertical plate sections 63 span between the upper and lower arcuate plate sections 61 , 62 .
[0068] Hydraulic pistons 64 are provided for elevating that portion of the leg 14 that is above the cuts that are made through the leg 14 (see FIGS. 10 and 16 ). Preferably three (3) or four (4) pistons can be used, but as few as two (2) rams can be used or more, such as many as eight (8) could be used, for example.
[0069] Each hydraulic piston 64 can be comprised of a cylinder 65 and an extensible push rod 66 . Each end portion of hydraulic piston 64 provides an opening 69 on cylinder 65 that enables a pinned connection to be formed between each end of hydraulic piston 64 and lugs 51 , 52 or 58 , 59 . The upper end portion of each hydraulic piston 64 attaches with a pinned connection to a lug 58 or 59 that is a part of ring 55 . The lower end portion of each hydraulic piston 64 forms a pinned connection with the lugs 51 , 52 of extension sleeve 44 as shown in FIGS. 14-15 . Arrows 74 in FIG. 14 illustrate assembly of pistons 64 to lugs 51 , 52 , 58 , 59 .
[0070] Once the hydraulic pistons 64 have been installed to the position shown in FIG. 15 , a cut can be completed for severing leg 14 . This can be seen in more detail in FIGS. 10 , 15 - 16 wherein the previously formed cuts 42 , 43 are shown. Notice that uncut portions 70 (DIM “B”, FIG. 16 ) of leg 14 align with the slots 47 or 48 of sleeve sections 45 , 46 . The leg 14 can thus be cut 360 degrees by cutting the previously uncut section 70 at slot 47 or 48 , indicated by phantom lines as cut 73 in FIG. 16 . The three hundred sixty degree cut ( 42 , 43 , 73 ) is made after the extension sleeve 14 , hydraulic pistons 64 and ring 55 form a structural support of the leg 14 above and below the cuts 42 , 43 . In order to then elevate the smaller diameter leg section 15 A relative to the larger diameter leg section 15 B below tapered section 13 , each hydraulic piston 64 can be activated as illustrated by arrows 72 in FIG. 17 .
[0071] Once elevated, the various openings and slots in sleeve 44 can be covered for corrosion protection using a plurality of curved cover plate sections 71 . To complete the repair, the sleeves 44 can be welded to the leg 14 and using shims as necessary between sleeve 44 and leg 14 , tapered section 13 or sections 15 A, 15 B. While the method disclosed herein contemplates that the elevation process would preferably take place as one jacking operation, the invention should not be so restricted. The method of the present invention contemplates a method wherein the jacking process could be subdivided into several smaller (or shorter) jacking elevations. The legs 14 would be pinned off at an intermediate point and the jacks moved to a second set of lugs. Arrow 75 in FIG. 17 shows the distance that the upper leg section 15 A is elevated.
[0072] FIGS. 20-40 show an alternate embodiment of the apparatus of the present invention designated generally by the numeral 80 in FIGS. 30-34 . Marine platform deck elevating system 80 can be used to elevate the same deck 16 that was shown and described with respect to FIGS. 1-19 . Therefore, the FIGS. 20-40 are schematic in that they do not show each and every part of the marine deck 16 to be elevated. FIGS. 5 , 24 , 29 , 30 illustrate an existing deck elevation 18 . The numeral 85 illustrates a spacing or clearance (for example, 20 feet (6.1 m)) between deck or upper deck 16 and a lower deck or lower deck portion 84 .
[0073] A plurality of legs 83 span between the lower deck portion 84 and the deck or upper deck 16 . Each of the legs 83 will be elevated using the method and apparatus of the present invention. An alternate method and apparatus 80 shown in FIGS. 20-40 can employ a two stage deck elevation. In FIG. 30 , the existing deck elevation 18 is shown. In FIG. 31 , an initial or first new deck elevation 81 is shown having a second clearance or elevation 86 (for example, 28 feet (8.5 m)). This second clearance 86 is thus an increase of 8 feet (2.4 m) (for example) over the initial clearance 85 of FIG. 20 . In FIG. 31 , the deck or upper deck 16 is now spaced 28 feet (8.5 m), as an example, above the lower deck portion 84 .
[0074] In FIG. 31 , a plurality of hydraulic rams or hydraulic jacks 102 have moved from the initial and collapsed position of FIG. 30 to a partially or first elevation. In FIG. 32 , the hydraulic rams 102 employed are two stage rams having a first push rod 106 and a second push rod 107 which is inside and which telescopes with the first push rod 106 . Such hydraulic rams 102 are commercially available, wherein the ram 102 has a first push rod 106 that telescopes inside of a lower ram cylinder 108 and a second push rod 107 that telescopes inside of the first push rod 106 . In FIGS. 32 , 33 , 34 and 40 , the deck 16 or upper deck has been elevated an additional 8 feet (2.4 m)to elevation or level at 82 so that the clearance or third clearance 87 in FIGS. 32-34 and 40 is now a spacing or clearance of 36 feet (11 m), as an example, between lower deck portion 84 and deck or upper deck 16 . In FIG. 34 , four legs 83 are shown, each having been extended a full clearance 87 (36 feet (11 m) per the example).
[0075] The method and apparatus of the present invention employs two sleeves 95 , 101 in order to accomplish the elevation of deck or upper deck 16 relative to lower deck portion 84 . FIGS. 20-21 illustrate that each leg 83 has a lower portion 88 and an upper portion 89 . Partial cuts 90 are made in the leg 83 upper portion 89 . These partial cuts through the deck legs can be, for example, about 45 degrees of the circumference of the leg 83 . These partial cuts 90 can also be spaced circumferentially about leg 83 in equal amounts such as a spacing of about 45 degrees apart. Pin receptive openings 91 are formed in leg 83 upper portion 89 just below the partial cuts 90 and 180 degrees apart as shown in FIG. 21 . After formation of the openings 91 , an inner/upper sleeve 95 is affixed to upper leg 89 above the partial cuts 90 (see FIGS. 23-25 ). For example, the connection of sleeve 95 to upper portion 89 of leg 83 can be a welded connection. A lower support ring 92 is attached (for example, welded) to leg 83 lower portion 88 and spaced vertically below inner/upper sleeve 95 as shown in FIG. 24 . Upper ring 97 is affixed (e.g., welded) to upper portion 89 . The lower support ring 92 provides a plurality of padeyes 93 , namely, one for each hydraulic ram 102 or a total of four padeyes 93 for the example shown in the drawings. Each padeye 93 provides a padeye opening 94 to which a pinned connection can be made between a ram 102 and a padeye 93 . Each ram 102 can have openings or sleeves or bearings at its end portions for enabling a pinned connection to be perfected with a padeye 93 or 98 .
[0076] The inner/upper sleeve 95 has sleeve openings 96 . Sleeve opening 96 can be provided on sleeve 95 spaced 180 degrees apart as shown in FIG. 23 . Similarly, there are two openings 91 in leg 83 , the openings 91 being spaced about 180 degrees apart. In this fashion, when the rams 102 extend, the openings 96 will align with the openings 91 so that a locking pin 50 ( FIGS. 27 , 28 ) can be placed through the aligned openings 91 , 96 . An upper ring 97 can be a part of sleeve 95 . The upper ring 97 is above the partial cuts 90 as shown in FIG. 24 . A plurality of padeyes 98 are affixed to ring 97 , each padeye 98 providing a padeye opening 99 .
[0077] Multiple windows 100 are provided. The windows 100 (for example, four windows 100 ) are centered over each of the uncut portions of the leg 83 that are in between the partial cuts 90 . In this fashion, once the sleeves 95 and rams 102 are attached as shown, the leg 83 upper 89 and lower 88 portions are structurally supported by the combination of sleeve 95 and rams 102 . Cuts can be made through the windows 100 of the sleeve 95 to cut the remaining uncut portion of leg 83 so that the leg 83 is now cut 360 degrees and ready for elevation of upper part 89 relative to lower part 88 .
[0078] In FIGS. 29-33 and 38 - 40 , an outer/lower sleeve 101 is attached to leg 83 in between the bottom of sleeve 95 and the lower support ring 92 . Pinned connections 103 join each hydraulic ram 102 to the padeyes 93 of lower support ring 92 at openings 94 . A lower ram pin 108 is shown in FIG. 31 forming a pinned connection between hydraulic ram 102 and a pair of padeyes 93 Similarly, a pinned connection 104 is formed between second push rod 107 of hydraulic ram 102 and padeyes 98 at openings 99 . In FIG. 31 , an upper ram pin 109 is shown making a connection between push rod 107 and padeyes 98 at openings 99 .
[0079] A pin trough 105 can be employed (e.g., welded to a sleeve 95 , 101 as shown) for holding a generally cylindrically shaped locking pin 50 prior to use. The pins 50 can be placed in the trough (see FIG. 28 ) and retained in that position until they are ready to be deployed. Locking pins 50 can thus be inserted in case of storm conditions when a first stage of the lift is completed as shown in FIG. 21 wherein the pin 50 would extend through to spaced apart openings 110 at the top of the lower/outer sleeve 101 through both openings 96 in the upper/inner sleeve 95 and through both openings 91 of the leg 83 .
[0080] In a fully extended position of FIGS. 32-34 and 40 , pin 50 is inserted through both openings 111 at the lower end of the outer sleeve 101 and the openings 91 of the leg 83 . A pin 50 is also inserted through the upper opening 110 of the outer/lower sleeve 101 and through the openings 96 of the inner/upper sleeve 95 as shown in FIGS. 32-34 and 40 . After installation, each sleeve 95 , 101 is connected (e.g., welded) to leg 83 . Inner sleeve 95 is welded to upper portion 89 of leg 83 . Outer sleeve 101 is welded to lower portion 88 of leg 83 . The sleeves 95 , 101 are connected (e.g., welded) together once full elevation ( FIGS. 22 , 23 ) is reached. Strokes or vertical spacers 112 can be placed (e.g., welded) on each leg 83 (see FIGS. 35 , 38 - 40 ) as shown by arrow 113 . Collar 114 having openings 115 can be used to reinforce leg 83 at openings 91 .
[0081] The following is a list of parts and materials suitable for use in the present invention.
[0000]
PARTS LIST
Part Number
Description
10
marine platform deck elevating system
11
platform
12
water surface
13
tapered section
14
leg
15A
smaller diameter leg section
15B
larger diameter leg section
16
deck/upper deck
17
diagonal brace
18
existing deck elevation
19
existing clearance above water
20
new deck elevation
21
new clearance above water
22
sleeve section
23
sleeve section
24
lower bushing sleeve
25
arrow
26
weld
27
sleeve section
28
sleeve section
29
upper bushing sleeve
30
weld ring section
31
weld ring section
32
weld ring
33
arrow
34
arrow
35
opening
36
opening
37
weld
38
extension sleeve guide
39
arrow
40
flange
41
web
42
cut
43
cut
44
extension sleeve
45
extension sleeve section
46
extension sleeve section
47
slot
48
slot
49
drilled/circular cut opening
50
support/locking pin
51
lug
52
lug
53
opening
54
opening
55
ring
56
ring section
57
ring section
58
lug
59
lug
60
lug opening
61
upper arcuate plate section
62
lower arcuate plate section
63
vertical plate section
64
hydraulic piston
65
cylinder
66
push rod
67
opening
68
opening
69
opening
70
uncut portion
71
cover plate
72
arrows
73
cut
74
arrow
75
arrow
80
marine platform deck elevating system
81
first new deck elevator
82
second new deck elevator
83
leg
84
lower deck portion
85
initial clearance
86
second clearance
87
third clearance
88
lower portion
89
upper portion
90
partial cut
91
pin receptive opening
92
lower support ring
93
padeye
94
padeye opening
95
inner/upper sleeve
96
sleeve opening
97
ring
98
padeye
99
padeye opening
100
window
101
outer/lower sleeve
102
hydraulic ram
103
pinned connection
104
pinned connection
105
pin trough
106
first push rod
107
second push rod
108
lower ram pin
109
upper ram pin
110
upper opening
111
lower opening
112
stroke/vertical spacer
113
arrow
114
collar
115
opening
[0082] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0083] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A method of elevating the deck area of a marine platform (e.g., oil and gas well drilling or production platform) utilizes a specially configured sleeve support to support the platform legs so that they can be cut. Once cut, rams or jacks elevate the platform above the cuts. The sleeve support is then connected (e.g., welded) to the platform leg and becomes part of the structural support for the platform. In one embodiment, two sleeves are employed. In another embodiment, the jacks or rams elevate in two stages including a first stage wherein one sleeve elevates and the other sleeve does not elevate and a second stage wherein both sleeves elevate together. | 4 |
This is a divisional of copending application Ser. No. 430,623, filed on Sept. 30, 1982, now U.S. Pat. No. 4,527,990.
FIELD OF THE INVENTION
This invention relates to an elasticized article and a method for elasticizing an article. More particularly, the invention relates to a disposable diaper which is elasticized in the waist area and a method for applying elastic in the waist area of the disposable diaper.
BACKGROUND OF THE INVENTION
Articles for uses such as garments or for protective packaging are frequently elasticized to provide a sealed tight fit. Among the various types of garments using elastic means to provide a sealed fit are disposable garments such as disposable diapers which are often sealed in the leg area to prevent leakage of body excretions. There has also been an increased interest in sealing the waist area of disposable diapers for the same purpose.
There are several ways that articles may be elasticized. These include the sewing of elastic into the substrate material which is to form the article, adhering the elastic onto the substrate material, and utilizing a heat shrinkable elastic which is bonded to the article and shrunk by the application of heat to an elastic form which permits the elastic extension and contraction of the substrate. Sewing of elastic into disposable articles is presently seldom used due to its complexity and slowness and resulting high cost. Adhering of the elastic onto a substrate material is commonly used, but nevertheless has its drawbacks. These include the difficulty of handling the elastic in a stretched form, particularly when it is applied in a direction transverse to the direction of movement of a moving substrate material. When elastic is glued to a substrate material in a relaxed condition, it is necessary to first corrugate the substrate material so that it will have excess material with can be extended to stretch the elastic and provide the elasticization effect. The need to corrugate the substrate material also complicates this approach, particularly when the elastic is applied in a direction transverse to the direction of a moving substrate material. Heat shrinkable elastic is applied in a relaxed form and, because it will gather the substrate material with it when it is caused to shrink, it is not necessary that the substrate material first be corrugated. The application of the heat shrinkable elastic in a relaxed form and the elimination of the need to corrugate the substrate material simplifies this approach considerably. However, the temperature level required to shrink the heat shrinkable elastic is above the tolerance level of some substrate materials commonly used in making disposable garments, particularly polypropylene and polyethylene films, and so it is difficult to use heat shrinkable elastic with these substrates. Moreover, heat shrinkable elastics often do not retain a sufficient amount of their elastomeric properties when heated and they thus are frequently unsuitable for many elasticization purposes.
SUMMARY OF THE INVENTION
It is a principal object of this invention to provide an elasticized article and a method for making the elasticized article on a high speed production basis with none of the drawbacks of presently known elasticized articles and methods for their fabrication. It is a more specific object of this invention to provide a method of elasticizing an article in which the elastic can be applied in a relaxed condition without having the substrate material in a corrugated condition. It is a further specific object of this invention to provide an elasticized article in which the elastic material and shrinkable material are separate but connected together and the shrinkable material applies tension to the elastic material.
According to the invention, an elasticized article is provided which includes a flexible substrate, elastic material having a surface area and which is bonded to the substrate over less than the surface area of the elastic material, and shrinkable means having a surface area and which is bonded to the substrate over less than the surface area of the shrinkable means and bonded to the elastic material over a surface area that is less than the surface area of the shrinkable means or the elastic material, the shrinkable means providing a force along a direction between the area of the bond of elastic material to the substrate and the area of the bond of the shrinkable means to the substrate for gathering the substrate upon shrinking whereby, when the substrate is extended, the elastic material applies gathering force to the substrate. The shrinkable material may be responsive to a stimulus such as heat or moisture to shrink to a smaller form such that the elastic material is extended to thereby apply elastic contracting force to the flexible article. Note that the term "elasticized" as used herein means the provision of an elastic contracting force to the article.
DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will appear when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a plan view of a portion of an elasticized article according to the invention;
FIG. 2 is an end elevation view of the elasticized article shown in FIG. 1;
FIG. 3 is a plan view of the elasticized article shown in FIG. 1 with the shrinkable material in a contracted condition and the elastic material in an extended condition;
FIG. 4 is a plan view of the elasticized article shown in FIG. 3 with the shrinkable material in a contracted condition, the substrate material gathered, and the elastic material in a relaxed condition;
FIG. 5 is a plan view, partially broken away, of an alternative embodiment of the invention in which the elasticized article is a disposable diaper;
FIG. 6 is a plan view, partially broken away, of the elasticized disposable diaper of FIG. 5 with the shrinkable material in a contracted condition and the elastic material in an extended condition; and
FIG. 7 is a simplified perspective view of the elasticized disposable diaper illustrated in FIGS. 5 and 6, just prior to the fitting of the diaper onto an infant, with an elasticized waist area in a relaxed condition.
FIG. 8 is a perspective view showing the diaper of FIG. 7 being worn by an infant; and
FIG. 9 is a schematic side elevation view of apparatus for elasticizing an article according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring generally to FIGS. 1-4, an elasticized article is shown which includes a flexible substrate 2, an elastic material 4 and shrinkable means 6. The elastic material 4 preferably is in the shape of a strip 5 with a length dimension greater than the width dimension. The elastic material 4 as illustrated in FIGS. 1-4 includes longitudinal edges 8 and 10, opposing ends 12 and 14, a surface area 24 facing the flexible substrate, and a surface area 28 facing away from flexible substrate 2. The shrinkable means 6 comprises a shrinkable material, preferably in the shape of a strip 7 in which the length dimension is greater than the width dimension. The shrinkable means 6 has longitudinal edges 16 and 18, opposite ends 20 and 22, a surface area 26 facing the flexible substrate 2, and a surface area 30 facing away from flexible substrate 2.
A first portion of the surface area 24 of elastic material 4, preferably the end area 12, is bonded to the flexible substrate 2 and a second portion of the surface area 24, preferably the end area 14, is bonded to the surface area 26 of shrinkable means 6, preferably at end area 22. A portion of the surface area 26 of shrinkable means 6, preferably the end area 20, is bonded to the flexible substrate 2. It is important that the elastic material 4 and the shrinkable means 6 are bonded to the substrate 2 at different locations and over surface areas that are less than their entire surface areas to permit the tensioning of the elastic material and the contracting of the shrinkable means without constriction by the substrate and between the bonded locations.
The flexible substrate 2 may comprise a wide variety of materials, depending on the ultimate use of the elasticized article, and will typically be of a material that can be provided in a thin film form. Preferred materials for fabricating disposable diapers are polyethylene film having a maximum thickness of about 5 mils and nonwoven fibrious polypropylene sheeting having a basis weight of from 0.5 to 1.25 oz./yd. The shrinkable means 6 may be of a material which has a stable extended condition, is preferably non-elastomeric, and is responsive to heat to shrink to a relatively stable contacted condition. Suitable materials include heat shrinkable oriented film materials such as ethyl vinyl acetate, polypropylene, polyvinyl chloride, and low density polyethylene. In selecting a heat shrinkable material it is critical that the temperature at which the material shrinks is lower than the heat distortion temperature of the substrate material to which the shrinkable material is bonded. For a polyethylene substrate, the heat distortion temperature is about 250° F.
In the views of FIGS. 1 and 2, the article is shown in a condition in which the flexible substrate 2 is ungathered, the elastic material is 4 is in a relaxed, contracted condition, and the shrinkable means 6 is in a stable, extended condition. In FIG. 3, the flexible substrate 2 is held by means (not shown) in an ungathered condition, the shrinkable means 6 is in a shrunken condition subsequent to its contraction, and the elastic material 4 is in an extended, stretched condition due to the tension applied to it by the contracted shrinkable means 6 while the flexible substrate 2 is held ungathered. Note that the tension force applied by the shrinkable means 6 to the elastic material 4 is along the direction between the location of the bond of the end area 12 of elastic material 4 to the substrateand the location of the bond of the end area 20 of the shrinkable means 6 to the substrate 2. In FIG. 4, the shrinkable means 6 is shown in its contracted condition and the elastic material 4 is in a relaxed, contracted condition. The flexible substrate 2 is in a gathered condition due to the contracting force applied to it by the elastic material 4 through the bonded end area 12 of the elastic material 4 and the bonded end area 20 of the shrinkable means 6.
The elasticized article may be made, as illustrated in FIG. 9, by feeding a roll 32 of continuous shrinkable material and a roll 34 of continuous elastic material 4 to a combining station 36 with the elastic material 4 in a relatively relaxed condition and applying adhesive to the elastic material 4 with an adhesive applicator means 38. The rolls 32 and 34 are positioned such that the shrinkable material and elastic material are overlapped only along one longitudinal edge of each material at the combining station 36. The adhesive is applied to either the elastic material or the shrinkable material in the overlapped area. The overlapped area is then passed between nip rolls 40 and 42 to bond the shrinkable material and elastic material together along the overlapped margins. The combined shrinkable material and elastic material 4 is then severed by cutting means 44 at cutting station 46. The severed strips of combined shrinkable material strips 7 and elastic material strips 5 each have adhesive applied to their respective end areas 12 and 20 by adhesive applicator means 48 and the combined strips are then moved on to an application station 50 where they engage a continuous web of flexible substrate 2. The flexible substrate 2 is supplied from a roll 52 on to a continuous moving screen 67 which moves continuously around rolls 69' and 65. The strips of combined elastic material 4 and shrinkable material are passed between nip rolls 54 and 56 to bond the end areas 12 and 20 of the elastic material 4 and shrinkable material 6, respectively, to the substrate 2. The web of flexible substrate material 2 may then be severed by cutting means 60 at cutting station 62 into a series of separate web pieces. The shrinkable material 6 may then be subjected to a stimulus, such as heat from a heat source 58, to elevate its temperature and cause it to shrink to a contracted condition and provide elasticized articles according to the invention. However, due to the clamping of the web of flexible substrate 2 by clamping rolls 68, 68' and 69, 69', the web maintains its width and the elastic material strip 5 assumes an extended, tensioned condition as shown in FIG. 3.
An alternative embodiment of the invention is illustrated in FIGS. 5-8 in which the elasticized article is a disposable diaper. Those elements shown in FIGS. 5-8 which are the same as or similar to corresponding elements in the embodiment of FIGS. 1-4 are identified with the same numerals and only those elements in FIGS. 5-8 which are substantially different from or in addition to the elements of FIGS. 1-4 are identified with different numerals. The disposable diaper comprises a flexible substrate in the form of a liquid impervious cover sheet 70, a flexible substrate in the form of a liquid pervious body side liner sheet 72 which is joined to the sheet 70 along the periphery of the two sheets, and an absorbent pad 74 disposed between the sheets 70 and 72. The diaper has a front waist area 64 and a rear waist area 66. The diaper also includes elastic strips 76 and 78 located in the leg area of the diaper for sealing the diaper about the legs when the diaper is being worn, and waist fastening tapes 80 and 82 for securing the diaper around the waist when the diaper is being worn.
As is best illustrated in FIGS. 5 and 6, the shrinkable means 6 includes a shrinkable material strip 7 and a shrinkable material strip 84 having opposite end areas 90 and 92 and surface area 94 facing the cover sheet 70. The elastic material 4 includes elastic strip 5 having opposite end areas 14 and 98 on the surface area 28 facing away from the sheet 70. The strip 5 also has a surface area 24 facing the sheet 70. A portion of the surface area 94 of shrinkable strip 84, preferably the end area 90, is bonded to the cover sheet 70 and a portion of the surface area 94, preferably the end area 92, is bonded to a portion of the surface area 28, preferably end area 98, of elastic strip 5. A portion of the surface area 26 of shrinkable strip 7, preferably the end area 20, is bonded to the cover sheet 70 and a portion of the surface area 26, preferably the end area 22, is bonded to a portion of the surface area 28, preferably end area 14, of elastic strip 5. The elastic strip 5 has a portion 96 of its surface area 24 intermediate its end areas 98 and 14 bonded to the cover sheet 70.
The disposable diaper is illustrated in FIG. 5 with the cover sheet 70 in an extended, ungathered condition, the elastic material strip 5 in a relaxed, contracted condition, and the shrinkable material strips 7 and 84 in a stable, extended condition. In FIG. 6, the cover sheet 70 is in an extended, ungathered condition, the material strips 7 and 84 are in a contracted condition, and the elastic material 4 is in a tensioned, extended condition. Due to the bonding of the elastic material strip 5 at the intermediate area 96, the tension applied to the strip 5 by the shrinkable material strip 7 is between the bonded area 96 and the end area 14 and the tension applied by the strip material 84 is between the bonded area 96 and the end area 92. Where the bonded surface portion 96 is located equidistant between its end areas 92 and 14, the tension applied to the elastic strip 5 will be asymetical about the bonded area 96. In FIG. 7, the diaper is shown in a condition in which cover sheet 70 and the liner sheet 72 attached to its are in a contracted condition, the shrinkable material strips 7 and 84 are in a contracted condition, and the elastic strip 5 is in a contracted, relaxed condition. In FIG. 8, illustrating the diaper being worn by an infant, the waist tapes 80 and 82 have been attached about the waist of the diaper to tension and extend the elastic material 4 so that it is in a condition similar to that shown in FIG. 6 and the tension of the elastic causes a tight seal between the skin of the infant and the liner sheet 72 of the diaper.
It will be understood that the foregoing description of the present invention is for purposes of illustration only and that the invention is susceptible of a number of modifications or changes, none of which entail any departure from the spirit and scope of the present invention as defined in the hereto appended claims. | An elasticized article and a method for elasticizing the article are disclosed in which a strip of elastic material has an end bonded to an end of a strip of shrinkable material to form a single elongated strip having spaced apart opposing ends. The combined strip is bonded at its opposing ends to a flexible substrate of an article with the elastic material in a contracted relaxed condition and the shrinkable means in a stable extended condition. Subsequent to the application of the combined strip to the flexible substrate, the shrinkable means is contracted by shrinking to thereby extend the elastic material and elasticize the flexible substrate. | 0 |
This is a continuation of application Ser. No. 07/395,208, filed Aug. 17, 1989, now U.S. Pat. No. 5,225,047, which is a continuation-in-part of application Ser. No. 140,922, filed Dec. 28, 1987, abandoned, which was a continuation-in-part of application Ser. No. 004,729, filed Jan. 20, 1987, abandoned.
BACKGROUND OF THE INVENTION
The present invention is directed to a method of making a sheeted crosslinked cellulose and the product resulting from the process. The invention is especially directed toward a crosslinked cellulose sheet which can later be easily reslurried in water without excessive fiber breakage.
Crosslinked cellulose products have been described in the chemical literature for many years. These products are normally made by reacting a material, ususally bifunctional, that will tie together hydroxyl groups on neighboring cellulose chains. Formaldehyde and various derivatives of urea have been the crosslinking agents which have received the greatest study. However, many other materials which have actual or latent bifunctional reactive groups have also been reported.
Crosslinked celluloses are of great commercial importance in the textile industry where they are widely used for the production of wash-and-wear and other wrinkle-resistant types of fabrics. Crosslinked cellulose fluff has also been described for use in disposable absorbent products such as diapers. Here advantage is taken of the fact that crosslinked fibers are normally stiffer than their untreated counterparts. The fluff products formed from these fibers are of Somewhat lower density (or greater bulk) and tend to hold retained liquid better under compressive forces encountered during use of the product.
While the advantages contributed to disposable absorbent products by crosslinked cellulose fibers are real, products using these crosslinked fibers have never become commercially important. This is apparently because of the difficulty of making a sheeted crosslinked fiber product that can be later refiberized at the point of use without creation of an excessive amount of fines. Unfortunately, crosslinking also results in considerable fiber embrittlement. Additionally, most of the crosslinking agents which have been used serve to give both chemical and physical bonding between adjacent fibers in the sheets. This, in addition to the increased fiber brittleness, has made mechanical wet or dry defiberization of sheeted crosslinked pulps impractical. In an effort to overcome this problem, various workers have considered treating sheeted pulp with a latent crosslinking material, fluffing, and then carrying out the crosslinking reaction by heating the cellulose fluff. An example of this is seen in Bernardin, U.S. Pat. No. 3,224,926. Van Haaften, Canadian Patent 806,352 treats loose fibers with a crosslinking material and catalyst. These moist fibers are then expanded into a loose fluffy condition and cured.
The stiffness of crosslinked cellulose fibers can add desirable properties to certain sheeted pulp products. Here it is typical to use only a portion of crosslinked fibers in the ultimate product. Attempts to do this have encountered the same problems mentioned earlier. If a product is crosslinked in sheeted form, it becomes very difficult to redisperse without serious fiber breakage by normal wet repulping processes employed in paper mills. As noted before, there are two apparent reasons for this. The strength of a sheeted cellulose product is developed in part by mechanical entanglement of the fibers but, much more so, by hydrogen bonding in those areas where fibers overlap are in intimate contact with each other. This hydrogen bonding develops only when the fibers are dry. In a crosslinked sheeted product, when the crosslinking reaction is normally carried out by heating after the sheet has been fully dried, two phenomena can occur. One of these is interfiber crosslinking. The reaction occurs in areas of intimate fiber-to-fiber contact and serves to chemically bind the fibers together. Perhaps of even greater importance, many of the crosslinking materials used also form thermosetting adhesives under the heated conditions used in the crosslinking reaction. Scanning electron micrographs of heated dimethylolurea treated fibers show many small spherical nodules of ureaformaldehyde resin on the surface and within the fiber lumen. These nodules serve to adhesively bond adjacent fibers so that it is very difficult to separate them under any conditions without considerable fiber breakage. Because the crosslinked fibers tend to be so brittle, the fibers themselves will often break leaving the bonded areas between adjacent fibers intact. There is a related side issue to this phenomenon. It is still an unresolved question as to how much of the crosslinking reaction is a surface phenomenon as opposed to an internal one.
Earlier workers in the field have also tried to deal with the problem of making a sheeted cellulose pulp product containing only a portion of crosslinked fibers. As one example, Bernardin, in U.S. Pat. No. 3,434,918, treats sheeted fiber with a crosslinking agent and catalyst. This is then wet aged to insolublize the crosslinker, so-called "wet fixation." This wet aged fiber is then redispersed before curing. The redispersed fiber can be mixed with untreated fiber and the mixture sheeted. The final product is then heat cured. In a variation of this process the same inventor, in Canadian Patent 813,616, heat cures crosslinked fibers as a fluff and then mixes this product with conventional papermaking fibers.
These mixtures of crosslinked fibers with untreated fibers are potentially useful for making products such as filter media, tissues, and towelling where high bulk and good water absorbency are desired without excessive stiffness in the product. Freimark et al, in U.S. Pat. No. 3,755,220, describe making a soft, high wet strength sheet, although this does not use crosslinked fibers. These inventors utilize well known debonders or softeners with cationic wet strength resins to gain an increase in the ratio of wet to dry tensile strength, usually without serious loss in absolute values of wet tensile strength. The debonder itself can be cationic or anionic and may be added to the papermaking stock prior to or following the addition of the wet strength resin.
In U.S. Pat. No. 4,204,054, Lesas et al describe spraying unsheeted bulk fibers with a solution of formaldehyde, formic acid and hydrochloric acid. These fibers are then immediately dispersed in a hot air stream at about 170°-200° C. for 1-20 seconds. This appears to give primarily surface area crosslinking without serious affect on fiber flexibility. The inventors note that 10-40% of these fibers can be mixed with conventional fibers to give a sheeted product with good flexibility and water absorbency.
Unfortunately, the problems encountered handling bulk fibers; i.e., those in individual loose form as opposed to a sheeted product, have been so great as to be commercially nearly insurmountable to the present time. The fiber must be dried by flash drying or some similar procedure where it is usually suspended in a hot air stream. The dried fiber is then baled or bagged. Because of the very short fiber length, compactly packaging a loose fiber form of wood pulp is technically very difficult and expensive. An alternative procedure, where the loose fibrous product might be prepared at the ultimate point of consumption, has been even more unattractive and has met with a wall of resistance by potential consumers.
The reader who might be interested in learning more detail of the chemistry of cellulose crosslinking can refer to any of the standard texts on cellulose. One resource which treats the subject quite thoroughly is by Tesoro and Willard in Cellulose and Cellulose Derivatives, Bikales and Segal, eds., Part V, Wiley-Interscience, New York (1971), pp. 835-875.
Reference was made to use of fiber debonders, also called sheet softeners in the earlier comments relating to U.S. Pat. No. 3,755,220. These materials can be generally classified as surfactants which are applied to the fiber while it is still wet, before any hydrogen bonding has occurred. Most typically they are cationic in nature, based on quaternary ammonium compounds which have one or more fatty substituents. Although not as commonly used, nonionic and anionic types are also commercially available. Frequently a combination of a cationic and nonionic type may be employed. These products are widely used within the pulp and paper industry and are commercially available from a number of suppliers. Similar products are used in the textile industry.
Debonders serve to make a softer sheet by virtue of the fatty portion of the molecule which interferes with the normal hydrogen bonding. They are quite commonly used in the manufacture of fluff pulps which will be later converted into absorbent products such as disposable diapers. The use of a debonder can reduce the energy required to produce a fluff to half or even less than that required for a nontreated pulp. This advantage is not obtained without a price, however. Many debonders tend to reduce water absorbency as a result of hydrophobicity caused by the same fatty long chain portion which gives the product its effectiveness. In order to overcome this problem, some manufacturers have formed adducts of ethylene or propylene oxide in order to make the products somewhat more hydrophilic. Those interested in the chemistry of debonders will find them widely described in the patent literature. The following list of U.S. patents provides a fair sampling, although it is not intended to be exhaustive: Hervey et al, U.S. Pat. Nos.3,395,708 and 3,554,862; Forssblad et al, U.S. Pat. No. 3,677,886; Emanuelsson et al, U.S. Pat. No. 4,144,122; Osborne, III, U.S. Pat. No. 4,351,699; and Hellsten et al, U.S. Pat. No. 4,476,323. All of the aforementioned patents describe cationic debonders. Laursen, in U.S. Pat. No. 4,303,471, describes what might be considered a representative nonanionic debonder.
U.S. Pat. No. 3,844,880 to Meisel, Jr. et al describes the use of deposition aid (generally cationic), an anionic resin emulsion, and a softening agent which are added sequentially to a pulp furnish to produce a soft product having high wet and dry tensile strength. The opposite situation; i.e., low wet tensile strength, is preferred for a pulp which is to be later reslurried for some other use.
Croon et al, in U.S. Pat. No. 3,700,549, describe a cellulose fiber product crosslinked with a polyhalide, polyepoxide, or epoxyhalide under strongly alkaline conditions. Epichlorohydrin is a preferred material. In their examples Croon et al teach the use of their treated fiber in absorbent products such as diapers and sanitary napkins. All of the crosslinking materials are insoluble in water. Croon et al teach three methods to overcome this problem. The first is the use of vigorous agitation to maintain the crosslinking agent in a fine droplet-size suspension. Second is the use of of a polar cosolvent such as acetone or dialkylsulfoxides. Third is the use of a neutral (in terms of being a nonreactant) water soluble salt such as magnesium chloride. In a variation of the first method a surfactant may be added to enhance the dispersion of the reactant phase. After reaction the resulting product must be exhaustively washed to remove the necessary high concentration of alkali and any unrelated crosslinking material, salts, or solvents. The method is suitable only for cellulosic products having a relatively high hemicellulose content. A serious deficiency is the need for subsequent disposal of the toxic materials washed from the reacted product. The Croon et al material would also be expected to have all other well known disadvantages incurred with trying to sheet a stiff, brittle crosslinked fiber.
To the knowledge of the present inventor, no one has ever before used a debonder with a cellulose pulp which is also treated with a crosslinking agent. One skilled in the art would not expect this to be an effective combination, i.e., they would expect the interfiber bonding propensities of the crosslinking agents to completely overpower any advantage in the reduction of wet or dry strength that might be contributed by the debonding agent.
SUMMARY OF THE INVENTION
The present invention is a method of making wet formed, sheeted crosslinked cellulose and the products produced thereby which can be easily reslurried to a free fiber condition without excessive fiber breakage. The method comprises including within the sheet while still wet a debonding agent and water soluble or water dispersable latent cellulose crosslinking agent. The sheet thus treated is dried and, during or after drying the crosslinking agent reacts with the cellulose. In the most preferred form of the invention, the debonding agent is added to an aqueous slurry of cellulose fibers prior to sheet formation and a latent crosslinking agent is added subsequent to sheet formation. This can be readily accomplished by spraying an aqueous solution or disperson of the crosslinking agent onto the sheet while it still on the forming wire or in the press section of the paper machine. However, it is within the scope of the invention to add both the debonding agent and the latent crosslinking agent to the wet sheet following sheet formation. In this ease it is preferable to add the debonding agent to the wet sheet prior to the addition of the latent crosslinking agent. The latent crosslinking agent should be added to sheeted cellulose while it is at a moisture content greater than about 10%, preferably greater than about 30%.
It is within the scope of the invention to use a debonding agent which may be either cationic, nonionic or anionic in nature.
The latent crosslinking agent may be selected from any of the following well known materials which serve this function. Preferred types are selected from urea derivatives such as methylolated urea, methylolated cyclic ureas, methylolated lower alkyl substituted cyclic ureas, dihydroxy cyclic ureas, lower alkyl substituted dihydroxy cyclic ureas, methylolated dihydroxy cyclic ureas, and mixtures of any of these types. A presently preferred latent crosslinking material is dimethyloldihydroxyethyleneurea (DMDHEU, 1,3-dihydroxymethyl-4,5-dihydroxy-2-imidazolidinone). This material is readily commercially available in a stable form. Other urea-based materials which are eminently suitable include dimethylol urea (DMU, Bis[N-hydroxymethyl)]urea), dihydroxyethyleneurea (DHEU, 4,5-dihydroxy-2-imidazolidinoe), dimethylolethylene urea (DMEU, 1,3-dihydroxymethyl-2-imidazolidinone, and 4,5-dihydroxy-l,3-dimethyl-2-imidazolidinone (DDI, dimethyldihydroxyethyleneurea).
In addition to those latent crosslinking agents based on urea, other materials that are suitable are polycarboxylic organic acids. Among these 1,2,3,4-butanetetracarboxylic acid is a presently preferred material.
All of the crosslinking agents just described may be reacted with the cellulose either during normal drying of the sheeted material or subsequent to this time by raising the dried sheet to an elevated temperature, preferably above 100° C.
A neutral or acidic catalyst may be included with the latent crosslinking agent to increase the reaction rate between the crosslinker and the cellulose. Acidic salts are particularly useful as catalysts when the urea-based materials are employed. These salts may typically be ammonium chloride or sulfate, aluminum chloride, magnesium chloride or mixtures of these or many other similar materials. Alkali metal salts of phosphorous-containing acids, such as sodium hexametaphosphate and sodium hypophosphite, with or without additional oxalic acid, are useful catalysts for 1,2,3,4-butane carboxylic acid.
The crosslinking agent is typically present in an amount in the range of 2-200 kg/t, preferably 20-100 kg/t, of cellulose fiber. Similarly, the debonding agent is generally present in an amount of about 0.1-20 kg/t, preferably 1-10 kg/t, of cellulose fiber.
A particular advantage of the new process is found in the lack of any need for washing the sheeted crosslinked product after the crosslinking reaction is completed.
It is an object of the present invention to provide a sheeted crosslinked cellulose product which can be readily reslurried in water to a free fiber condition without excessive fiber breakage or energy input.
It is a further object of the invention to provide a method of manufacturing such a product.
It is another object to provide a method and product as described which can be conveniently and readily made on conventional papermaking equipment.
It is yet another object to provide a product of the types described which can be readily redispersed in water and mixed with other types of fibers, which mixtures can be resheeted to give products having novel and useful properties.
These and many other objects will become readily apparent to those skilled in the art upon reading the following detailed description.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sheeted crosslinked cellulose products of the present invention are intended for use as manufactured, or for remanufacture by a process that involves redispersing the product in water, usually for admixture with other fibers, followed by resheeting. It is not a primary goal or intention of the invention to produce sheeted products useful in processes that involve dry mechanical defibering, even though some species may perform satisfactorily under these conditions. The present invention provides a sheeted crosslinked cellulosic product that contributes good bulk and absorbency to a remanufactured sheet with little or no loss of fiber integrity or length during the remanufacturing process.
While the individual use of debonding agents and crosslinking reagents have been both known for some time in the pulp and paper industry, these have never before been used in combination in a sheeted pulp product, to the knowledge of the present inventor. It was totally unexpected that the debonders would continue to function as such after treatment of and reaction of the fibers with crosslinking materials. This is especially the case since many crosslinking agents will, at least to some extent, form polymers as a side reaction while reacting with the cellulose. In many cases these polymeric side reaction products serve as powerful adhesive materials. As one example, the efficiency of urea-based polymers as bonding agents for cellulosic materials is well known. Many of the precursors of these urea adhesives are the identical materials that are also highly effective cellulose crosslinking agents.
To the inventors best knowledge, any latent cellulose crosslinking composition is effective in the present invention. Those that can be reacted at relatively low temperatures in short periods of time during or after normal drying are preferred from a technical and economic standpoint. The urea-based crosslinking materials seem to fill this requirement well since their reaction speed can be greatly accelerated with small amounts of inexpensive acidic salt catalysts. Other classes of crosslinking agents can probably be similarly accelerated as well. No representation is made here that any of the processes described in the following examples have been optimized.
In similar manner, it appears that any class of debonding agent will be satisfactory, although there is some indication that cationic types may be superior to nonionic or anionic materials. Again, the systems reported here have not been optimized.
Cationic debonders are most usually based on quaternary ammonium salts having one or two lower alkyl substituents and one or two substituents that are or contain a fatty, relatively long chain hydrocarbon. Most of these fall into one of four general types as follows: ##STR1## where R 1 and R 2 are methyl, ethyl, or hydroxyethyl, R 3 is a hydrogen having 1-40 carbon atoms, R 4 is a hydrocarbon having 10-40 carbon atoms, E is an oxyalkylene group having 2 or 3 carbon atoms, m is an integer from 1-20, n is an integer from 0-20, and X is Cl or SO 4 , said hydrocarbon substituents being selected from linear and branched alkyl or alkenyl groups, and branched and linear alkyl and alkenyl substituted phenyl groups. Most typically R 3 will have from 1-22 carbon atoms and R 4 from 10-22.
Originally most debonders were Type 1 fattyalkyl di- or trimethyl ammonium compounds. These have now been superceded in many cases by the other types since they may induce an undesirable hydrophobicity.
The Type 2 debonders, diamidoamine types, are quite inexpensive and are widely used as fabric softeners.
Dialkyl alkoxylated quaternary ammonium compounds (Type 3) are widely used in making fluff pulps for disposable diapers since the polyethylene or propylene oxide chains give better hydrophylicity and cause less degradation of absorbency, especially when compared with Type 1 compositions.
The imidazoline materials that comprise Type 4 materials are somewhat newer materials. However, they are also now widely used.
Nonionic materials that can serve as debonders comprise a very large class of materials. Principal among them are adduct type reaction products of fatty aliphatic alcohols, fatty alkyl phenols and fatty aromatic and aliphatic acids with ethylene oxide, propylene oxide or mixtures of these two materials. Most typically the fatty portion is a hydrocarbon chain having at least 8, more typically 10-22, carbon atoms. Other useful nonionic debonders include partial fatty acid esters of polyvalent alcohols and their anhydrides wherein the alcohol or anhydride has 2-8 carbon atoms.
Anionic debonders also include a large class of materials, including many having surfactant properties. In general these are sulfated fats, fatty esters, or fatty alcohols. They also include fatty alkyl substituted aromatic sulfonic acids. The fatty substituent groups may have from 8-40 carbon atoms, more typically from 10-22 carbon atoms.
In the most preferred practice of the invention the debonder will be added to the cellulose fiber stock at some point before the headbox of the paper machine. When anionic or nonionic debonders are used it is normal practice to also use a cationic retention aid at the point of or immediately prior to their addition. Otherwise, they will have very poor substantivity to the cellulose fibers. It is within the scope of the invention to add both the softener and latent crosslinking agent after formation of the sheet. In this case it is not always necessary to use retention aids with nonionic or anionic debonders.
The following examples will illustrate the best modes presently known to the inventor for carrying out the present process and making the resulting products.
EXAMPLE 1
The following procedure was used to make laboratory handsheets for evaluation. A 25 g (dry weight) sample of unrefined cellulose pulp was reslurried in a Waring Blendor at about 2% consistency for 20 seconds. After 5 seconds of agitation, one of the commercially available softening agents was added to the blender in amounts ranging from 0% (for control samples) to 2% based on dry pulp. Most typical usage was about 0.5% (5 kg/t), on an as received basis. The reslurried, softener treated pulp was further diluted to a volume of about 6800 mL with water. This slurry was formed into a sheet on a standard 8×8 inch (203×203 mm) Noble and Wood laboratory sheet mold, using a 150 mesh stainless steel screen. The sheet was removed from the former and pressed between synthetic fiber felts so that the moisture content was reduced to about 50%.
The moist sheet prepared as above was then immersed into a bath containing a known concentration of a latent crosslinking agent and catalyst, if the latter component was used. After immersion the sheet picked up sufficient treating liquid so that its consistency was reduced to about 13.5%. It was again pressed between felts to about 50% fiber content. It can be readily calculated to show that the final pickup of latent crosslinking agent and catalyst, based on pulp, was about 84% of the concentration in the bath. The handsheet was then drum dried to about 5% moisture content.
Depending on the particular crosslinking agent and/or catalyst used, the crosslinking reaction with the cellulose occurred either during the drying step or in an oven curing stage following drying.
EXAMPLE 2
The bulk density of a crosslinked pulp sheet is dependent on a number of interacting factors: the physical nature of the cellulose, the type and amount of softener used, the type and amount of crosslinking agent and/or catalyst used, and the time and temperature of the crosslinking reaction. The effect of time-temperature relationship for one set of conditions can be seen in the following example using laboratory handsheet samples.
A bleached Douglas-fir kraft pulp was reslurried as described in Example 1 and treated with 0.5% as received of Berocell 584 softener. This material is a quaternary ammonium based softener believed to be principally a fatty substituted oxyalkylatedphenol dialkyl quaternary ammonium chloride (see the Type 3 quaternary formula noted earlier). This is compounded using 30% of the quaternary compound with 70% of a nonionic polyoxyalkylene composition. It is available from Berol Chemical Co., Reserve, Louisiana. After sheeting and pressing, the handsheets were treated with a 10%, as received basis, aqueous solution of Aerotex 900 latent crosslinking agent. Aerotex is a registered trademark of and is available from American Cyanamid Company, Wayne, New Jersey. It is believed to be a dimethyloldihydroxyethyleneurea product and is sold as an aqueous solution at about 45% solids concentration. For every 100 parts of the Arotex 900 solution, 30 parts by weight of Arotex Accelerator 9 catalyst solution were used. This is a 30% by weight solution of acidic salts believed to be aluminum and magnesium chlorides. Retention of the latent crosslinking agent, on a 100% solids basis, was calculated to be 3.78% of the dry cellulose present. The dried sheets were cured at 150° C. for 3 minutes.
In order to determine the reslurring and bulking properties of the treated fiber a 3.5 g, dry weight, sample was torn into small pieces and reslurried in about 2 L of water in a British Disintegrator. Agitation was continued until the slurry was smooth and free of obvious knots or fiber bundles. The number of revolutions to this point was counted and is an indicator of the ease with which the material can be redispersed. The slurry was then sheeted in a standard 61/4 in (159 mm) TAPPI sheet mold. After draining it was vacuum couched but was then drum dried without pressing. Bulk density was measured on the dried samples. High bulk values are generally an indication of high fiber stiffness. However, high bulk values cannot be obtained if there has been any significant amount of fiber breakage during reslurring. For this reason, bulk density is also strongly indicative of fiber length and of any fiber damage during reslurrying.
TABLE I______________________________________ Control Crosslinked Pulp (Untreated) No Debonder Debonded______________________________________Disintegration Energy, 15,000 125,000 20,000revs.Handsheet Bulk Density, 3.1 9.5 16.5cm.sup.3 /g______________________________________
EXAMPLE 3
The reaction conditions; i.e., time, temperature, and catalyst concentration, between the potential crosslinking agent and the cellulose affect the bulking potential and ease of reslurrying of the sheeted product. A series of handsheets was made according to the procedures outlined in Examples 1 and 2. However, this time the amount of as received Arotex 900 in the treatment bath was varied in 5% steps between 0% and 20%, resulting in pickups by the fiber varying between 1.9 and ? .6%, as calculated on a dry materials basis. A constant weight ratio of 10:3 between as received crosslinker and catalyst was maintained for all samples. This ratio may be expressed as 5:1 on a dry solids basis. The resulting 203×203 mm Noble and Wood handsheets were resheeted as in Example 2 in the TAPPI sheet mold to obtain samples for bulk densities. Results were as follows:
TABLE II__________________________________________________________________________Effect of Curing Conditions on Handsheet Bulk DensityTAPPI Handsheet Bulk Densities, cm.sup.3 /gCrosslinkerSolids Reaction TemperatureBased on 120° C. 140° C. 160° C.Pulp, % 1 min 3 min 5 min 1 min 3 min 5 min 1 min 3 min 5 min__________________________________________________________________________0 3.21.89 3.8 6.7 5.2 7.6 9.5 10.5 10.3 14.1 15.83.78 9.7 13.2 16.0 15.3 15.7 17.7 19.3 14.6 14.55.67 6.7 16.8 20.4 18.6 17.7 16.7 20.0 14.8 14.87.56 9.0 19.3 19.7 19.6 16.1 17.4 20.0 -- --__________________________________________________________________________
It is readily apparent that with the present crosslinker system, TAPPI sheet bulk density increased directly with increases in crosslinker usage, reaction time, and reaction temperature. However, little change was seen in sheet bulk with increase in reaction time from 3 to 6 minutes, especially at the two higher curing temperatures. Likewise, there does not appear to great advantage at reacting at the higher temperature of 160° C. compared with 140° C. In fact, at higher crosslinker usages the higher temperature may cause undesirable fiber embrittlement.
EXAMPLE 4
A series of samples was made using a 10% Arotex 900 bath treatment and comparing the Berol 584 softener, used in Examples 2 and 3, with a nonionic softener and a nonionic/cationic softener combination. The nonionic material was Triton X-100, a nonylphenol type. Triton is a registered trademark of and the product is available from Rohm and Haas Co., Philadelphia, Pennsylvania. The samples without softener and with the cationic softener were made as in Example 2. In the case where the nonionic softener by itself was used in combination with the crosslinking agent, both were included in the crosslinker bath and no softener was added prior to sheet formation. Estimated concentration of nonionic material solids incorporated into the final product, based on dry cellulose, is 0.8%. When the cationic/nonionic combination was used, the cationic was added as in Example 2, prior to sheeting, and the nonionic was included with the crosslinking agent as just described. In addition to sheet bulk density values, disintegration energy was estimated by noting the number of British Disintegrator revolutions necessary to give a uniform fiber dispersion without knots or fiber clumps. Results were obtained as shown in Table III.
TABLE III______________________________________ Disintegration Handsheet BulkSample Energy, revs Density, cm.sup.3 /g______________________________________No debonder 120,000 11.9Cationic debonder 22,500 24.7Nonionic debonder 62,500 16.9Cationic/nonionic 62,500 18.4______________________________________
The nonionic softener significantly improves ease of dispersibility and increases bulk value, However, it is not as effective here as the cationic debonder and, when used in combination under these conditions, reduces the effectiveness of the cationic material.
EXAMPLE 5
A major use of the products of the invention is expected to be in filtration medium. Here some portion of the crosslinked fiber would normally be repulped, blended with untreated fiber, and resheeted. A major contribution of the crosslinked fiber is porosity control and, in some eases, it can make higher porosities possible than can now be readily attained. One common measure of the expected behavior of a filter medium is air porosity. A number of test procedures are employed. The particular one chosen is in part dependent on the expected air resistance of the sheet. The tests on the present product were conducted on sheets having a basis weight of 160+5 g/m 2 by measuring the pressure drop caused by an air flow of 0.085 m 3 /min.
Sheets were formed using 3.5 g, dry weight, of pulp dispersed in a British Disintegrator in about 2 L of water until a uniform slurry was produced. Sheets were formed in a standard laboratory British Sheet Mold, couched at 68.9 kPa, drum dried between blotters, and heated for 1.5 minutes at 150° C. to react the cellulose and crosslinker. Before testing sheets were conditioned to equilibrium at 50% RH at 23° C.
For the tests reported below in Table IV, Arotex 900 was used in bath concentrations of 1, 3, 5, 10, and 15% and the fiber was treated before sheeting with 0.5% Berocell 584 debonding agent.
TABLE IV______________________________________Bulk and Air Resistance of Crosslinked FiberCrosslinker Solids Handsheet Bulk Air ResistanceBased on Pulp, % Density, cm.sup.3 /g Pressure Drop, mm______________________________________0 3.7 370.38 -- 191.13 8 4.31.89 10 3.03.78 21 0.55.67 23 0.5Untreated Control.sup.(1) 5.5 3.3______________________________________ .sup.(1) A commercially available prehydrolyzed, cold caustic extracted southern pine kraft pulp widely used in filter media.
The desirable air resistance properties contributed by the readily redispersible crosslinked cellulose pulp are immediately apparent.
EXAMPLE 6
Another expected major use of the products of the present invention is in tissues and toweling in order to maintain high bulk and softness with good water absorbency. To show the effectiveness of the crosslinked material, a sample was prepared as in Example 3 using a bath concentration of 15% Arotex 900. This resulted in a pickup of crosslinker solids based on dry pulp of about 5.7%. Varying amounts of this product were reslurried and added to fiber obtained by reslurrying two popular brands of toilet tissue. One of these, Tissue A, was a conventional hot drum dried product while the other, Tissue B, was originally dried using heated air passed through the tissue to maintain softness.
Sheets were formed in a standard laboratory British Sheet Mold as described in the previous example using 0.44 g, dry weight, of fiber to give a final sheet having a basis weight of about 24 g/m2. In addition to the bulk density value, softening efficiency of the crosslinked pulp in the ultimate sheet was estimated. This was calculated by taking the ratio (% increase in bulk density over a control sample) divided by (% treated pulp used in the sample). Results are given in the following table:
TABLE V__________________________________________________________________________Addition of Crosslinked Pulp into Tissue FurnishTreated Pulp Used Tissue A Tissue Bin Furnish, % Bulk, cm.sup.3 /g Efficiency Bulk, cm.sup.3 /g Efficiency__________________________________________________________________________ 0 4.0 -- 3.5 --10 4.5 1.2 4.9 3.720 5.4 1.7 5.8 3.140 7.7 2.3 8.4 3.060 11.2 3.0 13.0 4.5__________________________________________________________________________
The effectiveness of the crosslinked pulp at increasing bulk is immediately apparent. It was unexpected that the bulking efficiency would increase as higher levels of crosslinked pulp were used.
EXAMPLE 7
In order to compare different cyclic urea compositions a supply of dihydroxyethyleneurea (DHEU) was prepared by reacting equimolar portions of glyoxal and urea, generally as taught in British Patent 717,287. This was compared with the Arotex 900 dimethyloldihydroxyethyleneurea (DMDHEU) used in the previous examples. Using 15% of each compound in respective treatment baths, samples were made up as described in Example 2. 30% of Arotex Accelerator 9 was used with the Arotex 900 in the treatment bath while 30% of a 10 g/L zinc nitrate solution was used with the DHEU. After drying, reaction times between the crosslinking agent and cellulose of 1-3 minutes were used at a temperature of 140° C. Table VI shows that nearly identical bulk values were obtained with the two compounds.
TABLE VI______________________________________ Handsheet Bulk Density cm.sup.3 /gReaction Time, min DMDHEU DHEU______________________________________1 25 243 28 295 26 25______________________________________
The two compounds appear to be about equally effective and there appears to be no advantage for using longer reaction times.
EXAMPLE 8
The following tests were made to show the effectiveness of other generic classes of chemical crosslinking agents for cellulose.
A 20 g (oven dried weight) sample of never dried Northwest bleached kraft softwood pulp at 35% consistency was weighed out and placed in a British Disintegrator, made up to 2 L with deionized water, and agitated for 5 min at 600 rpm. The reslurried fiber was then dumped into an 8"×8" (203×203 mm) Noble and Wood laboratory sheet mold containing 4 L of deionized water. More water was added up to 2" below the top of the mold to give a total of about 6.3 L. A perforated stainless steel plate somewhat less than the cross sectional size of the sheet mold, with a 12" handle, was inserted into the sheet mold and moved up and down three times in rapid succession and 1 time slowly. The valve on the bottom of the sheet mold was opened and the stock drained through the screen. The pad of pulp remaining on the screen was removed, placed between synthetic fiber felts, and squeezed very gently through press rolls. The final weight of the pad was 65 g (45 g water and 20 g pulp).
A 1% solution of as received Berocell 541 (Berol Chemical Company, Reserve, Louisiana) was made up and sprayed onto both sides of the pulp pad (approximately equal distribution) to obtain an uptake of 1% softener based on OD pulp. After 3 min a 15% solution of maleic anhydride (MA) in water was sprayed onto the pulp pad in the same manner for a 15% (based on OD pulp) material uptake. The pad was then placed between 2 dry 8"×8" pulp blotters and fed through the drum dryer until the pad was completely dry. It was then transferred to a watch glass and placed in a 160° C. oven for 15 minutes. A 3.5 g sample was torn off the pad and reslurried in the British Disintegrator (using 2 L of deionized water) for 5 min at 600 rpm. The slurry was passed into a 61/4" TAPPI sheet mold and processed to a hand sheet. The pad was drum dried without pressing, conditioned at 50% RH and 23° C., and measured for bulk density.
In like manner, additional samples were treated with 1,2,3,4-butanetetracarboxylic acid (BTCA), 4,5-dihydroxyl-1,3-dimethyl-2-imidazolidinone (DDI), with and without softener. The samples made with DDI included 1% (based on pulp) of a mixed AlCl 3 *MgCl 2 catalyst. All samples were run in duplicate. Results are given in Table VII. Sheet formation was graded relatively as follows:
1--uniform good formation
2--fairly good formation without nits (undispersed fiber clumps)
3--fair formation with some knots or floes present
4--very poor formation with original sample not completely redispersed.
TABLE VII______________________________________Bulk Values Using Various Cellulose Crosslinking Agents Bulk Value RelativeTreatment cm.sup.3 /g Dispersibility______________________________________Untreated 4.90 21% softener 4.87 115% MA 5.38 315% MA + 1% Softener 6.51 115% DDI 5.82 215% DDI + 1% Softener 7.73 115% BTCA 6.3(1) 415% BTCA + 1% Softener 10.17 1______________________________________ .sup.(1) Best estimate attainable due to very poor formation
In all cases, except with glyoxal, the bulk value was improved when a softener was incorporated into the cellulose prior to addition and reaction of the crosslinking agent. Tests made under other conditions have shown glyoxal to be an effective material in the application. All of the softened samples reslurried more readily than those without the softener.
EXAMPLE 9
The work described in Example 2 was repeated in order to make a fiber length measurement study on reslurried sheets. One difference this time was an increase in the concentration of Arotex 900 from 10% to 15% on an as received basis in the treatment bath. A second difference was the use of 0.5% Varisoft 727 as the debonding material. Varisoft is a registered trademark of Sherex Chemical Company, Dublin, Ohio. Verisoft 727 is a formulated alkyl diamidoamine type quaternary compound in which the alkyl substituents are typically oleyl or tallow based. The composition contains about 30% quaternary material.
The higher concentration used here, as compared with Example 2, would be expected to increase the ultimate concentration of the latent crosslinking material in the cellulose fiber from about 3.8% to 5.7% and also to increase the brittleness of the crosslinked fibers. Fiber length determinations were made using a Kajanni Type FS-100 automatic fiber length analyzer, available from Kajanni Electronics Co., Kajanni, Finland. As before, the samples were dispersed in the British Disintegrator until smooth, knot free slurries were attained. Results are given below.
TABLE VIII______________________________________ Crosslinked pulp Control No (Untreated) Debonder Debonded______________________________________Disintegration Energy, 15,000 138,000 25,000revsHandsheet Bulk Density, 3.1 7.9 20.9cm.sup.3 /gWeighted Ave. Fiber 3.0 1.3 2.4Length, mm______________________________________
The debonded crosslinked pulp retained 80% of the fiber length of the control sample with very little more disintegration energy being required to redisperse the sheets in water. The crosslinked samples without debonder had only 43% of the average fiber length of the control samples. This major reduction is probably due to the very much higher energy required to obtain a smooth, knot-free fiber slurry.
EXAMPLE 10
A set of experiments was made to show the relative effectiveness of other types of quaternary debonding agents when used in conjunction with the Arotex 900 dimethyloldihydroxyethyleneurea (DMDHEU) latent crosslinking agent. The type numbers listed below refer to those noted earlier in the description of preferred embodiments.
Variquat and Adogen are registered trademarks of Sherex Chemical Company. Variquat 638 is described as a methyl bis(2-hydroxyethyl) coco ammonium chloride having 74-75% quaternary material. Adogen 471 is a tallow trimethyl ammonium chloride with 49-52% quaternary material. Varisoft 222-90% is a methyl his(tallow amidoethyl) 2-hydroxyethyl ammonium methyl sulfate with 89-91% solids. Quaker 2006 is an imidazoline type debonder available from Quaker Chemical Co., Conshohocken, Pa.
TABLE IX______________________________________Effect of Quaternary Debonder Type withDMDHEU Crosslinking Agent Disintegration Bulk Density, Type Energy, revs cm.sup.3 /g______________________________________Variquat 638.sup.(1) 1 125,000 10.5Adogen 471 1 30,000 14.6Verisoft 222-90% 2 30,000 19.9Verisoft 727 2 30,000 18.3Quaker 2006 4 30,000 19.5______________________________________ .sup.(1) This is a modified Type 1 material in that R.sub.2 and R.sub.3 are 2hydroxyethyl or polyoxyethanol.
Representatives of all the general types of quaternary debonders worked well, although the modified Type 1 material does not seem as effective under the conditions used as the other materials.
EXAMPLE 11
Nonionic and anionic material additives are not substantive to cellulose fibers in an aqueous slurry unless the electrical charge on the fiber surface is made more compatible. This is normally done by adding one of the class of papermaking chemicals generally called retention aids prior to the addition of the nonionic or anionic composition. These are most typically cationic materials that are substantive to the fibers and make the surface charge more positive. When anionic or nonionic debonders are used in the present invention they can be added at the wet end, prior to sheeting, or after the sheet is formed. When wet end addition is chosen a cationic retention aid is normally required. If a shower over the forming wire or press section, or a pad bath, is used the retention aid is normally not necessary since most of the debonder remains with the water entrapped in the sheet.
A series of experiments was made to show disintegration energy and bulk values with the two modes of addition using cationic, anionic and nonionic debonding agents. For the wet end addition of the nonionic and anionic materials, 0.5% (5 kg/t) of the retention aid Reten 210 was added to the fiber slurry prior to the addition of the debonder. Reten is a registered trademark of Hercules, Inc., Wilmington, Delaware, for a very high molecular weight polyacrylamide having approximately 2-4 mol % cationic sites. No retention aid was used with the cationic material. The cationic debonder was Varisoft 727, described in Example 10; the nonionic material was Triton X-100, described in Example 4; and the anionic was a sodium linear alkyl sulfonate composition with 26.8% active material obtained from Chemithon Corp., Seattle, Washington. These were all used in dosages of 5 kg/t of the as received material. Those samples in which the debonder and latent crosslinking agent were added after sheet formation were prepared according to the procedure of Example 4, with the two materials being mixed in the same treating solution. All samples were made using 15 kg/t as received of Arotex 900 crosslinking agent in the treating bath. Relative dispersibility was evaluated by the criteria set forth in Example 8, with the exception that here the samples were retained in the British Disintegrator for a sufficient number of revolutions to obtain a relatively smooth slurry. Results were as follows.
TABLE X______________________________________Point of Addition of Debonding Agent BulkDebonder Point Disintegration Density, RelativeClass Addition Energy,revs cm.sup.3 /g Dispersibility______________________________________Cationic Wet End 30,000 17.9 1 Pad Bath 30,000 18.3 1Nonionic Wet End 138,000 11.9 3 Pad Bath 62,500 16.9 2Anionic Wet End 175,000 11.0 3 Pad Bath 112,500 13.0 3______________________________________
Under the conditions of the present test the cationic debonder was the most efficient class of material. Pad bath addition was more efficient for the nonionic and anionic debonders than wet end addition. This may be due to an incompatibility or zeta potential unbalance between the particular type or concentration of retention aid and debonder. It is expected that with additional experimentation similar results would be obtained for wet end and pad bath addition. The particular anionic system chosen for these samples was not particularly efficient.
EXAMPLE 12
Wet tensile strength is believed to be one measure of the ease of reslurrying a sheeted material. An additional set of samples was made in similar fashion to those of Example 9. Wet tensile strength was measured on specimens taken from the Noble and Wood handsheets. Measurements were made using horizontal specimens 100 mm wide and 80 mm between grips, with a head speed of 1/3 mm/see. Values were as noted in Table XI.
TABLE XI______________________________________Wet Tensile Strength Values Tensile Strength,Treatment kN/m______________________________________None 8Crosslinked, no softener 89Crosslinked, with softener 30______________________________________
The combination of softener with the crosslinked pulp reduced wet tensile strength to 1/3 of that without softener.
EXAMPLE 13
While some latent crosslinking reagents require additional heating at elevated temperatures after the sheet is normally dried, in order to effect reasonably complete reaction with the cellulose, others will react sufficiently under normal drying conditions. The use of urea nitrate as a catalyst for the urea-based latent crosslinking materials generally eliminates the need for post-drying heating. This material appears to be more active than the normally used inorganic salts or salt mixtures. Urea nitrate can be made with equimolar portions of urea and nitric acid under aqueous reaction conditions, using the method of Hebeish and Ibraham, Textile Res Jour., 52 (2):116-122 (1982).
A series of samples was made following the procedure of Example 5. Arotex 900 DMDHEC latent crosslinker was used in pad bath percentages varying between 2.5% and 20% with urea nitrate present in the bath equivalent to 3.3% of the DMDHEC, as calculated on a dry materials basis. Samples for testing were dried to about 4% moisture content without any additional post drying heating. The sample temperatures probably did not exceed about 90° C. at any time. Bulk densities and air resistance values age given in the following table.
TABLE XII______________________________________Bulk Density and Air Resistance of Low TemperatureCrosslinked SheetsAs Received Handsheet Air ResistanceCrosslinker in Crosslinker Solids Bulk Density, Pressure Drop,Pad Bath, % Based on Pulp, % cm.sup.3 /g mm______________________________________0 0 3.0 47.22.5 1.0 6.3 17.85.0 1.9 10.0 13.210.0 3.8 15.4 3.115.0 5.7 20.5 1.820.0 7.6 22.5 1.5______________________________________
Bulk and air resistance results are generally comparable with those reported in Table VI where a post drying reaction period of 1.5 minutes at 150° C. was used.
It will be apparent to those skilled in the art that many departures can be made from the present description and examples while remaining within the spirit of the invention. The invention is to be considered as being limited only by the following claims. | The invention is a method of making a wet formed, sheeted, readily reslurriable sheeted crosslinked cellulose and the products made by the method. Crosslinked wood pulp fibers tend to be quite brittle. If crosslinked while in sheeted form, the sheets cannot be readily defibered, either in a wet or dry state, without serious fiber degradation. The sheet products of the present invention can be easily redispersed or repulped in water without significant fiber breakage. The present products are made by including within the sheet, while still in wet form, a debonding or softening agent which is preferably added before the latent crosslinking reactant. Most preferably the debonder is added prior to the headbox of a paper machine and the crosslinking reactant is applied near the end of the forming wire or at the press section. The treated sheet is dried conventionally. Crosslinking may occur entirely during drying or during a period of additional heating, usually at a temperature in excess of 100° C. for a short period of time. Conventional debonding agents and crosslinking reactants are suitable. The softening agent apparently reduces or prevents adhesive bonding between adjacent fibers caused by polymer formation external to the fibers under reaction conditions. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device for measuring the flow rate of a fluid in a passage, in particular in a hydrocarbon well.
2. Description of Prior Art
A device known in the prior art is described in document EP-A-234 747. Such a device is shown in FIG. 1 and it essentially comprises a first section 1 of a passage that is of uniform diameter followed by a second section 2 that is of tapering diameter so as to form a venturi. Three pressure take-off points 3, 4, and 5 are provided, the point 4 being situated at the inlet to the venturi, the point 3 upstream from the point 4, and the point 5 downstream from the venturi. The flow direction of the fluid is marked by the arrow given reference 6. A first differential pressure measurement ΔP m can be obtained between points 3 and 4, at the ends of constant diameter section 1. This differential pressure ΔP m serves to determine the mean density of the flowing fluid. A second differential pressure measurement ΔP v can be performed between points 4 and 5, i.e. across the venturi. This measurement serves to determine the flow rate of the fluid, providing the density thereof has previously been determined by measuring ΔP m . More precisely, the flow rate v can be calculated using the relationship:
ΔP.sub.v =aρv.sup.2 +b(ρ.sub.o -ρ)
where ρ is the density of the fluid and ρ o corresponds to the density of a fluid present in the measurement circuit of the differential pressure sensors. The coefficient a is equal to 1/2(1-d 4 /D 4 ), where d and D are respectively the diameter of the smallest section and the diameter of the largest section of the venturi.
This relationship shows that the measured differential pressure is the sum of two terms, one of which is proportional to the square of the flow rate while the other (the static component) is independent of flow rate. Consequently, when the flow rate is small, the static component predominates, such that the slightest error in determining density gives rise immediately to an apparent flow rate. The use of two differential pressure sensors, typically having an accuracy of 15 mpsi (10 -3 bar), can generate apparent flow rates of the order of 1,000 barrels/day (bpd) (i.e. 6.6 cubic meters per hour (m 3 /h)), and this can happen even when there is no fluid flowing in the passage. This is shown in FIG. 2 which, for two different densities (I: 1250 kg/m 3 , II: 500 kg/m 3 ) shows how the two components of the differential pressure vary as a function of flow rate: one of these components depends on flow rate while the other component (the static component) is independent thereof. From this graph, it can be seen that the static component is largely predominant for flow rates of less than about 600 bpd (3.96 m 3 /h). Up to 2,000 bpd (13.2 m 3 /h), the differential pressure measurement, and consequently the flow rate measurement, is highly sensitive to the static component.
In addition, the known device relies, as do all other systems using venturis, on a reduction in the diameter of the passage or channel in which the fluid is flowing. Nevertheless, the flow rate to be measured is the flow rate in the portion of the passage having diameter d, i.e. in the normal section of the venturi. When subjecting wells to testing for hydrocarbon extraction (drill stem testing or "DST"), standard values need to be satisfied with respect to production tubing, i.e. the diameter d: this value is set to 21/2" (57.15 mm). Consequently, the only way of achieving a restriction in order to form a venturi is to begin by enlarging the inside diameter of the tubing to a diameter D and subsequently to return it to its standard diameter d. This has the consequence that in the above expression for ΔP v , the term v is subjected to a coefficient of (1-d 4 /D 4 ) of less than 1. Thus, where d=21/4" (57.15 mm) and D=3" (76.2 mm), the term v 2 is subjected to an attenuation coefficient of about 0.3. Consequently, the sensitivity of ΔP v to measured flow rate is small, particularly when the flow rate is small. Typically, for a flow rate of the order of 1,000 bpd (6.6 m 3 /h), an error of 30% is common, and the error on flow rates of the order of 600 bpd (3.96 m 3 /h) can be as much as 50% to 60%. Errors of less than 5% are obtained only at flow rates greater than about 5,000 bpd (33 m 3 /h).
Consequently, the known device is subject to two main sources of error: one is associated with the fact that attempts are made to measure flow rate in the small section of a venturi whose diameter cannot be reduced to less than the nominal value of d=21/4" (57.15 mm); and the other is associated with the static component that is independent of flow rate.
SUMMARY OF THE INVENTION
The present invention provides a device for measuring the flow rate Q of a fluid in a fluid passage, in a well, the device comprising a first venturi section and first means responsive to the pressure difference ΔP 1 across the first venturi section between two points that are separate from each other in the flow direction, a second venturi section, and second means responsive to the pressure difference ΔP 2 across the second venturi section between two points that are separate in the flow direction, the two venturi sections being disposed relative to each other in such a manner that for a given direction of fluid flow, the diameter of one of them increases whereas the diameter of the other one of them decreases, said venturi sections being further arranged in such a way that the static pressure components present in said pressure differences ΔP 1 and ΔP 2 can be cancelled out.
Such a measurement device makes it possible:
to eliminate the presence of the interfering static component, completely; and
to reduce the error in the measured flow rate, substantially: for a given flow rate, error values can be obtained that are five to ten times smaller than with the prior art device.
The distances between the two pressure take-off points of the two venturis are preferably equal. The same applies to the normal sections (and indeed the large sections of the venturis).
In a particular embodiment, the first and second venturi sections may each be constituted by a locally thicker portion of the wall delimiting the outside of the passage.
In an apparatus of the present invention, the most accurate determination of flow rate is nevertheless obtained at the cost of a small amount of loss in accuracy concerning density at high flow rates. However, this can be compensated by adding a pressure difference measurement in a straight portion of the passage. Under such circumstances, excellent density measurement is achieved while simultaneously obtaining very good flow rate measurement.
The two venturi sections may be fixed in a string of production test rods, and recording means may also be provided in the string of rods so as to record signals representative of ΔP 1 and ΔP 2 .
The invention also relates to a system for measuring fluid flow rate, the system comprising a device as described above and means for calculating the fluid flow rate by forming a linear combination of the pressure differences ΔP 1 and ΔP 2 . Such a system may also include means for determining the density of the fluid. Means may be provided for determining the flow rate Q i (i=1,2) of the fluid in at least one of the two venturis on the basis of the pressure difference ΔP i , and also, optionally, means for comparing Q i and Q.
The invention also provides a method of measuring the flow rate of a fluid in a fluid passage in a well, using a device for a system as defined above, the method including the steps of:
measuring a first pressure difference ΔP 1 across a first venturi section;
measuring a second pressure difference ΔP 2 across a second venturi section; and
calculating the flow rate from said values ΔP 1 and ΔP 2 measured during the two above steps, while eliminating the static component.
The distances between the two pressure take-off points of the two venturis are preferably equal. The same applies to the normal sections (and also the large sections) of the venturis.
The static component can be eliminated by a linear combination of ΔP 1 and ΔP 2 .
The method may additionally include a step of calculating the static component.
Further, it may also include a step of determining the fluid flow direction in the passage, which method comprises the following sub-steps:
assuming a fluid flow direction;
determining, for said assumed direction, the flow rate Q i (i=1,2) of the fluid through at least one of the two venturis, on the basis of the pressure difference ΔP i ;
comparing Q and Q i to verify the assumption concerning the flow direction.
The pressure differences (ΔP i ) j corresponding to different instants t j can be measured, and the corresponding data can be stored, optionally after being compressed, with the values Q j of flow rate at different instants t j being calculated subsequently.
This provides a data set Q j (t j ).
BRIEF DESCRIPTION OF THE DRAWINGS
In any event, the characteristics and advantages of the invention appear more clearly in the light of the following description. The description relates to embodiments given in non-limiting and explanatory manner, with reference to the accompanying drawings, in which:
FIG. 1 shows a prior art flow rate measuring device;
FIG. 2 shows the weights of the two components in a prior art differential pressure measurement; and
FIGS. 3 and 4 show two devices of the present invention.
DESCRIPTION OF THE INVENTION
A first embodiment of a device of the invention is shown in FIG. 3. In this figure, references 12, 14, and 16 represent different sections of the inside wall of a pipe string adapted for DST (DST=Drill Stem Test). These sections are of a string of production test rods (i.e., a pipe string adapted for DST (Drill Stem Test)). In a drill stem test, the diameter d is set at a nominal value of 21/4" (57.15 mm), whereas the diameter D of the central enlargement is 3" (76.2 mm). Thereafter, the fluid passes through a converging venturi 20: the wall tapers so the fluid goes from a section of diameter D to return to a section of diameter d. A differential pressure sensor 22 serves to measure the pressure difference between two pressure take-off points 26 and 28 situated upstream and downstream respectively from the diverging venturi 18. A differential pressure sensor 24 serves to measure the pressure difference between two pressure take-off points 30 and 32 situated respectively upstream and downstream from the converging venturi 20. The points 28 and 30 could equally well coincide.
Another embodiment is shown in FIG. 4. The fluid, e.g. flowing in the direction represented by arrow 33 first passes through a converging venturi 34 whose wall defines a large section of diameter D (3", 76.2 mm) and a normal section of diameter d (21/4", 57.15 mm). A first differential pressure sensor 38 serves to measure the pressure difference between two pressure takeoff points 40 and 42 situated respectively at the inlet and at the outlet of the converging venturi 34, and a differential pressure sensor 44 serves to measure the pressure between two pressure take-off points 46 and 48 situated respectively at the inlet and at the outlet of the diverging venturi 36. In this case as well, the points 46 and 42 could coincide.
In both cases, the spacing (in the direction of flow) between the two pressure take-off points in one venturi is preferably equal to the spacing between the two pressure take-off points in the other venturi. However, the invention also extends to any embodiment in which these two spacings are different.
Likewise, the normal sections (or the large sections as the case may be) of the two venturis are preferably equal, but the invention also extends to the case where they are not equal.
In any event, the different pressure sensors 22, 24, 38, and 44 may be connected in a manner known to the person skilled in the art to means (not shown in the figures) enabling the data delivered by said sensors to be stored and/or operated on. In particular, when working a hydrocarbon well, such means may include computer means situated on the surface.
On the basis of the signals produced by the pressure sensors at various instants t j , e.g. during a given test sequence, it is possible to obtain signals representative of the variation over time Q(t) of the flow rate.
In the two cases shown in FIGS. 3 and 4, these same equations govern pressure variations between the inlets and the outlets of the venturis, and from the fluid flow point of view, the device presents the same advantages over the prior art. From the practical implementation point of view, the FIG. 4 device is easier to implement than the FIG. 3 device.
Consider the device shown in FIG. 3, the pressure ΔP 1 measured between the points 26 and 28 is given by the following relationship:
ΔP.sub.1 =a.sub.1 ρ.sub.x v.sup.2 +b(ρ.sub.o -ρ.sub.x) (1)
Similarly, the pressure difference between the points 30 and 32 is given by the following relationship:
ΔP.sub.2 =a.sub.2 ρ.sub.x v.sup.2 -b(ρ.sub.o -ρ.sub.x) (2)
In the above equations, ρ x designates the density of the flowing fluid, ρ o designates the density of a reference oil present in the ducts of the differential sensors 22, 24 (or 38 and 44 for the embodiment shown in FIG. 4), and v designates the flow speed of the fluid. Also:
a.sub.1 =k/Cd.sub.1.sup.2 and a.sub.2 =k/Cd.sub.2.sup.2
where ##EQU1## Cd 1 and Cd 2 being calibration coefficients for the venturis.
From the measured values of ΔP 1 and ΔP 2 , it is possible to deduce the density and/or the flow speed of the fluid by the following relationships: ##EQU2##
Relationship (4) gives the flow speed in the section of diameter D. The volume flow rate of the fluid is calculated using:
Q=1/4(πD.sup.2 v) (5)
From this equation system, it is possible to deduce various consequences relating to the characteristics of the double venturi device of the invention.
Firstly, the static component, although it is indeed present in each of equations (1) and (2), has opposite signs therein, so that it disappears completely when summing ΔP 1 and ΔP 2 : consequently, whatever the flow rate, this component has no influence on the result.
It may be observed at this point that the above equations are given for the case where the spacing between the two pressure take-off points of one venturi is equal to the spacing between the two pressure take-off points of the other venturi. Otherwise (i.e. different spacings), the static component is not eliminated when summing ΔP 1 and ΔP 2 , but it is eliminated when making a linear combination of ΔP 1 and ΔP 2 using coefficients in the combination that take the ratio of spacings into account.
The measurements ΔP 1 and ΔP 2 obtained with each of the sensors may also suffer from error or uncertainty associated with the sensors themselves. Nevertheless, compared with the gradio venturi measurement system, error associated with the sensor has much smaller influence on the final result. In the gradio venturi system, the error necessarily varies with 1/v, i.e. in a manner that is inversely proportional to the flow rate. Using the dual venturi of the invention, the overall error depends on the sign of the error in each sensor: it may happen that an error is obtained which varies in a manner that is inversely proportional to flow rate (but in this case the error is nevertheless approximately five to ten times smaller than that of a gradio venturi), however it is also possible to obtain an error that is constant over the entire range of measured flow rates, particularly when the error on one of the sensors compensates the error on the other sensor. This possibility is mathematically impossible when using only one venturi.
Another advantage of a dual venturi device in accordance with the invention is that it makes it possible to achieve a very good estimate of the discharge coefficient over a wide range of flow rates. In a single venturi, the discharge coefficient is a function for which an analytical expression has not been rigorously established. Certain expressions make use of Stolz's equation, others are more empirical, but they all share in common the fact of using the Reynolds number. With venturi flow meters, the standard ISO-5167 provides a table which gives the approximate variation in discharge coefficient as a function of Reynolds number. That table is reproduced below as Table I.
TABLE I______________________________________ R.sub.E Cd______________________________________ 4 × 10.sup.4 0.957 6 × 10.sup.4 0.966 10.sup.5 0.976 1.5 × 10.sup.5 0.982______________________________________
In the field of hydrocarbon production, the measured flow rates lie in the range about 500 B/d to about 15,000 bpd (i.e. about 3.3 m 3 /h to 99 m 3 /h). For a flow rate of 1,000 bpd (6.6 m 3 /h, corresponding to a flow speed of about 0.7 meters per second (m/s)), a Reynolds number is calculated having a value of R E =4×10 4 , whereas for a rate of 10,000 bpd (66 m 3 /h, i.e. about 7 m/s), the Reynolds number as calculated is R E =4×10 5 . On comparison with above Table I, it can be deduced that the discharge coefficient Cd is not constant over the range of flow rates involved. The dual venturi device of the present invention makes it possible to overcome this difficulty since the equivalent discharge coefficient of the system as a whole can be given as being the root mean square of the discharge coefficients Cd 1 and Cd 2 of each of the venturis. More precisely, the equivalent discharge coefficient is given by: ##EQU3##
This results in attenuation of variations in the discharge coefficient over the entire range of flow rates of interest. Table II below gives the value of the discharge coefficient at two different flow rates (1,000 bpd and 10,000 bpd) respectively for a convergent venturi (Cd 1 ), a divergent venturi (Cd 2 ), and for a dual venturi system of the invention (Cd e ). The error given at the bottom of each column corresponds to the error obtained on flow rate when the discharge coefficient calculated for 10,000 bpd is applied to a small flow rate (1,000 bpd): this error drops to 2.5% for the dual venturi of the invention, whereas it is about 5% for the convergent venturi and is greater than 15% for the divergent venturi.
Consequently, the dual venturi of the invention makes it possible to use a single discharge coefficient over the entire range of flow rates of interest.
TABLE II______________________________________ Cd.sub.1 Cd.sub.2 Cd.sub.e______________________________________1,000 bpd 0.95 1.43 0.785(6.6 m.sup.3 /h)10,000 bpd 0.988 1.21 0.765(66 m.sup.3 /h)ERROR 5.1% 15.4% 2.5%______________________________________
Because the discharge coefficients of a convergent venturi and of a divergent venturi are not the same, a density measurement performed with a device of the invention suffers from an interfering component that is proportional to the sum of the signals from the two sensors (ΔP 1 +ΔP 2 ), which is itself proportional to the square of the speed of the fluid (see equations 3 and 4 above). Consequently, the error in determining the discharge coefficient for each venturi shows up in the density, and this effect increases with increasing fluid flow speed. This means that the improvement in flow rate determination is obtained at the price of reduced accuracy concerning density.
In order to remedy this drawback, it is possible to determine density at low flow rates (e.g. at a zero flow speed), and subsequently to use the density value obtained in this way for determining the flow speed at higher flow rates.
Another method of compensating for said loss of accuracy concerning flow rate consists in adding a differential pressure sensor in a section that has no change of diameter (e.g. between points 28 and 30 in FIG. 3 or between points 42 and 46 in FIG. 4), thereby directly measuring the static component independently of the flow speed of the fluid: this makes it possible to obtain simultaneously very good density measurement and good flow rate measurement.
Because of the symmetrical configuration of the dual venturi in a device of the present invention, fluid may flow through it in either direction, and the flow speed can be determined under all circumstances. In particular, the invention is also applicable to injection wells. This is not possible with the prior art gradioventuri structure in which the convergent venturi must extend in the fluid flow direction.
Conversely, the device of the invention can be used to determine fluid flow direction. This can be particularly advantageous under transient conditions, e.g. after a valve has been closed. It is possible to proceed as follows:
it is assumed that the fluid is flowing in a particular direction, e.g. the direction indicated by arrow 13 (or 33) in FIG. 3 (or FIG. 4);
thereafter the values of ΔP 1 and ΔP 2 are measured and the flow speed and the density are deduced therefrom using equations (3) and (4);
equation (1) is used to deduce the flow speed v 1 through the venturi 18 (a diverging venturi if the fluid is flowing in the direction 13), and from the value of the density ρ and the differential pressure ΔP 1 ; it may be assumed that Cd 1 =1;
equation (2) is used to deduce the fluid flow speed v 2 through the venturi 20 (a convergent venturi if the fluid is flowing in the direction 13), on the basis of the density ρ and the differential pressure ΔP 2 ; it may be assumed that Cd 2 =1;
if the fluid is indeed traveling in the direction indicated by arrow 13 (FIG. 3), then the following must apply:
v.sub.1 >v and v.sub.2 >v;
otherwise, v 1 <v and v 2 <v, which means that the venturi 18 is convergent in the present fluid flow direction whereas the venturi 20 is divergent, and consequently the fluid is flowing in the opposite direction to that given by arrow 13 (or arrow 33). Density must then be recalculated, assuming fluid flow in the opposite direction. The value for flow speed is then corrected to take account of the new value for the density.
All of the methods described above, and in particular the methods of calculating flow rate and/or density of a fluid, or the method of determining fluid flow direction, can be implemented using suitably programmed computer means of appropriate type; for example, when working hydrocarbons, these means may be the means that are situated on the surface and that have already been mentioned in the description above.
Finally, the invention has been described in its application to a hydrocarbon well. The measurement devices and methods described are not limited to applications of that type, and the invention can be applied to measuring fluid flow in any non-horizontal passage (when the flow is horizontal, there is no static component). | The invention relates to a device for measuring the flow rate Q of a fluid in a fluid passage, in a well, the device comprising a first venturi section and first means responsive to the pressure difference ΔP 1 across the first venturi section between two points that are separate from each other in the flow direction. It comprises a second venturi section, and second means responsive to the pressure difference ΔP 2 across the second venturi section between two points that are separate in the flow direction, the two venturi sections being disposed relative to each other in such a manner that for a given direction of fluid flow, the diameter of one of them increases whereas the diameter to the other one of them decreases, said venturi sections being further arranged in such a way that the static pressure components present in said pressure differences ΔP 1 and ΔP 2 can be cancelled out. | 4 |
This application is a continuation of 07/880,289, filed May 4, 1992, now abandoned, which is in turn a continuation of 07/767,246, filed Sep. 27, 1991, now abandoned, which is in turn a continuation-in-part of 07/629,160, filed Dec. 18, 1990, which is now U.S. Pat. No. 5,052,064.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to bedding, and more particularly to a nestably stackable bedding foundation.
2. Description of the Prior Art
Bedding foundations or so-called box spring assemblies generally comprise spaced border wires between which are disposed coil or bent wire spring modules. As thus manufactured, these box spring assemblies are bulky and shipping to the manufacturer for application of padding and covering thereto is costly because of space requirements. In order to reduce the space requirements, it is customary to compress the assemblies to reduce their individual thicknesses and, when compressed, to tie them in their compressed state. This involves providing presses and ties which are expensive, and the extra operations of pressing and tieing the assemblies. At the delivery end, the manufacturer must cut and discard the ties before applying the covering. These additional material and handling costs increase the end cost of box spring assemblies.
It has therefore been one object of the invention of this application to construct a bedding foundation assembly that can be stacked for shipping without having to compress and tie the assembly.
Another object of the present invention has been to provide a bedding foundation assembly which is relatively simple to manufacture, and which may substitute for a traditional box spring assembly having coil spring modules.
SUMMARY OF THE INVENTION
The present invention is a nestably stackable bedding foundation assembly for use in place of the traditional box spring assembly. This bedding foundation assembly comprises a rectangular border wire and transversely-spaced, parallel, and longitudinally-extending support wires parallel to the border wire sides and having ends connected to the border wire ends. These support wires are generally corrugatedly formed along their lengths, having peaks and valleys with the peaks being generally coplanar with the plane defined by the border wire and the valleys being displaced beneath and intermediate of the peaks. Longitudinally-spaced, parallel and transversely-extending upper connector wires, parallel to the border wire ends, are connected along their lengths to the peaks of the support wires. Longitudinally-spaced, parallel, and transversely-extending lower connector wires, parallel to the border wire ends, are connected to the valleys of the support wires. The longitudinal voids between the peaks of the support wires are of a greater dimension than the valleys of the support wires. This configuration enables one nestably stackable bedding foundation assembly to be nestedly stacked atop a second assembly since the support wire valleys of the first assembly may enter into the voids between the peaks of the support wires of the second assembly. Such a nestedly stacked arrangement results in a total height dimension which is less than the sum of the individual assembly height dimensions.
A bedding foundation incorporating the present invention comprises a rectangular base, a nestably stackable wire core assembly according to the present invention fixedly attached atop the base, and spring means disposed between and connected to the base and the nestably stackable assembly.
The primary advantage of the present invention is that it enables relatively inexpensive bedding foundation wire cores to be tightly compacted and shipped in a minimum of space to an assembly destination, thereby reducing the ultimate cost of the core to the assembler.
Another advantage of the present invention is that bedding foundation assemblies may be rapidly loaded by a manufacturer for transportation to the destination of assembly without the need for compressing and tieing the assemblies.
Yet another advantage of the present invention is that the need for costly presses and ties necessary to compress a conventional box spring assembly for transportation is obviated.
A further advantage of the present invention is that bedding foundation assemblies may be rapidly unloaded without the time consuming and labor intensive tasks of clipping and discarding the tie wires used to hold conventional box spring assemblies in a compressed state.
These and other objects and advantages of the present invention will more readily become apparent during the description of the drawings herein, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, partially broken away, of a bedding foundation assembly embodying the invention of this application;
FIG. 2 is a view taken along lines 2--2 of FIG. 1 illustrating the corrugatedly formed support wires and optional end connection wires;
FIG. 3 is a view like FIG. 2 but illustrating two unmounted foundations stacked and nested one within the other for shipment;
FIG. 4 is a perspective view, partially broken away, of a bedding foundation assembly embodying an alternative embodiment of the present invention;
FIG. 5 is a view taken along line 5--5 of FIG. 4;
FIG. 6 is a view like FIG. 5 but illustrating the alternative embodiment foundations unmounted on base frames and stacked and nested one within the other for shipment;
FIG. 7 is a top plan view, partially broken away, of a quarter of a bedding foundation assembly including the present invention with springs disposed between and connected to the nestably stackable assembly and the base;
FIG. 8 is a view taken along lines 8--8 of FIG. 7; and
FIG. 9 is a perspective view of the bedding foundation assembly of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, a bedding foundation 1 is illustrated. The foundation i has a rectangular wooden base frame 2 on which are attached transverse wooden slats 3. Atop these transverse slats 3 is the nestably stackable assembly or wire core 4, which is the invention of this application. A foam pad 5 overlies the nestably stackable assembly 4, and a fabric covering 6 overlies the foam pad 5 and surrounds the nestably stackable assembly 4 and the base frame 2.
Describing the nestably stackable assembly 4 now in more detail, it comprises a rectangular steel border wire 10 having two parallel sides 11, 11 and two parallel ends 12, 12, with the parallel sides 11, 11 being longer than the parallel ends 12, 12. Transversely-spaced, parallel, and longitudinally-extending steel support wires 13 are parallel to the border wire sides 11, 11 and have ends 14 which are crimped around the ends 12, 12 of the border wire 10. These support wires 13 are formed so as to be generally corrugatedly-shaped along their lengths, having peaks 15 and valleys 16. These peaks 15 and valleys 16 are flattened at their extrememost locations 17 and 18, respectively. These flattened peaks 17 are generally coplanar with the plane defined by the border wire 10, with the flattened valleys 18 being vertically spaced beneath and intermediate of the flattened peaks 17.
Longitudinally-spaced, parallel, and transversely-extending steel upper connector wires 19 extend parallel to the border wire ends 12, 12 and have ends 20 which are crimped around the border wire sides 11, 11. These upper connector wires 19 are welded intermediate of their ends along their lengths 21 to the flattened peaks 17 of the support wires 13. The upper connector wires form a generally planar top of the assembly 4.
The support wires 13 define a plurality of support wire means depending from and forming part of the upper connector wires, each support wire means of which tapers downwardly from the planar top to a lower end, the lower ends being located in a common base plane and being adapted to be secured to a foundation base 2.
Longitudinally-spaced, parallel, and transversely-extending steel lower connector wires 22 extend parallel to the border wire ends 12, 12 and are welded at their ends 23 and intermediate of their ends along their lengths 24 to the flattened valleys 16 of the support wires 13.
Referring now to FIG. 2, the support wires 13 have flattened peaks 17 and flattened valleys 18, with the support wire ends 14 being crimped around the border wire 10. In this embodiment, three upper connector wires 19 per flattened peak 17 are illustrated, along with one lower connector wire 21 per flattened valley 18. The flattened valleys 18 of the support wires 13 are stapled or otherwise attached to the transverse slats 3 which are in turn affixed to the base frame 2.
If desired, additional steel end wires 25 may be added either before or after the stackable assembly 4 has reached its final assembly destination. These end wires 25 have ends 26 and 27 which are crimped around the border wire 10 and the endmost upper connector wire 28, respectively. These end wires 25 provide additional stiffness to the stackable assembly 4 in an edgemost location of the ends of the assembly 4 so as to prevent the end border wires from deflecting and being permanently distorted when a person sits on the end of a bed of which the foundation forms a part.
The metal core portion of a bedding foundation is generally manufactured by a supplier, who then ships it to an assembler. The assembler adds to the metal core a wooden base 2, slats 3, padding 5, and upholstery 6 to make a completed product.
The invention of this application facilitates shipment of the metal core or stackable assembly by a supplier to the assembler. With reference to FIG. 3, it will be seen that a first stackable assembly or core 4 may be placed upon a surface with the flattened valleys 18 of the support wires 13 oriented downwardly and the flattened peaks 17 of the support wires 13 oriented upwardly. Next, a second like assembly 4 is placed atop the first assembly 4, with its flattened support wire valleys 18 and flattened support wire peaks 17 likewise oriented downwardly and upwardly, respectively. The flattened valleys 18 of the second assembly 4 are thereby allowed to enter into the voids between the flattened peaks 17 of the first assembly 4. The second assembly 4 nestles downwardly within the first assembly 4 until the outside dimension of the valleys 16 of the second assembly 4 is equal to the inside dimension of the valleys 16 of the first assembly 4. At this point, the second assembly 4 comes to rest within the first assembly 4, with the overall heighth of the nested assemblies being substantially less than the sum of the individual heighths of the assemblies. Of course, any number of assemblies may be nested and stacked together for storage or shipment.
An alternative embodiment of the present invention is illustrated in FIG. 4. In this embodiment, the optional end wires 25 have been removed and replaced with continuous longitudinal wires 31. These longitudinal wires 31 have their ends crimped around the border wire ends 12. These end wires 31 may be welded along their lengths to the upper connector wires 19 as desired. In this embodiment, the lower connector wires 22 of the first embodiment of FIGS. 1-3 have been eliminated. This facilitates stacking of the assemblies as illustrated in FIG. 6. In this embodiment, the upper connector wires 19 are welded intermediate of their ends along their lengths to the underneath sides of the flattened peaks 17 of the support wires 13. This allows the longitudinal wires 31 to rest atop and be generally coplanar with the flattened peaks 17 of the support wires 13 when the assemblies are stacked as illustrated in FIG. 6.
With reference to FIGS. 7, 8 and 9, and with like numbers representing like components, there is illustrated a bedding foundation 1 and further including modular springs 50 incorporated therein. These modular springs 50 are fully described in U.S. Pat. No. 4,000,531 to Inman, issued Jan. 4, 1977 and assigned to the assignee of the present invention. The disclosure of Inman U.S. Pat. No. 4,000,531 is hereby incorporated fully by reference.
As can be seen, each spring 50 includes a pair of fish mouth sections 56 extending upwardly from the wooden slats 3 and a connecting section 58 that interconnects the fish mouth sections. Each fish mouth section 56 includes a torsion bar 60 whose opposite ends are connected to downwardly and upwardly inclined spacer bars 62 and 64. The lower ends of the downwardly extending spacer bars 62 are integrally joined with J-shaped attaching sections 66 of the springs which are secured by staples 68 to the associated wooden slats 3. The upper ends of the upwardly extending spacer bars 64 are integrally joined with torsion bars 70 that are also integrally connected with height spacer bars 72. An inboard main section 74 of the spring connecting section 58 is connected to outboard end portions 76 of the connecting section by outwardly extending wire legs 78.
As can be seen more particularly in FIG. 9, the connecting sections 58 are secured to the transversely spaced, parallel, and longitudinally extending steel support wires 13 with sheet metal clips 80. Similarly, the inboard main portion 74 of these spring connecting sections 58 are secured to the longitudinally spaced, parallel, and transversely extending steel upper connector wires 19 with sheet metal clips 80. The springs 50 resiliently support the support wires 13 intermediate of the peaks 15, thereby bridging the gap between the valleys 16 to provide support along the entire length of the assembly.
While we have described only two embodiments of our invention, those persons skilled in the art will readily recognize modifications and changes which may be made without departing from the spirit or scope of the invention. Specifically, those persons will readily appreciate that springs of differing configurations from that of the springs 50 may be utilized in the practice of this invention. Accordingly, we intend for our invention to be limited only by the following claims. | A nestably stackable bedding foundation assembly which replaces the traditional border wire and disposed coil spring foundation assembly in a so-called box spring. The nestably stackable foundation assembly may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping. A bedding foundation comprises a rectangular base, a nestably stackable bedding foundation assembly fixedly attached atop the base, and spring means disposed between and connected to the base and the nestably stackable assembly. | 0 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application claims priority on U.S. Provisional Application Ser. No. 61/578,404, filed on Dec. 21, 2011, the disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is directed to improvements in the use of solar energy to generate heat. The present invention has particular applicability in the use of solar energy to produce heat which can be harnessed for a variety of uses. The heat for example can be in the form of heated water particularly water heated to a temperature higher than traditional solar hot water heaters have been able to achieve on a sustained basis.
BACKGROUND OF THE INVENTION
Many people are concerned about our dependence upon foreign energy sources. In addition there are environmental issues in using coal and other carbon based fuels. As a result there is a greater desire to use solar energy for more of our energy needs.
One problem with solar energy has been the relatively high cost of solar cells that are used to generate electricity. The materials used in the solar cells, i.e. the silicon wafers and silver ribbons, are fairly expensive. Their cost of manufacture is also high.
Solar collectors have also been used for a number of years for heating water. A solar collector is often secured to a roof or wall surface and positioned so it is facing the sun. The sun heats water or a working fluid that passes through piping in the collector. A pump or natural convection transports the heated fluid to a heat exchanger or a storage tank for use by occupants of the building. Sometimes a parabolic mirror is used to concentrate the sunlight on the tube containing the fluid.
One issue that has inhibited the use of solar collectors has been the relatively low temperatures that are achieved using these devices. Except for really sunny days a supplemental system may also be necessary to really heat the water to high enough temperatures for most uses.
OBJECT OF THE INVENTION
It is an object of the invention to provide a solar collector type device that generates heat from the sun's rays that can be used for a variety of purposes where heat can be used.
It is an object of the invention to provide a solar energy based device for warming water.
It is also an object of the invention to provide a solar collector type device where the temperatures achieved are higher than conventional systems.
It is a further object of the invention to use an adjustable lens to concentrate the focal point of the light on a tube containing a fluid.
It is a still further object of the invention to provide a solar collecting system which takes into account the movement of the sun during the day.
It is still another object of the invention to provide a solar collector system with a main assembly with a plurality of lenses and two auxiliary mirrors to increase the light directed on the tube containing the fluid to be heated.
It is a still further object of the invention to provide a solar collecting system which takes into account the movement of the sun during the day.
It is still another object of the invention to provide a solar collector system with a main assembly that rotates for the lenses to better receive the sun's light.
It is also another object of the invention to provide a solar collecting system in which the main assembly rocks back and forth so that the lenses better receive the sun's light.
It is a still further object of the invention to provide a solar collector which has a spherical configuration.
It is another object of the invention where the solar collector is a sphere that rotates.
It is another object of the invention to provide a solar collector that is generally cylindrical in configuration.
It is a further object of the invention to provide a solar collector that is generally a polygonal tube in configuration
SUMMARY OF THE INVENTION
The present invention is directed to a unique solar collection that can raise the temperature of a fluid to temperatures where the fluid can be used directly as hot water for use in homes and businesses. Alternatively the fluid can be used to heat water in a heat exchanger for similar uses. Depending on the heat generated by the device through the use of the lenses it may be possible to generate steam from water in the device. The present invention has a solar collector which has a housing with a plurality of lenses assemblies. The housing is preferably generally at least a portion of a cylinder. The surface of the cylinder may be curved or made up of a plurality of longitudinal flat strips extending from one end to the other end. The solar collector may have one or more mirror assemblies positioned along the lower portion of the solar collector.
Light from the sun passes through the lens in the lens assembly where it is focused to penetrate past an evacuated glass shroud and be concentrated onto a black pipe, where the fluid to be heated passes through. This arrangement of the black tube within the glass shroud, being supported therein by end caps, which permit evacuation of the air between the tube and the shroud, is referred to hereinafter generally as the “core.” The focal point of the lens can be adjusted by the lens assemblies so that the light is focused light and heats a fluid passing therethrough. The solar collector may be rotated so that the sun's rays pass through each of the lens in the lens assemblies. This increases the amount and location where light impinges on the surface of the core during the “passage” of the sun across the sky each day.
Where the solar collector is less than a complete cylinder the collector may be rocked instead of rotated. In addition to the solar collector having a cylindrical configuration or portion thereof the solar collector may be a sphere or hemispherical or spherical arrangement between the two.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an end view of one embodiment of the present invention.
FIG. 2 shows a perspective view of the embodiment of FIG. 1 .
FIG. 3 shows a top view of an array of several devices of the present invention.
FIG. 4 shows a plurality of the lens assemblies useful with the present invention.
FIG. 5 shows a view all one end of the assembly of the present invention.
FIG. 5A shows an enlarged perspective view of the evacuated glass shroud, end caps, with a tube therein being connected to end fittings in the caps, according to one embodiment the current invention.
FIG. 5B is a first side view of the glass shroud, end caps, tube, and end fittings of FIG. 5A , looking at the side of the valve.
FIG. 5C is a second side view of the glass shroud, end caps, tube, and end fittings of FIG. 5A , looking at a first end of the valve.
FIG. 5D is a third side view of the glass shroud, end caps, tube, and end fittings of FIG. 5A , looking at a second end of the valve.
FIG. 5E is a first side view of the glass shroud, end caps, tube, and end fittings of FIG. 5A .
FIG. 5F is a second side view of the glass shroud, end caps, tube, and end fittings of FIG. 5A .
FIG. 6 shows a end view opposite the end of the assembly.
FIG. 7 shows a prospective side view of the device of the present invention without the lens assemblies being present.
FIG. 8 shows an example of a motor used to rotate the assembly of the present invention.
FIG. 9 shows another embodiment of the solar collector of FIG. 1 where the cylindrical housing is not a complete cylinder.
FIGS. 10A and 10B show the movement of the solar collector of FIG. 9 .
FIG. 11A to 11F show various views of the modular members that can make us the assembly of FIG. 9 .
FIG. 12 shows an alternate embodiment of the present invention where the solar collector is in the form of a sphere.
FIG. 13 is a side view of the embodiment of FIG. 12 .
FIG. 14 is a top view of the embodiment of FIG. 12 .
FIG. 15 is an alternate embodiment of the sphere of FIG. 12 showing the inner sphere.
FIG. 16 is a cutaway view of the embodiment of FIG. 12 .
FIG. 17 is an embodiment where the solar collector is a more than a hemisphere but less than a complete sphere.
DETAILED DESCRIPTION OF THE INVENTION
As seen in FIG. 1 there is a base 10 which supports the solar energy collector assembly 11 of one embodiment of the present invention. In this embodiment the solar energy collector rotates about an axis 12 which is preferably horizontal to the ground or other flat surface. As the device rotates one or more lenses 13 are perpendicular to the sun and placed in position to receive the direct rays of the sun. The rotation enables the device to compensate for movement of the sun across the sky as the earth rotates during the day. The multiplicity of lenses increases the incidence of light onto a tube 14 through which a fluid that is heated passes. While it is preferable that the device be positioned generally horizontal to the ground it can be at any angle to the ground including perpendicular. To compensate for the seasonal tilt of the sun the North end of the device can be raised and lowered so that the lenses are perpendicular to the sun and the rays will directly hit the lenses and the opposite in the southern hemisphere.
The base 10 may be a flat plate that extends from one end of the solar power assembly to the other or it may be a plurality of individual bases that support each respective end of the assembly. Extending upwardly from the base 10 are one or more supports 15 and 16 that support the center axis of the assembly of the present invention and permit the assembly to rotate. The assembly of the present invention is generally a cylindrically shaped hollow tube having first end 17 and a second end 18 and one or more sidewalls 19 extending from one end to the opposite end. It will be appreciated that in addition to a circular cylindrical configuration the cylindrical tube may alternatively have several different polygonal shapes that may be used. These polygonal shapes will have one or more generally flat surfaces extend across the surface of the cylinder from generally near one end to the generally near the opposite end of the cylinder. Preferably the assembly has nine or more sides in the polygon-shaped assembly. The generally cylindrical assembly has an inner surface 20 and an outer surface 21 .
At each end of the cylindrical assembly there may be an end wall 22 to provide support for the device. The end wall may be a solid wall surface without any opening across the end of the cylindrical assembly or it may have a ring shaped as shown. Within the cylindrical member there is a center support member or rod or tube 14 which extends from one end of the cylinder to the opposite end of the cylinder. This tube has a couple of purposes. One it acts as a center support for the cylindrical assembly and permits the cylinder to be positioned on the supports 15 and 16 at each end of the device that extend upwardly from the base 10 . The center support member 14 enables the cylinder to rotate about the center axis. The center support member is preferably a tubular member having one or more wall surfaces and which is hollow from one end to the other. The center rod is preferably made of metal, such as, for example, stainless steel and more preferably made of a metal that conducts heat. A fluid passes through the hollowed tube. This fluid is heated by the sunlight that passes through the lenses and is focused onto the tube.
As the device of the present invention rotates the light from the sun enters one or more of the lenses 13 . The lenses focus the beam of light onto the surface of the center rod. The focused light increases the temperature of the rod particularly in the areas where the light directly impinges on the surface of the rod. This increases the temperature of the rod and it's contents. The outer surface of the cylinder is provided with a plurality of orifices 23 extending from the outer surface 21 of the cylinder through to the inner surface 20 . These orifices receive the lens assemblies 13 used in the present invention. The lens assemblies 13 include a lens 24 that can focus the lights that passes through the lens on to the surface of the center rod. The lens are positioned in a height adjustable flexible sleeve 25 that retains the lens in position in the orifice 23 and which can be used to adjust the distance the lens is from the center rod to optimize the focal distance. This permits the light to be better focused on the center rod. In one embodiment the flexible sleeve is a flexible rubber that can cushion the lens in the orifice in the cylinder. This prevents thermal expansion problems caused by heat or cold due to the differences in the coefficient of expansion between the material which the cylinder is made of and the material (e.g. glass) the lens is made of.
Extending from the inner surface of the cylinder wall are one or more cylinder drum supports 26 that extend to the center rod 14 or core of the device. These supports maintain the center rod in the center axis of the device. The core 14 of the device has at least a hollow portion through which a fluid may pass during the heating step. The supports 26 help reduce the amount of weight that the device has, thereby reducing the power needed to rotate the device during use.
On either side of the cylinder extending along its length are bottom side reflectors 27 , 28 . These reflectors have a base 29 that may be secured to the base 10 . Extending upwardly from the base is a support member 30 to hold each end of the reflector 31 in place and enable the reflector to pivot about an axis. In one embodiment as seen in FIG. 1 , there is a first mirrored surface, a second mirrored surface, and a third mirrored surface that are held in position by a pivoting mirror base which has an open area between two arms. In this embodiment the arms may be joined at an apex, but it is not necessary. A parabolic or hyperbolic mirror could be used instead if the focal length was sufficient to focus light from them through the lens 13 onto the tube 14 . Based on the location of the sun the number of lens in the main assembly, the distance from the center axis, etc., the bottom side reflectors 27 , 28 may be adjusted to direct light into the main assembly but they are not required.
At the end of the assembly shown in FIG. 1 there is a drive means for rotating the solar assembly during operation. The drive means may be any type of driving mechanism that rotates the assembly at a slow speed. Preferably, the rotation speed is about 1 to 5 rpm's or less. In the embodiment of FIG. 1 there is a sprocket chain drive 33 with a sprocket disk 34 with a plurality of teeth. The chain drive may be similar to a chain used on a bicycle. The chain is driven by an AC high torque motor 32 . The motor 32 is preferably a variable speed motor which can preferably rotate the drum at a speed of about 1 rpm. The purpose of the rotation is to permit the light to fall through at least one and preferably a plurality of lenses at any given time during a rotation cycle and as the sun traverses the sky.
In the preferred embodiment the surface of the cylinder has a series of flat surfaces around the cylinder so that during rotation of the earth, the suns rays will fall directly on the lens so that the lens can focus the light onto the surface of the center core thereby increasing the heat of the core. Depending on the arrangement of the lenses across the surface of the drum, at any given time when the surface of the drum is perpendicular to the sun's direct rays there should be focused light impinging onto the surface of the core thereby heating the core and the fluid being transported within it.
The assembly is preferably arranged as close as possible to a north south configuration when the device is in operation. The device may also preferably be adjusted so that the North end can be higher than the south end to allow for seasonal tilting of the earth on its axis. This will permit the rays to directly impinge on one or more lenses and provide the optimal performance when the lens axis is at a 90°. When the light passes through a lens, the lens focuses the light to a point on the surface of the tube that is the center axis or core of the device. When a user is facing the south, the cylinder rotates counter clockwise. i.e. in the opposite direction as the sun appears to be moving in the sky so that the light passes through different lenses as the solar collector rotates thereby spreading the heat evenly across the surface of the tube.
FIG. 1 shows the movement of the sun in relation to the device. As the sun rises in the sky the rays of light hit the east side of the drum. Light enters the lens where it is focused by the lens into a point on the surface of the core along the center axis. This light warms the surface of the core and because the core is made from a material that conducts the heat, the fluid passing through the core is warmed as well. This fluid passes out of the core to where the heat can be used for any suitable purpose. In one embodiment, a heat exchanger 37 can be used to heat potable water for household use. In another embodiment, the fluid itself can be used in other applications as well.
The lens assembly is preferably selected based on where on the surface of the cylinder the lens will be placed. Where the lens will be in the center row it is preferable that the lens be positioned in the orifice 23 on the assembly so that the long axis of the lens is perpendicular to the light entering into the lens from the sun. On each side of the center row it is preferable that the lens assembly 35 have a tilt so the lens is positioned at about 15° off of the center axis of the lens to better aim the light onto the center rod.
FIG. 2 shows a perspective view of the assembly of the present invention. As seen in the Figure the surface of the drum is provided with three rows of orifices 23 . While these rows are shown in straight lines, other configurations are possible. The rows are preferably offset slightly as shown in the Figure. This can permit more lens in the given surface area of the flat strip 19 .
FIG. 2 also shows how light is reflected off of the bottom side reflectors 27 and 28 and directed to lens assemblies on lower strips 36 of the solar collector. In addition, there can be a reflective surface on the base 10 to direct light on the underside of the solar collector.
FIG. 3 shows an example of an array of solar heating assemblies that may be placed on a roof or on the ground. The assemblies are lined up adjacent to each other in the example but could be end to end if the space was available. In another embodiment, the array can be pyramidal, i.e. higher in the center than at the ends, although any configuration is possible based on space requirements. The fluid travels through the center rod of each of the assemblies being heated as it goes through each one. When the fluid's travel through the array is completed, it passes into a heat exchanger 37 which can heat for example, water for use in a shower, or to heat a hot water heating system in a house. In the example shown in FIG. 3 the heat exchanger 37 is in the form of a coil 38 that warms a second fluid 39 in a storage unit. The fluid being heated can include but is not limited to water, oil or a glycol antifreeze.
FIG. 4 shows a plurality of lens assemblies. The lens assemblies include a lens 24 that is a convex lens usually a biconvex lens that converges the ray of light at a focal point on the axis of the lens that is on the core of the solar collector. The focal length of the lens can be adjusted by the use of shims with respect to the housing or sleeve 25 that retains the lens. The sleeve is preferably a flexible rubbery material or polyvinyl chloride and rubber or a pvc fitting or other material. The sleeve surrounds at least a portion of the lens and retains the lens in the orifice of the cylinder drum. It also eliminates any issues due to different coefficients of expansion between the material the cylindrical drum is made from and the lens material. Also, the rubber sleeve can permit the distance of the lens from the core be adjusted to permit the focal point of the light to be focused on the surface of the core. It will be appreciated by those skilled in the art, that other arrangements for supporting the lens and adjusting the distance of the lens from the core in the cylindrical assembly are possible.
FIG. 5 shows a close up view of the cylindrical drum support on one end of the solar collector. These drum supports can be any shape and extend from the drum to a ring or bushing 40 that surrounds the center core. The cylindrical drum supports support the drum and the bearing or ring or bushing permits the drum to rotate about the center core. Also shown in FIG. 5 is the end of the center core.
In this embodiment there is a nipple 41 for securing the end of the core to the line that transports fluid to the center core for heating. The fluid can be any suitable fluid that can be heated and transport the heat to a heat exchanger. Water can be used, if desired, or oil or other suitable fluid. While potable water can be used in the system, it may be easier to use not potable water in the system and have potable water as the fluid in the heat exchanger. This may make it easier to keep the water used for household hot water purer.
FIG. 6 shows the opposite end of the assembly of FIG. 5 . As seen in the drawing there are a pair of supports 15 and 16 that meet at there ends where the end of the center core is rotatably secured. The toothed wheel which receives the drive sprockets is between the supports and the cylinder drum supports. In this example the cylinder drum supports are in the form of a rod 41 that extends outwardly of the end wall of the cylindrical drum. There is a generally 90° bend in the support so that the rod supports a ring not shown, not unlike the arrangement of the cylinder drum supports of FIG. 5 . While different types of drum supports have been shown in FIGS. 5 and 6 it will be appreciated that other arrangements are possible.
FIG. 7 shows a side perspective view of a portion of the cylindrical drum of the present invention. In this embodiment, the drum is a nonagon of nine sides. It will be appreciated that depending on the diameter of the drum more or less sides are possible. Each side is preferably a flat sheet with a plurality of orifices present for receiving the lens assembles. There are three rows of orifices extending generally from one end of the drum to the opposite end. As can be seen from the Figure, the lenses are offset in their alignment. More specifically, the three rows of lenses are generally parallel to each other but the arrangements of each row of lenses across the narrow portion of the strip do not line up in a straight line perpendicular to the rows. It will be appreciated that other arrangements of the orifices are possible.
FIG. 8 shows an example of a low speed motor that may be used to turn the cylindrical assembly. The motor of FIG. 8 has a toothed member on the stem of the motor that is used to turn the recesses in the sprocket drive.
Another embodiment is disclosed in FIG. 9 . As seen in FIG. 9 , there is a base 101 on which is a first and second support 102 , 103 that supports one end of the solar collector of the present invention. There is also a support at the opposite end of the solar collector. The solar connector of this embodiment has a core 105 that has a fluid that passes through at least a portion of the core. The core may be retained in a ring like the ring shown in FIG. 4 or a suitable housing. The ring at each end permits the assembly to rock back and forth. There is a low speed motor 106 that is secured to the wall of the assembly. The low speed motor rocks the assembly back and forth as the motor rotates. The outer surface of the collector assembly is provided with a plurality of longitudinal strips 107 that provide a flat surface for receiving the lens assemblies. Generally parallel to the collector assembly and in proximity to the lower portion of the assembly are first and second bottom side reflectors 108 and 109 .
As the motor rotates the linkage 110 the linkage pivots or rocks the assembly back and forth causing the lens to have a greater opportunity to receive a direct beam of light from the sun during its travels. The motor has a cam 111 that is rotated by the motor. The linkage is secured to a pin 112 extending from the surface of the dish. The pin is not in the center of the disk. FIGS. 10A and 10B show the operation of the motor to rock the solar collector. As seen in FIG. 10A , there is a cam that has a pin or other means to secure a tie rod to the cam. As the cam rotates, the pin moves the tie rod back and forth thereby causing the solar collector to rock back and forth. The rocking back and forth causes the lens to move into and out of direct alignment with the sun. Because of the arrangement of the lens on the strips there is always one or more lenses that can focus light from the sun onto the core which has a fluid passing through. There is also a tie rod connection for securing one or more additional assemblies in a modular format.
FIG. 11 shows an example of a modular assembly of the solar collector of the present invention. In the modular assembly embodiment of FIG. 11A there is a lens holder 150 that has a flat surface 151 for supporting a plurality of lens assemblies. Extending from the lens surface there are first and second lens assembly supports 152 and 153 at each end of the strip. At the opposite end of the strip from the lens surface there is a collar 155 or bushing to support the core. This collar or bushing can be rubber if desired. In the example of FIG. 11A the lens assembly supports have an angle 154 to the center point of the core or axis of the core of about 40° where the assembly is cylinder as shown in FIG. 1 where the cylinder is a manogon. This angle changes based on the number of sides the polygon has as well as whether or not the assembly is forming a circular cylindrical member or something less than a circle. The other assemblies can have the same configuration as the one shown in FIG. 11A where the core passes through the ends of each or they can be secured together in some other manner such as a screw connection.
FIG. 11B shows an alternate embodiment of the lens assembly supports. In this embodiment there is a flat surface 151 extending from the flat surface are a pair of supports 160 and 101 which can be secured to a ring 162 by means of screws 163 . The ends of the supports 160 and 161 may be provided with recesses for receiving the screws. FIG. 11C shows an end view of an example of the collar and how it may be secured by the screws to the supports 155 of the lens holder 150 . FIG. 11D shows a side view of the collar. FIG. 11E shows a perspective view of the collar. It will be appreciated that other means of securing the collar to the supports are possible. FIG. 11F shows a profile of how the assemblies may be placed together to form the solar collector assembly.
FIG. 12 shows an alternate embodiment of the present invention. In this embodiment the solar collector is spherical in shape with a plurality of lens assemblies positioned across the surface of the sphere. As can be seen from FIG. 12 , the lens assemblies are positioned over a major portion of the surface of the sphere. Around at least a portion of the sphere may be a plurality of bottom side reflectors which direct light from the sun to the lower portion of the sphere. The sphere is positioned on a base which permits the sphere to be rotated by a motor, preferably an AC motor. The base may be provided with a fluid line. In one end water or other fluid comes in the line that brings fluid into the sphere where it is heated by the lenses. Water leaves the base through another line after it has been heated in the core of the sphere. The core, in this spherical embodiment, may be tubing that rises from the base into the sphere, and which may be enclosed therein by a corresponding glass shroud that may be evacuated similar to the cylindrical glass shroud discussed hereinabove. The sphere has a plurality of adjustable individual lenses as discussed above so that the focal length can be adjusted. The sphere preferably is open to the inside for cleaning, etc. FIG. 13 shows a side view of the embodiment of FIG. 12 and FIG. 14 shows a top view. In this embodiment the bottom side reflectors are positioned in a semicircle around the north side of the sphere.
In the embodiment drawn in FIG. 15 there is an inner sphere of a tube 200 that is used to transport fluid from an outside source through the solar collector to a heat exchanger or other location where the heat generated by the device is used. The tube forms a sphere that spirals around the interior of the device. When the tube reaches the peak of the sphere, it passes downwardly from the top of the sphere to the base where it exits. The outer sphere is shown more clearly in FIG. 12 which surrounds the inner sphere. When light is directed onto the tubing by the lenses, the fluid, such as water, is heated. The inner sphere of tubing can be supported by an inner sphere or it can comprise the inner sphere. A pump may be used to circulate the fluid through the device. FIG. 16 shows how the lenses on the external sphere focus the light onto the tubing. As the sun traverses the sky, different lenses direct the focused light onto the tubing so that there is continuous heating. This is assisted by revolving the outer globe around the inner heat sink framed by the tubing. It is believed that the average direct contact of the sun's heat through the lens striking the tube or fittings which support the tubing will be greater with the rotation than if there was just the sun's motion without the rotation of the lenses.
In FIG. 17 the assembly is in the form of a hemisphere or a three dimensional object that has an arc greater than 180° but less than 360°. The external sphere is mounted on a turntable that rotates the hemisphere at a selected rate of speed. Bottom side mirrors direct light toward the lower portions of the outer sphere. The lens may have fixed focal lengths or may be adjustable. The base may be adjustable so that the device is in proper alignment with respect to the plane of the earth. Alternatively, the base can be positioned on a roof.
FIG. 5A shows a detail view of one embodiment of the central core from FIG. 5 . A central black pipe or tube, in one embodiment, may be one inch in diameter and may be thirty-eight inches long (although other sizes could also be used). This black pipe may be coated with a matte black high heat spray paint so as to absorb and not reflect suns rays, to thereby be efficiently heated. A 2½ inch Pyrex high heat high pressure glass tube (shroud) may be mounted over and around that black pipe using end caps, so as to suspend the black pipe within the center of the Pyrex tube. The end caps may each be 2¾ inches wide and may engage both ends of the Pyrex tube. The chamber depth of the end caps is then filled on each end with Liquid marine resin and allowed to harden. A narrow ⅛th inch airway (valve) may be inserted in one end next to black pipe to be able to evacuate the air therein to create a vacuum within the chamber. The hollow black pipe may stick out beyond both end caps, so as to allow fluid to pass through the end cap and not invade the space that has been evacuated in between the exterior of the black pipe and the interior of the Pyrex shroud. A connector may be threadably engaged onto the protruding ends of the black pipe that extend past the end caps, which may be used to permit the fluid to re circulate into the hot zone in the black tube, and back to a holding tank. An electric suction pump is attached to the ⅛th inch nipple and a rotating ball valve can be closed once the desired vacuum is obtained, after which a second sealing after the ball valve is a dead plug is inserted to maintain a sealed environment within vacuum tube. The vacuum pump is removed and the chamber is sealed. The core is now ready for utilization The vacuum created between the black pipe and the glass shroud serves to retain and maintain heat similar to the vacuum used in the chamber between the inner compartment and the outer shell of a coffee thermos. The lack of air between the black pipe and the Pyrex tube insulates the captured heat when sun is reflected upon the black tubing, hence preheating and maintaining a hot pipe which water passes through and re circulates from a holding tank . . . or in best case boils water in another pot by submerging the re circulating coils fluid within it. | A solar collection device includes a solar energy collector assembly being received and supported by a base. The solar energy collector assembly includes: a plurality of lenses secured within an elongated holder. Positioned concentric to the axis of the holder is a cylindrical glass shroud through which a tube passes. A first end of the tube, which is preferably formed of a high thermally transmissive metal, receives a supply of water, which is heated within the evacuated glass shroud by sunlight passing through the lenses and being focused onto the tube. The solar collector assembly is rotatably mounted to the base and may be caused to rotate at a slow speed by a drive means, or may be rocked at a slow speed. The elongated holder may be cylindrical, or may have a polygonal cross-sectional shape, with lenses staggered along each side of the holder to increase collection capability. | 5 |
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